Crewsaver CREWFIT 190N User manual

Date: March 2014
Issue No: 5
Crewsaver - Servicing Manual : Crewsaver Crewfit 190N Lifejacket
Page
of 46
1
R29965
SERVICE MANUAL
CREWFIT 190N LIFEJACKET
Survitec House, Lederle Lane, Gosport,
Hants. PO13 0FZ, England.
Tel: [phone] Fax: [phone]
email: crewsa[email protected]
Web: www.crewsaver.com

Date: March 2014
Issue No: 5
Crewsaver - Servicing Manual : Crewsaver Crewfit 190N Lifejacket
Page
of 46
2
No.
Issue 2
Issue 3
Issue 4
Issue 5
Description
Section 5.1 - new requirement to inspect stitching.
Section outlining the scope of the Manual added
on Index page.
Details of Manual Inflation Heads and CSL Lights
added
Page 4 - change in procedure for accessing
manuals on the website.
Section 5.9 and Section 6.4 - Expired L6 Lights to
be replaced by CSL Lights.
CSL Light added to Parts List.
Date
February 2011
June 2011
March 2012
March 2014
Service Bulletins and Amendments Register
DN: cn=scott.
sanders@survite
cgroup.com
Date:
2014.07.22
15:46:11 +01'00'

Date: March 2014
Issue No: 5
Crewsaver - Servicing Manual : Crewsaver Crewfit 190N Lifejacket
Page
of 46
3
Index
Section 1
1.1 Introduction
1.2 Product Description
1.3 Data Sheet
1.4 General Features
1.5 Donning Instructions
Section 2
2.1 Service Station Guidelines
2.2 On Receipt Inspection
2.3 General Care
2.4 Servicing Tools
2.5 Service Record Sheet
Section 3
3.1 Unpacking the Lifejacket
Section 4
4.1 Cleaning & laundering
Section 5
5.1 Inspection
Section 6
6.1 Testing
Section 7
7.1 Repairs
Section 8
8.1 Assembly
8.2 Packing instructions
Section 9
9.1 Replacement parts
Scope
This manual covers the servicing of the Crewfit 190N lifejacket without any current derivatives.

Date: March 2014
Issue No: 5
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1.1 Introduction
1.2 Product Description
1.1.1. This Service Manual will be published on the Crewsaver website (www.crewsaver.com). Click on PARTNER
AREA/LOGIN at the top of the screen. Personnel who have been trained in the servicing procedures for this
lifejacket will be issued with a Username and Password to enable them to access the download section. Each
manual carries an Issue Number and records of issue are logged by Crewsaver to ensure that the service network
maintains correct and up to date servicing information. Emails will be sent regarding any new Issues. Periodically
service bulletins may be issued which will be published on the Crewsaver website (www.crewsaver.com). Emails
will also be sent. It is the service station's responsibility to regularly check the website for any new bulletins and to
ensure inclusion within the servicing manual. The service bulletin register at the front of the Manual should be
completed.
1.1.2. The information referenced in each section, follows a standard servicing procedure by which the inspection should
take place.
1.1.3. This servicing manual details information to enable regular maintenance and servicing of the lifejacket to help
prolong the life of the product and ensure it functions correctly.
1.1.4. The manual should be used as a reference document following training in servicing procedures instructed by
Crewsaver approved personnel. The manual also details the equipment and parts needed for correct
maintenance to be performed.
1.1.5. Servicing must be carried out annually at a service station authorised by the manufacturer.
1.1.6. Regular servicing is to be carried out by qualified personnel trained by Crewsaver and holding a valid servicing
certificate. Certificates are valid for a period of 3 years.
1 yr
1.2.1. The Crewfit 190N is a single chamber Level 150 PFD (Inflatable lifejacket).
1.2.2. The lifejacket is CE approved to BS EN ISO 12402-3.
1.2.3. The lifejacket is easy to don.
1.2.4. The buoyancy of the jacket is provided by a single chamber with an oral tube to ensure the full buoyancy can be
achieved upon or after inflation.
1.2.5. This lifejacket is inflated by either a manual firing mechanism or a standard automatic firing mechanism.
1.2.6. This lifejacket comes in two different versions, the waist belt version and integral deck safety harness version
which are both available with either a velcro or zipped cover closure.
1.2.7 The outer cover is made from a hard wearing material. The colour of the outer cover of the standard Crewfit 190N
is normally red or black. The zipped version is available in black only and the Junior version in red only.
1
Section

Date: March 2014
Issue No: 5
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1.3.1 Data Sheet
Features:
Chamber Buoyancy:
Buoyancy Category:
Cover Colour
MCA (UK) Approved
SOLAS Approved
CE Approved
Cylinder size
Standard Automatic
Manual Firing head
Hammar Automatic
Manual Override
Oral inflation tubes
Pressure relief valves
Hard wearing cover
Whistle - fitted
Retro-reflective tape
Twin Lifting Becket - fitted
Light - fitted
Spray Hood
Dual Thigh straps - fitted
Fall Arrest Harness
Closure method
Alternative covers
Crewfit 190N Lifejackets
190N
150N
Red or Black (Zipped version Black only)
-
-
X
38g
According to
customer choice
-
X
X
N/A
X
X
X
X
Optional
Optional
X
N/A
Velcro or Zip
-
1
Section

Date: March 2014
Issue No: 5
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1.3.2 Data Sheet
Features:
Chamber Buoyancy:
Buoyancy Category:
Cover Colour
MCA (UK) Approved
SOLAS Approved
CE Approved
Cylinder size
Standard Automatic
Hammar Automatic
Manual Firing head
Manual Override
Oral inflation tubes
Pressure relief valves
Hard wearing cover
Whistle - fitted
Retro-reflective tape
Single Lifting Becket - fitted
Light - fitted
Spray Hood - fitted
Dual Thigh straps - fitted
Fall Arrest Harness
Closure method
Alternative covers
Crewfit 190N Junior Lifejackets
115N
150N
Red
-
-
X
23g
X
-
-
X
X
N/A
X
X
X
X
Optional
-
X
N/A
Velcro
-
1
Section

Date: March 2014
Issue No: 5
Crewsaver - Servicing Manual : Crewsaver Crewfit 190N Lifejacket
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1
Section
1.4.1 General Features - Crewfit 190 Non Harness
PU Coated Nylon 400d
Crewsaver Badge
Firing Head
pull toggle
Twin 25mm
crotch straps
Neoprene neck
protector
Information label
Padded Lifejacket
chassis
High strength plastic
buckle
Waist belt tidies
Hanging loop
Crotch strap
belt tidies
40mm Black
Nylon belt
READ INSTRUCTIONS CAREFULLY BEFORE USE!

Date: March 2014
Issue No: 5
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1.4.2 General Features - Crewfit 190 Harness
1
Section
READ INSTRUCTIONS CAREFULLY BEFORE USE!
PU Coated Nylon 400d
Crewsaver Badge
Firing Head
pull toggle
Twin 25mm
crotch straps
Neoprene neck
protector
Information label
Padded Lifejacket
chassis
Stainless steel linesman’s
buckle and D-ring
Waist belt tidies
Hanging loop
Crotch strap
belt tidies
50mm Black
Nylon belt

Date: March 2014
Issue No: 5
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READ INSTRUCTIONS CAREFULLY BEFORE USE!
PU Coated Nylon 400d
Crewsaver Badge
Firing Head
pull toggle
Twin 25mm
crotch straps
Neoprene neck
protector
Information label
Padded Lifejacket
chassis
High strength plastic
buckle
Waist belt tidies
Hanging loop
Crotch strap
belt tidies
40mm Black
Nylon belt
Zip break point
closure tab
YKK QBR
nylon zip
1.4.3 General Features - Crewfit 190 Non Harness with Zip
1
Section

Date: March 2014
Issue No: 5
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READ INSTRUCTIONS CAREFULLY BEFORE USE!
PU Coated Nylon 400d
Crewsaver Badge
Firing Head
pull toggle
Twin 25mm
crotch straps
Neoprene neck
protector
Information label
Padded Lifejacket
chassis
Stainless steel linesman’s
buckle and D-ring
Waist belt tidies
Hanging loop
Crotch strap
belt tidies
50mm Black
Nylon belt
Zip break point
closure tab
YKK QBR
nylon zip
1.4.4 General Features - Crewfit 190 Harness with Zip
1
Section

Date: March 2014
Issue No: 5
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1.4.5.1 General Features - Crewfit 190 Inflation Chamber
1.4.5.2 General Features - Crewfit 190 Plus Inflation Chamber
1
Section
Heavy Duty
1000D Binding
Retro Reflective
Tape 210mm
Cylinder and firing
head underneath bladder
Cover Collar
Retro Reflective
Tape 210mm
Retro Reflective
Tape 210mm
Oral Tube and Whistle
Reinforcement corner
pieces
Retro Reflective
Tape 210mm
Clear Visor
Ventilation Holes
Elasticated
webbing loops
Light
Ventilation Holes

Date: March 2014
Issue No: 5
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1.4.6 General Features - Crewfit 190 Junior and Harness version
1
Section
PU coated nylon 400d
Crewsaver badge
40mm black
Nylon belt
Firing head
Pull toggle
Crotch strap
Belt tidies
Twin 25mm
Crotch straps
Neoprene neck
Protector
Waist belt tidies
High strength plastic
Buckle
PU coated nylon 400d
Crewsaver badge
50mm black
Nylon belt
Crotch strap
Belt tidies
Neoprene neck
Protector
Waist belt tidies
Stainless steel linesman’s
Buckle and D-ring
Twin 25mm
Crotch straps

Date: March 2014
Issue No: 5
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1
Section
M
T
T
R
M
Inflatable
1.4.7 General Features - Crewfit 190 Junior Inflation Chamber
Heavy Duty
1000D Binding
Retro Reflective
Tape 210mm
Cylinder and firing
head underneath bladder
Cover Collar
Retro Reflective
Tape 210mm
Retro Reflective
Tape 210mm
Oral Tube and Whistle

Date: March 2014
Issue No: 5
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1.5 Donning Instructions - Crewfit 190 All Adult Models
1
Section
DONNING YOUR CREWFIT 190N LIFEJACKET
ADJUSTING AND FITTING YOUR LIFEJACKET

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2.1.1 Service stations shall comply with the following as a minimum;
2.1.1.1 Servicing of Inflatable Lifejackets shall be carried out in a fully enclosed area only.
2.1.1.2 The area shall be well lit and protected from direct sunlight
2.1.1.3 The temperature and humidity shall be sufficiently controlled to ensure that the servicing of inflatable
Lifejackets may be carried out successfully.
2.1.1.4 The area shall be efficiently ventilated but free from draught
2.1.1.5 Sufficient tools (including specialist tools) shall be available to ensure Lifejackets may be disassembled,
tested and reassembled in accordance with this Manual. These shall include but not limited to:
2.1.1.5.1 Manometers and pressure gauges
2.1.1.5.2 Oil free and dry air supply
2.1.1.5.3 Scales for weighing Gas Cylinders
2.1.1.5.4 Crewsaver Service tool kit (See 2.6). This is recommended but similar calibrated devices may
also be used.
2.1.1.6 Stock of materials and components to allow efficient servicing with readily available replacement parts to
ensure a prompt service for the customer.
2.1.1.7 Only personnel trained and certified in accordance with Crewsaver requirements are approved to carry out
Servicing and Maintenance. They must be holders of a valid Certificate issued by Crewsaver.
2.1.1.8 The service station shall be of an approved standard.
2.1.1.9 Procedures shall be introduced to ensure that service bulletins, Manuals and replacement parts are
obtained from Crewsaver.
2.1.1.10 Subsequent to initial approval and thereafter the service station shall be subject to regular surveillance by
Crewsaver.
2.1.1.11 The service station must comply and have met all QA criteria in the Crewsaver servicing protocol file.
2.2.1 On receipt of the Lifejacket(s), check the state of the packaging before opening and notify the owner and the
company delivering the package of any defects or damage.
2.2.2 On opening the package, check the contents for their general condition and quantity.
2.2.3 Prepare Servicing Record Sheet.
2.2.4 Visually inspect the cover and inflation chamber for damage, abrasion, contamination etc. in accordance
with this manual.
2.2.5 Note replacements required on the record sheet.
2.2.6 Unless obvious damage is evident, test the Lifejacket in accordance with Section 6. If it is considered that
the damage found would cause the Lifejacket to fail the tests then corrective action shall be carried out
prior to testing.
2.2.7 Damaged areas shall be marked using wax based crayon only. Marks shall be made with a small circle or
cross. Ballpoint, rollerball or other forms of ink shall not be used. If in doubt refer to Crewsaver for
guidance.
2.2.8 Repairs to the outer cover and the webbing are not permitted.
2.2.9 Repairs to welded components including the inflation chamber are expressly forbidden.
2.1 Service Stations
2.2 On Receipt Inspection
2
Section

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2.3.1 The Lifejacket should be stowed in accordance with the manufacturer’s instructions
2.3.1.1 Lifejackets should be stowed in a dry compartment. Avoid high humidity, such as a car boot.
2.3.1.2 Lifejackets should have stowage facilities which are provided with a method to encourage
moisture removal.
2.3.1.3 Lifejackets should be stowed vertically, for example hung on hooks, in order that any trapped water
or condensation can drain away naturally.
2.3.1.4 Lifejackets should be rinsed in fresh water and dried thoroughly after use.
WARNING
Prior to sponging or washing remove automatic capsules from the firing mechanism. Allow to dry thoroughly
afterwards.
2.3.2 Contaminants such as oil or diesel fuel may be sponged off immediately with clean water and allowed
to dry naturally.
2.3.3 Mud can be removed with a stiff (not wire) brush when dry.
o
2.3.4 The outer cover may be hand washed in good quality mild detergent in cool water (40 C). Rinse well, drip dry
naturally in air.
2.3.5 Sponge the inflation chamber with pure soap solution only. Rinse in clean water immediately, inflate and allow
to dry naturally in air.
WARNING
Do not use proprietary cleaning fluids, thinners, spirits or similar substances.
2.3.6 In cases of severe contamination the unit shall be deemed beyond economic repair and the customer advised to
purchase a replacement lifejacket.
WARNING
Make sure you know how to use and fit this Lifejacket before an emergency occurs.
Always try and inflate the Lifejacket in the water. If already inflated, cross arms over the chest before jumping.
2.3.7 It is advised that personnel are familiarised with the operation of all Lifejackets and lifesaving appliances.
2.3 General Care
2
Section

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2.4 Lifejacket Servicing Tools
2.5 Lifejacket Service Record Sheet
2.5.1. An electronic copy of the sheet is available to aid reproduction (or copy next page).
2.5.2. Each lifejacket serviced should be recorded either individually or as a batch, showing the serial
numbers and the work performed during the service.
2.5.3. The service record sheet should be signed and a copy given to the owner certifying that the lifejacket
has been serviced.
2.5.4. All replacement parts should be noted - recording either the serial numbers of the component or the
expiry date.
2.5.5 The record sheet shown on the next page is a recommended version. Similar record sheets,
including the same information, may also be used.
2
Section
Fig. 2.4 Table of Tools Required
Crewsaver Servicing Tool Kit
A fine screw driver or tool suitable for removing gaskets
Boning tool
Roller
Brushes
Scissors or good quality trimming shears
“Chinagraph” pencil
Tailors chalk
Fine point indelible pen
1 off metal calibrated metre stick
Scales to weigh gas cylinders 0-1000gram (+1/-1 grams)
Adaptor/tee piece for testing inflation chambers.
Manometer 0-500Mbar
Timing Device
Thermometer 0-40ºC
Clean and dry air supply
1 off ball pein hammer
450mm wide bag sealer (3mm element)
Suitable large surface area for the work to be carried out
1 off FR steel cabinet (adhesive store)
1 off HD industrial sewing machine (e.g. Singer 96K, Juki, Durkopp etc.)
N.B. In case of difficulty contact Crewsaver direct (Not sewing machines, cabinets or tables - these parts may be sourced locally).
Description Type

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2
Section 2
LIFEJACKET SERVICING SCHEDULE
SERVICED BY:
CERTIFICATE NUMBER:
VESSEL
W/O Number:
Crewsaver
LAST SERVICED BY DATE OF LAST SERVICE
SERIAL NUMBER/S:

CHAMBER INSPECTION COMMENTS
GENERAL CONDITION
MATERIAL
WELDS
WEBBINGS
RETRO TAPE
WHISTLE
ORAL TUBES
RELIEF VALVES
MANIFOLDS
SCHRAEDER VALVES
CYLINDERS
LIGHT
CYALUME POCKET
BUDDY LINE

INFLATION MECHANISM COMMENTS
OPERATING MECHANISM
CORD
AUTOMATIC CAPSULE
WASHERS
RETAINING NUT
RETAINING CLIP
TOGGLE

SPRAY HOOD COMMENTS
FABRIC
ATTACHMENT
VELCRO
REPAIRED ITEMS (COMMENTS)
TYPE
CUSTOMER

WEBBINGS COMMENTS
WAIST BELT / HARNESS
BACK STRAP
LIFTING BECKET
CROTCH STRAP
BUCKLES
STITCHING
ON
OFF
RELIEF VALVE TEST RESULTS FRONT
CHAMBER
OPEN
CLOSE
REAR
CHAMBER
DATE:

COVER COMMENTS
MATERIAL
VELCRO
ZIP
PLB POCKETS
PRESSURE TEST RESULTS
FRONT
CHAMBER
REAR
CHAMBER
TIME
TEMP. ON OFF

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UML Mk3 Auto Socket
2.6 Lifejacket Servicing Tool Kit
UML Mk5 Auto Socket
Turned Socket
Calibrated Socket Driver
(Tighten Cylinder)
Calibrated Socket Driver
(Remove & Replace Locking Nuts
For UML & HR)
Calibrated Torque Driver
(Schraeder Valve)
2
Section 2

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3.1 Unpacking
3.1.1 Starting at the inflation mechanism side of the outer cover, unpeel the velcro or pull the zips apart (zipped
version only), exposing the operating head and cylinder. Care should be taken not to snag the firing line.
See Fig 3.1 and Fig 3.2 for Adult versions & Fig 3.3 for Junior version.
WARNING: All defects should be noted onto the service record sheet.
3.1.2 Remove the operating mechanism.
3.1.2.1 Following unpacking refer to:
a.) Manual Operation: Fig 3.3 - Halkey Roberts operating head removal.
b.) Automatic Operation: Fig 3.4 - United Moulders Mk5 Automatic operating head.
3.1.2.1.1 Automatic Only. Unscrew the Automatic Capsule if fitted from the operating
mechanism. Place to one side for testing and reassembly later. See Section 6 for details.
3.1.2.1.2 Carefully remove the inflation cylinder by unscrewing it from the operating
mechanism. Retain for further Inspection. Refer to Section 5.
3.1.2.1.3 Remove Operating Mechanisms (and upper and lower manifold gaskets on
Halkey Roberts operating heads only) by unscrewing the retaining nut on the top of the
inflation mechanism. Retain for further Inspection. Refer to Section 5.
3.1.3. Remove light and battery if fitted and if required. Place to one side for further inspection. Refer to
section 5.
3.1.4. For Cleaning. Refer to Section 4.
3.1.5. Carry out visual inspection. Refer to section 5.
3
Section