Crewsaver VOYAGER 275N User manual

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
1
SERVICE MANUAL
VOYAGER 275N LIFEJACKET
Survitec House, Lederle Lane, Gosport,
Hants. PO13 0FZ, England.
Tel: [phone] Fax: [phone]
email: crewsa[email protected]
Web: www.crewsaver.co.uk
R29965

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
2
No.
Issue 2
Description
Section outlining the scope of the Manual added on Index
page.
Reference to Venturi Vacuum System added (sections 6.1.2,
8.1.3 and Parts List).
CSL Light updated to show new switch.
Back pressure testing of the operating head added
Date
November 2016
Service Bulletins and Amendments Register

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
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 Lifejacket Servicing Record Sheet
Section 3
3.1 Unpacking the Lifejacket
Section 4
4.1 Cleaning Lifejackets
Section 5
5.1 Inspection
Section 6
6.1 Testing
Section 7
7.1 Repairs
Section 8
8.1 Assembly
Section 9
9.1 Replacement parts
Scope
This manual covers the servicing of the Voyager 275N lifejacket without any current derivatives.

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
4
1.1 Introduction
1.2 Product Description
1.1.1. This Service Manual will be published on the Crewsaver website ( ). Click on Industrial www.crewsaver.co.uk
Commercial Products on the left hand side of the screen then select Trade Area. 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 ( ). Emails will also be sent. It is the service www.crewsaver.co.uk
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 Voyager 275 is a single chamber 275N inflatable lifejacket.
1.2.2. The lifejacket is CE approved to EN 399 -275N Lifejackets.
1.2.3. The lifejacket is easy to don and work in whilst still retaining high in-water performance.
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. The high buoyancy of this lifejacket allows it to be suitable when the user is wearing heavy clothing , an
immersion suit or carrying tools.
1.2.6. The standard version of this lifejacket is inflated by a Hammar automatic firing mechanism. Other versions
may be encountered which are inflated by a Hammar manual system, a Halkey Roberts manual system or a
Crewsaver standard auto mechanism.
1.2.7. This lifejacket comes in a waist belt version which has a velcro cover closure system.
1.2.8 The outer cover is made from a heavy duty PVC coated polyester, flame retardant material.
1
Section

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
5
1.3 Data Sheet
Features:
Total 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
Heavy Duty cover
Whistle - fitted
Retro-reflective tape
Lifting Becket - fitted
Light - fitted
Spray Hood
Thigh straps
Fall Arrest Harness
Closure method
Alternative covers
Voyager 275N Lifejacket
290N
275N
Orange
-
-
X
60g
According
to customer
choice
X
X
N/A
N/A
X
X
X
Optional
Optional
Optional
N/A
Zip and Velcro
-
1
Section

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
6
USE ONLY
CREWSAVER
60g CO2
Disposable Cylinder
FOLD
UNDER
Hammar
Operating Head
FOLD
UNDER
Plastic Press Studs
40mm Black Polyester
Back Strap
Crewsaver Badge
Solas Approved
Retro Reflective Tape
40mm Black Polyester
Waist Belt
SS-40 Buckle
Heathcoat Mesh
1
Section
1.4.1 General Features - Non-Harness Hammar
Orange PVC coated polyester,
flame retardant
Spanish Gold PU Coated Nylon
Solas Approved
Retro Reflective Tape
60g CO
Cylinder
2
20mm Velcro - Hook
20mm Velcro - Loop
Oral Tube
40mm Black Polyester
Retaining Strips

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
7
1
Section
1.4.2 General Features - Non-Harness
Auto
Spanish Gold PU Coated Nylon
Solas Approved
Retro Reflective Tape
60g CO
Cylinder
2
USE ONLY
CREWSAVER
60g CO2
Disposable Cylinder
FOLD
UNDER
FOLD
UNDER
20mm Velcro - Hook
20mm Velcro - Loop
Oral Tube
40mm Black Polyester
Retaining Strips
Mk5 Firing Head
and Capsule
Plastic Press Studs
40mm Black Polyester
Back Strap
Orange PVC coated polyester,
flame retardant
Crewsaver Badge
Solas Approved
Retro Reflective Tape
40mm Black Polyester
Waist Belt
SS-40 Buckle
Heathcoat Mesh

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
8
CREWFIT
CREWFIT
Don the lifejacket like a normal jacket The backstrap should then be positioned
down the centre of the back.
The lifejacket will inflate
a u t o m a t i c a l l y u p o n
immersion in water. (Pull
lanyard down if manual
inflation is required).
Fasten the interlocking
front buckle as shown.
Adjust the belt length by pulling the
webbing through the side buckle to
achieve a secure fit.
(As shown above).
1
1
Section
1.5.1 Donning Instructions - Voyager 275 Non-Harness
2
3
4
5

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
9
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 (3 years from date of issue)
Certificate.
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 there after 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 repairs or 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 only be marked using wax based crayon; Marks shall be 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 are limited to that detailed in section 7.1
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

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
10
2.3.1 This automatic jacket should be stowed in accordance with the manufacturers 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 Automatic 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 allow
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 inflatable stole 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 simular 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
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.
2.3.8 It is advised that personnel are familiarised with the operation of all lifejackets and lifesaving appliances.
2.3 General Care
2
Section

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
11
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
Hammar inflator body bench clamp
Hammar cylinder torque clamp
Loctite 222 Adhesive
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).
Note: Prior consent to carry out any repairs must be pre-approved by Crewsaver. All repairs to stitching must be in
accordance with this manual.
Description Type

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
12
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
Schrader 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

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
13
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)

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
14
3.1 Unpacking
3.1.1. Firstly open the press studs around the collar of the jacket. Then starting at the inflation mechanism
side of the pouch, unpeel the velcro, opening the pouch and exposing the operating head and cylinder.
Then unpeel the velcro on the other side of the jacket. See Fig 3.1.
WARNING: Care should be taken not to snag the firing line
3.1.2. Open out the inflation chamber fully . Care should be taken not to snag the operating cords.
WARNING: All defects should be noted onto the service record sheet.
3.1.3 Remove the operating mechanisms.
3.1.3.1 If a Hammar operating mechanism is fitted, remove using the special Hammar operating head
“Service Key". See Fig 3.2. Place to one side for further inspection. Refer to Section 5.
3.1.3.2 Where other operating mechanisms are fitted, refer to:
a.) Manual Operation: Fig 3.4 - Halkey Roberts operating head removal.
b.) Automatic Operation: Fig 3.3 - Crewsaver Mk5 Automatic operating head removal.
C.) Automatic Operation: Fig 3.5 - United Moulders Mk3 Automatic operating head.
3.1.3.2.1 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.
3.1.3.2.2 Carefully remove the inflation cylinder by unscrewing it from the operating
mechanism. Retain for further Inspection. Refer to Section 5.
3.1.3.2.3 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.
3.1.4. Remove light and battery if fitted and if required. Place to one side for further inspection. Refer to
section 5
3.1.5. For Cleaning. Refer to Section 4.
3.1.6. Carry out visual inspection. Refer to section 5.
3
Section

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
15
Fig 3.1 Unpacking the Lifejacket
3
Section
Fig. 3.1.1 Fig. 3.1.2
JERK TO
INFLATE
Fig. 3.1.3 Fig. 3.1.4

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
16
Fig 3.2 Hammar Operating Head
1
1.
Place the lifejacket (PFD) on a
smooth, flat surface and wipe off
any water. Hold the gas cylinder
through the fabric, using one
hand.
2a
Locking ring
Key
2b
2.
Insert metal key as shown in 2a and turn the key counter-clockwise
(2b) between black locking ring and labelled yellow cap. The black
locking ring will now turn counter-clockwise.
Fig. 3.2.1 Fig. 3.2.2
Cap
3a3b
3.
Now turn black locking ring counter-clockwise (3a) and lift cap (3b).
(cap = yellow inflator operating head) Dispose of used cap.
Inflator body
Sealing ring
Red Indicator
4
4.
Squeeze sealing ring to elongate
and remove the inflator body
through the sealing ring. Dispose
of used inflator body in an
environmentally approved manner.
Please Note: The operating head may not match the images above, but the processes are always as above.
Fig. 3.2.3 Fig. 3.2.4
Section
3

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
17
3
Section
Fig. 3.3.3 Fig. 3.3.4
Fig. 3.3.2
Fig. 3.3.1
Fig 3.3 Crewsaver Mk5 Operating Head
Remove the operating head from the manifold which is
welded to the inflation chamber fabric. Inspect the
bottom sealing O-ring. This must be replaced with a new
part if damaged.
Unscrew the retaining nut from the top of the
operating head. Check for corrosion and discard if
corroded. Inspect the top sealing O-ring. This must be
replaced with a new part if damaged.
Unscrew the 60 gram cylinder from the automatic
operating head. Once the cylinder has been removed
inspect the cylinder O-Ring seal. Check the seal is in
place and that it is in a good condition. Take the cylinder
and check to see if the cylinder has been used. This
should be performed by check weighing. If under the
minimum weight as displayed on the cylinder body,
discard in a safe manner.
Unscrew the Automatic firing capsule from the end of the
operating head. This should only be done after the test
detailed in Section 6 has been performed in order to test
the old unit, or if the operating head has already been
fired. Discard and replace with a new automatic firing
capsule upon reassembly. The Capsule must be
replaced if it expires before the date of the next annual
service.

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
18
Fig. 3.4.2Fig. 3.4.1
Unscrew the 60 gram cylinder from the manual firing head. Check
to see if the cylinder has been used.
NOTE: This should be performed by check weighing. If under the
min. weight as displayed on the cylinder body, discard in a safe
manner.
Unscrew the valve retaining nut from the top of
the firing head, using a 9/16” socket or spanner.
Check for corrosion, discard if corroded.
Remove the top sealing gasket/ washer and
discard. This must be replaced with a new part
upon reassembly.
3
Section
Fig 3.4 Halkey Roberts Operating Head
Fig. 3.4.3
Remove the operating head from the manifold which is welded to
the inflator fabric. Remove the bottom gasket / sealing washer and
discard. This must be replaced with a new part upon reassembly.
Please Note: The operating head may not match the images above, but the processes are always the same.

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
19
Fig 3.5 United Moulders Mk3 Operating Head
JACKETS FITTED WITH THE Mk3 OPERATING AS ILLUSTRATED ABOVE SHOULD BE
RETURNED TO CREWSAVER WHO WILL DETERMINE WHETHER A REPLACEMENT Mk5
OPERATING HEAD CAN BE FITTED.
R29965
Section
3

Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
Date: November 2016
Issue No: 2
Page
of 36
20
4.1 Cleaning Lifejackets
4.1.1 The current standard cover of the Voyager 275 has a PVC coated polyester outer cover that can be
cleaned with care. In the event that contamination is such that the materials are inherently damaged
refer to section 7.
4.1.2 For all types of cover, mud can be removed with clean water and the zip can be cleaned with a stiff (not
wire) brush when dry.
4.1.2.1 Contaminants such as oil or diesel fuel may be sponged off immediately with clean water.
Allow to dry naturally.
4.1.2.2 Mud can be removed with a stiff (not wire) brush when dry.
4.1.2.3 Covers may be hand washed in good quality mild detergent in cool water (40°C). Rinse well, air
drip dry.
4.1.3 Sponge the inflation chamber with PURE SOAP SOLUTION ONLY. Rinse in clean water immediately,
inflate and air dry.
WARNING: Do not use proprietary cleaning fluids, thinners, spirits or similar substances.
4
Section