Crewsaver ERGOFIT 190 User manual

Date: November 2016
Issue No: 3
Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets
Page
Of 50
1
SERVICE MANUAL
ERGOFIT 190 & 290
LIFEJACKETS
Survitec House, Lederle Lane, Gosport,
Hants. PO13 0FZ, England.
Tel: [phone] Fax: [phone]
email: crewsa[email protected]
Web: www.crewsaver.com
R29965

Date: November 2016
Issue No: 3
Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets
Page
Of 50
2
No.
Issue 2
Issue 3
Description
Page 4 - change in procedure for accessing
manuals on the website.
Manual expanded to include Ergofit 190N Pro and
290N EX
References to Schrader Valves changed to UML
PS Short Valves
Reference to Venturi Vacuum System
added (sections 6.1.2, 8.1.2 and Parts List)
Back pressure testing of the operating head added
Date
April 2014
November 2016
Service Bulletins and Amendments Register

Date: November 2016
Issue No: 3
Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets
Page
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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
2.6 Servicing Tool Kit
Section 3
3 Unpacking the Lifejacket
Section 4
4 Cleaning & Laundering
Section 5
5 Inspection
Section 6
6 Testing
Section 7
7 Repairs
Section 8
8 Assembly & Repacking
Section 9
9 Replacement parts
Scope
This manual covers the servicing of the Ergofit 190N and 290N lifejackets without any
current derivatives.

Date: November 2016
Issue No: 3
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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 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 Ergofit 190N CS (Coastal), Ergofit 190N OS (Offshore) and Ergofit 190N Pro are single chamber Level
150 PFDs (Inflatable lifejackets).
1.2.2. The lifejackets are CE approved to BS EN ISO 12402-3.
1.2.3. The lifejackets are easy to don.
1.2.4. The buoyancy of the jackets 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. The Ergofit 190N CS is inflated by either a Prosensor manual firing mechanism, a standard Prosensor
automatic firing mechanism or a Hammar hydrostatic mechanism, and uses a 38 gr. CO cylinder.
2
1.2.6 The Ergofit 190N OS and Ergofit 190N Pro are inflated by a standard Prosensor automatic firing mechanism
or a Hammar hydrostatic mechanism, and use a 38 gr. CO cylinder.
2
1.2.7. All versions come with an integral soft loop deck safety harness approved to ISO 12401 and EN1095. All
versions have a zip closure system and in addition the CS version has a front zip.
1.2.8 The outer covers are made from a hard wearing black material.
1.2.9 All versions have permanently fitted dual crutch straps and dual lifting beckets.
1.2.10 The Ergofit 190 OS and Ergofit 190N Pro ha a light and sprayhood fitted as standard (optional on CS ve
version).
1
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Issue No: 3
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1.2 Product Description (Continued)
1.2.1. The Ergofit 290N OC (Ocean) and Ergofit 290N EX are single chamber Level 275 PFDs (Inflatable
lifejackets).
1.2.2. The lifejackets are CE approved to BS EN ISO 12402-2.
1.2.3. The lifejackets are easy to don.
1.2.4. The buoyancy of the jackets 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. Both versions are inflated by a standard Prosensor automatic firing mechanism or a Hammar hydrostatic
mechanism, and use a 60 gr. CO cylinder.
2
1.2.6. Both versions come with an integral soft loop deck safety harness approved to ISO 12401 and EN1095 and
have a zip closure system.
1.2.7 The outer cover is made from a hard wearing black material.
1.2.8 Both lifejackets have permanently fitted dual crutch straps and dual lifting beckets. They also have a light
and sprayhood fitted as standard.
1
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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 Prosensor Automatic
Manual Prosensor
Hammar Automatic
Manual Override
Oral inflation tubes
Pressure relief valves
Hard wearing cover
Whistle - fitted
Retro-reflective tape
Dual Lifting Becket - fitted
Light - fitted
Spray Hood - fitted
Dual Thigh straps - fitted
Fall Arrest Harness
Closure method - Standard model
Ergofit 190N CS
190N
150N
Black
-
-
X
38g
According to
Customer
Choice
X
X
N/A
X
X
X
X
Optional
Optional
X
N/A
Zip
-
1
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Date: November 2016
Issue No: 3
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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 Prosensor Automatic
Hammar Automatic
Manual Override
Oral inflation tubes
Pressure relief valves
Hard wearing cover
Whistle - fitted
Retro-reflective tape
Dual Lifting Becket - fitted
Light - fitted
Spray Hood - fitted
Dual Thigh straps - fitted
Fall Arrest Harness
Closure method - Standard model
Ergofit 190N Pro
190N
150N
Black
-
-
X
38g
According to
Customer
Choice
X
X
N/A
X
X
X
X
X
X
X
N/A
Zip
-
1
Section

Date: November 2016
Issue No: 3
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1.3.3 Data Sheet
Features:
Chamber Buoyancy:
Buoyancy Category:
Cover Colour
MCA (UK) Approved
SOLAS Approved
CE Approved
Cylinder size
Standard Prosensor Automatic
Hammar Automatic
Manual Override
Oral inflation tubes
Pressure relief valves
Hard wearing cover
Whistle - fitted
Retro-reflective tape
Dual Lifting Becket - fitted
Light - fitted
Spray Hood - fitted
Dual Thigh straps - fitted
Fall Arrest Harness
Closure method - Standard model
Ergofit 190N OS
190N
150N
Black
-
-
X
38g
According to
Customer
Choice
X
X
N/A
X
X
X
X
X
X
X
N/A
Zip
-
1
Section

Date: November 2016
Issue No: 3
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1.3.4 Data Sheet
Features:
Chamber Buoyancy:
Buoyancy Category:
Cover Colour
MCA (UK) Approved
SOLAS Approved
CE Approved
Cylinder size
Standard Prosensor Automatic
Hammar Automatic
Manual Override
Oral inflation tubes
Pressure relief valves
Hard wearing cover
Whistle - fitted
Retro-reflective tape
Dual Lifting Becket - fitted
Light - fitted
Spray Hood - fitted
Dual Thigh straps - fitted
Fall Arrest Harness
Closure method - Standard model
Ergofit 290N OC and EX
290N
275N
Black
-
-
X
60g
According to
Customer
Choice
X
X
N/A
X
X
X
X
X
X
X
N/A
Zip
-
1
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Date: November 2016
Issue No: 3
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1
Section
1.4.1 General Features - Ergofit 190N CS
Spray Hood
Inflatable Chin
Support
Cover: Zipped
Closure
X300cm² of
Reflective Tape
Lifting Beckets
And retainers
Spray Hood
Retaining
Webbings velcro to
inflation chamber
Oral Inflation Tube
and whistle
UML Prosensor
Automatic
Operating Head
Or
UML Prosensor
Manual Operating
Head
Or
Hammar Auto
Operating head
And 38gm CO
2
cylinder
CSL light
With auto
water
activation
Velcro retainer
for Epirb

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1.4.2 General Features - Ergofit 190N OS and
Pro
1
Section
Spray Hood
Inflatable Chin
Support
Cover: Zipped
Closure
X300cm² of
Reflective Tape
Lifting Beckets
And retainers
Spray Hood
Retaining
Webbings velcro to
inflation chamber
Oral Inflation Tube
and whistle
UML Prosensor
Automatic
Operating Head
Or
Hammar Auto
Operating head
and 38gm CO
2
cylinder
CSL light
With auto
water
activation
Velcro retainer
for Epirb

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1.4.3 General Features - Ergofit 290N OC and EX
1
Section
Spray Hood
Inflatable Chin
Support
Cover: Zipped
Closure
X400cm² of
Reflective Tape
Lifting Beckets
And retainers
Spray Hood
Retaining
Webbings velcro to
inflation chamber
Oral Inflation Tube
and whistle
UML Prosensor
Automatic
Operating Head
Or
Hammar Auto
Operating head
and 60gm CO
2
cylinder
CSL light
With auto
water
activation
Velcro retainer
for Epirb

Date: November 2016
Issue No: 3
Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets
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1.5.1 Donning Instructions - Ergofit 190N CS
1
Section
2
45
Don like a normal jacket.
Fasten front Zip and buckle. Adjust waist belt by
pulling webbing
forward for a close
secure fit .
Fasten crutch strap
buckles and adjust
straps by pulling
webbing downwards
for a close secure fit .
2
1
3
21 3
Tidy crutch straps by rolling excess webbing and securing with velcro tab

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1.5.2 Donning Instructions - Ergofit 190N OS and Ergofit 290N
OC
13
Don like a normal jacket.
2
1
45
3
21 3
Tidy crutch straps by rolling excess webbing and securing with velcro tab
Fasten the front buckle. Fasten crutch strap buckles
and adjust straps by pulling
webbing downwards
for a close secure fit .
Adjust waist belt by
pulling webbing forward
for a close secure fit .
1
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1.5.3 Donning Instructions - Ergofit 290N EX
2
Don like a normal jacket.
2
1
21 3
Tidy crutch straps by rolling excess webbing and securing with velcro tab
Fasten two front buckles. Adjust waist belt by
pulling webbing
forward for a close
secure fit .
Fasten crutch strap
buckles and adjust
straps by pulling
webbing downwards
for a close secure fit .
3 4 5
1
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Date: November 2016
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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
1
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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 2

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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.
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)
Crewsaver Venturi Vacuum System
Back pressure test unit
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
2
Section 2

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2
Section 2
R29965R29965
LIFEJACKET SERVICING SCHEDULE
SERVICED BY:
CERTIFICATE NUMBER:
VESSEL
W/O Number:
LAST SERVICED BY DATE OF LAST SERVICE
SERIAL NUMBER/S:
RQ
CHAMBER INSPECTION COMMENTS
GENERAL CONDITION
MATERIAL
WELDS
WEBBINGS
RETRO TAPE
WHISTLE
ORAL TUBES
RELIEF VALVES
MANIFOLDS
UML PS Short Valves
CYLINDERS
LIGHT
CYALUME POCKET
BUDDY LINE
RQ
INFLATION MECHANISM COMMENTS
OPERATING MECHANISM
CORD
AUTOMATIC CAPSULE
WASHERS
RETAINING NUT
RETAINING CLIP
TOGGLE
RQ
SPRAY HOOD COMMENTS
FABRIC
ATTACHMENT
VELCRO
REPAIRED ITEMS (COMMENTS)
TYPE
CUSTOMER
RQ
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:
RQ
COVER COMMENTS
MATERIAL
VELCRO
ZIP
PLB POCKETS
PRESSURE TEST RESULTS
FRONT
CHAMBER
REAR
CHAMBER
TIME
TEMP. ON OFF

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2
Section 2
2.6 Lifejacket Servicing Tool Kit
Cylinder Torque Strap
UML Mk5 Auto Socket
Manometer
Valve Extraction Tool
Pressure Measuring
Adaptor
Inflation Adaptor
Turned Socket
Calibrated Socket Driver
(Tighten Cylinder)
Calibrated Socket Driver
(Remove & Replace Locking
Nuts For UML & HR)
Calibrated Torque Driver
(Schraeder Valve)