Stearns I590 Operating instructions

Stearns®I590 Cold Water
Immersion Suit
Repair Manual
The Coleman Company, Inc.
3600 North Hydraulic
Wichita, KS 67219 U.S.A.
Telephone: [phone]
Website: www.Colemanotation.com
(Revision Date: January 14, 2014)

TABLE OF CONTENTS
Page
Introduction 1
Identication Stamps (Section 1.0) 2
Inspection Documentation (Section 1.1) 6
Cleaning Instruction (Section 1.2.1) 9
Visual Inspection (Section 1.3) 13
Repairs (Section 1.4) 19
A) Technical Tips (Section 1.4) 19
B) Reection Tape (Section 1.4.1) 20
C) Hole, Jagged Tear (Section 1.4.2) 23
D) Clean Edge Tear (Section 1.4.3) 29
E) Repair Seam (Section 1.4.4) 33
F) Oral Tube (Section 1.4.5) 35
G) Head Support (Section 1.4.6) 38
H) Gloves (Section 1.4.7) 41
I) Wrist Gasket (Section 1.4.8) 45
J) Foot Repair (Section 1.4.9) 47
K) Replace Buddy Line (Section 1.4.10) 50
L) Turn Suit (Section 1.4.11) 53
Air Retention Testing (Section 1.5) 56
Stamp Suit (Section 1.6) 63
Repack (Section 1.7) 65
Closing Statement 68

1
INTRODUCTION
• These maintenance and test instructions are applicable to Stearns brand immersion suits and
related neoprene products manufactured by Coleman. Actual suits may look slightly different
from the suits shown in the pictures through out this manual due to variations among
different models.
• Maintenance and testing can only be carried out by a person who has successfully completed
a Coleman service-training seminar or under the direct supervision of such person.
• Recipients of these maintenance procedures are required to fully comply with all contents.
Contact The Coleman Company, Inc. for clarication of any procedure that is unclear.
• A documented record of all inspections is to be recorded and forwarded to Coleman quarterly
per year (January 1, April 1, July 1 and October 1) (copy of Form 4010009817).
• It is understood that authorization for maintenance and testing is limited to inspections and
minor repairs. Repair work other than outlined in this manual is prohibited and unauthorized
by Coleman.
• The maintenance and test facility bears full responsibility for ensuring test equipment is
calibrated and fully functional.
• The maintenance and test facility accepts full responsibility for all inspections and repairs
conducted under their supervision. Coleman will not be held accountable nor liable for repairs
performed by the repair facility.
• Contents, pictures, or any part of this manual cannot be copied or reproduced without written
authorization from The Coleman Company, Inc.
• I have read the above introduction and understand the responsibilities associated with
each paragraph.
Company Name
Date
Stamp
Signature
Printed Name

2
INSPECTION AND IDENTIFICATION STAMPS
Section 1.0
1.0 Purpose: This procedure sets forth the requirements for issuing, using, and
controlling the quality inspection and identication stamps.
2.0 Application: This procedure applies to inspectors and other personnel associated with
the issuance, use and/or control of quality inspection and identication
stamps.
3.0 Denitions:
3.1 None
4.0 Associated Materials
4.1 Receipt - - Immersion Suit Inspection and Identication Stamps Form 1.0.1-1
4.2 Identication Stamps - - Immersion Suit Inspection and Identication Stamps
Form 1.0.1-2
5.0 Procedure
5.1 Quality inspection and identication stamp must be of permanent waterproof ink.
5.2 Each stamp will be identied with a unique number and assigned to a specic
individual company.
5.3 The types of stamps are illustrated in Figure 1.0.1 -2 Quality Inspection and
Identication Stamps. Their uses are as follows:
Immersion Suit Acceptance Stamp indicates parts and assemblies tested and found
to be functionally acceptable.
Equipment Calibration Stamp is used to identify testing equipment and measuring
devices that have been calibrated to acceptable standards.
5.4 Coleman is responsible for issuing and controlling stamps.
5.5 One or more stamps, all with the same identifying number, will be issued
to a qualied person using Form 1.0.1-1. Receipt - - Quality Inspection and
Identication Stamps.
5.6 A separate record of stamps, by stamp number, is to be maintained using the
Control Log - - Quality Inspection and Identication Stamps Form 1.0.1-2.

3
5.0 Procedure (continued)
5.7 The stamp recipient is the only person permitted to use the assigned stamp and
is responsible for keeping it clean, its impression legible. Worn stamps must be
replaced.
5.8 The stamp recipient is responsible for immediately reporting the loss of a stamp
to The Coleman Company, Inc.
5.9 The Coleman Company, Inc. is responsible for the immediate preparation and
distribution of a quality bulletin announcing the loss of a stamp and citing dates
when its use will not be valid.
5 10 Stamps returned because of transfer or termination shall not be reissued for
6 months. Any stamp numbers that have been lost shall not be reused for 24
months after their reported loss.
Section 1.0

4
RECEIPT
IMMERSION SUIT INSPECTION AND IDENTIFICATION STAMPS
DATE STAMP(S) NO.*
ISSUED TO:
CITY AND STATE:
INDIVIDUAL:
IMPRESSION AND DESCRIPTION OF EACH STAMP ISSUED:
STAMPS ARE TO BE USED ONLY AS SPECIFlED IN COMPANY PROCEDURES.
STAMP DESCRIPTION
ACKNOWLEDGED:
AUTHORIZED ISSUER STAMP RECIPIENT
*ONLY ONE STAMP NUMBER SHOULD BE SHOWN. A SEPARATE RECEIPT SHOULD BE FILLED OUT
FOR EACH ADDITIONAL NUMBER.
FORM 1.0.1-1

SUBJECT:
Quality Inspection and
Identication Stamps
Effective Date
December 1, 1992
Number
1.0.1-2
Page Revision
IS
A
1
CAL
1
IMMERSION SUIT
EQUIPMENT CALIBRATION STAMP
Figure Quality Inspection and
Identication Stamps
Page 5

6
INSPECTION DOCUMENTATION
1.0 Purpose: This procedure denes the documentation of inspected immersion suits.
2.0 Application: Applies to the Coleman authorized and certied companies and their
certied inspectors.
3.0 Material: Form 4010009817 Inspection Report
Form 7.1.1-3B I590 AIR RETENTION RESULTS
4.0 Procedure: Inspection Report must be completely lled out when inspecting
immersion suits. All boxes should be checked or lled in as required.
Air retention results should be noted on Form 7.1.1-3B.
4.1 Distribution of Copies: Original (White): Customer
Yellow: Repair Facility
Pink: The Coleman Company, Inc.
4.2 Copies of all inspection reports (pink copies) should be forwarded to The
Coleman Company, Inc. January 1, April 1, July 1 and October 1 of each year.
Section 1.0

7
INSPECTION REPORT
Next Suggested Inspection Date:
FORM 4010009817
Certied Repair Facility:
REPORT #: DATE:
NAME & ADDRESS PHONE #: VESSEL NAME:
Needs Cleaning? (Y/N)
Main Zipper & Zipper Tab
Ination Valve and Hose
Reective Tape
Stencilling
Repairs Needed (Y/N)
Repairs Made (Form ISI -001-2)
Leak Test
Is Suit Seaworthy? (Y/N)
Stamp Suit
PFD Light
Battery Date
Whistle
Repack (Serial #’s Agree)
Storage Bag & Bag Closure
Other (Describe)
Suit Condemned
Suit Serial Notes

8
LOT/SERIAL # DEFECT LOCATION RETEST DATE PASS/
FAIL
ISSUE DATE 02/02/2012
REVISED DATE 08/02/2012
FORM 7.1.1-3B
I590 AIR RETENTION RESULTS
Annex to Resolution MSC. 81(70) - Production and Installation Tests, Part 2, 2.2:
Test each immersion suit with a constant pressure (minimum 0.29 psi) for a minimum of 15 minutes. Checked for leaks using a
leak detection uid. The air pressure should be appropriate to the type of material used in the manufacturer of the suit and should
never be less than 0.02 bar (0.29 psi).

9
1.0 Purpose: This procedure denes the cleaning care of Coleman immersion suits.
2.0 Application: Applies to the Coleman authorized and certied companies and their
certied inspectors.
3.0 Association Materials:
3.1 Materials Needed:
A) Mild liquid soap, same soap as used for leak detection may be used.
B) Soft bristle brush and/or sponge for scrubbing stains.
C) Fresh water only.
D) Large wooden hangers.
4.0 Procedure:
4.1 CAUTION: Do NOT dry clean or expose suit to any chemical solvents or
cleaners.
4.2 The suit should be laid on a clean at surface.
4.3 The suit should be hand washed with mild liquid soap and rinsed thoroughly
with plenty of fresh water (Figure 10-A)
4.4 If stains are present, gently rub the stain with a soft bristle brush and soap.
4.5 Hang suit on a large wooden hanger to dry in a well ventilated area. Do not
expose to sunlight or direct heat. Turn suit inside out and hang to dry if inside of
suit is damp or wet (Figure 10-B).
4.6 After suit is thoroughly dried, go to section 1.3.
Section 1.2
HAND WASHING OF IMMERSION SUIT

10
10-A Use a soft bristle brush and mild soap. Rinse well with fresh water.
10-B Hang suit on a large wooden hanger in a well ventilated area. Dry thoroughly inside and out.

11
1.0 Purpose: This procedure denes machine cleaning of immersion suits.
2.0 Application: Applies to the Coleman authorized and certied companies and their
certied inspectors.
3.0 Materials Needed:
A) Front loading automatic washer (Figure 12-A)
B) Aquaseal Wet Suit Shampoo (or similar neoprene shampoo)
C) Large wooden hanger
4.0 Procedures:
4.1 CAUTION: Do NOT dry clean or expose suit to any chemical solvents or
cleaners.
4.2 Open the front zipper completely.
4.3 Put ½ a tube of Wet Suit Shampoo in the machine.
4.4 Run machine on a warm water cycle.
4.5 When the machine cycle is done, carefully remove the suit to a clean wash tub.
There will be water trapped in the suit.
4.6 Hold the suit up by the legs with the hood inside the wash tub and let the water
drain out of the legs (Figure 12-B).
4.7 Hold the arms up by the gloves and let the water drain out of the arms (Figure
12-C).
4.8 Hang suit on a large wooden hanger to dry in a well ventilated area. Do not
expose to sunlight or direct heat. Turn suit inside out and hang to dry if inside of
suit is damp or wet (Figure 10-B).
4.9 After the suit is thoroughly dried, go to Section 1.3.
Note: A fan may expedite drying procedure.
Section 1.2
MACHINE WASHING OF IMMERSION SUIT

12
12-A Use a commercial grade
front loading wash
machine.
12-B Hold the suit by the feet
to expel water trapped
in the suit
12-C Hold suit by hands to
expel water trapped
in the arms.

13
NOTE: If suit is soiled, see cleaning section prior to visual inspection.
1.0 Purpose: This procedure denes the inspection and documentation systems for
verifying conformance with internal quality standards and regulatory
specications.
2.0 Application: Applies to the Coleman authorized and certied company and their
certied inspectors.
3.0 Procedure:
3.1 Place suit with storage bag on a well lit, dry surface. Compare storage bag serial
number with suit serial number. These two numbers should match exactly.
3.2 Visually inspect zipper teeth to insure there are no damaged or missing teeth.
Zipper toggle should be attached. Grasp zipper slide and slide up and down a
total of 5 cycles (up and down is one cycle). Again, inspect zipper for damage. If
damage is present, return to Coleman for repairs (Figures 15-A through 15-C).
3.3 Visually inspect head support system to ensure it is properly attached to the suit
and the ination tube is operable. If head support is not securely attached or
leaks are detected, refer to the repair section of this manual (Figures 16-A
through 16-C).
  NOTE:Knurlednutontheoralvalveislockedintheopenposition.
3.4 Check reective tape for general condition. Does suit have 31 sq. inches (200 sq.
cm.) of reective tape above the water line? Does it have a good bond to the suit
(Figure 17-A)?
3.5 Check to determine if suit is properly labeled with owner’s or ship’s name.
Section 1.3
VISUAL INSPECTION

14
3.6 Inspect all seams for missing stitching, rips, tears, or small punctures on both
front and back of suit. Refer to repair section for instruction on repairing or
returning suit to manufacturer. Make sure suit is dry and there are no chemical
stains on suit or auxiliary xtures (Figures 17-B through 18-C). If stains
exist, refer to cleaning section. If your immersion suit is tted with optional
accessories such as a buddy line or lifting harness - check condition visually
for damage.
3.7 After the suit has passed visual inspection, the results and comments shall be
recorded on the inspection form. Any needed repairs should be noted on Form
7.1.1-3B.
3.8 Make obvious repairs now.
3.9 Check whistle and light for proper operation. Make note of light and/or battery
expiration date. If whistle is missing, replace. If light is inoperable, replace
battery or complete light. Lights or batteries with expiration dates that are due
to expire in 6 months or less must be replaced. Replace with Coleman or other
approved light complying with SOLAS/MED.
3.10 Check storage bag for cleanliness and operational closures. If snaps are missing
or bent or bag is ripped - replace.
3.11 If no repairs are needed, go to Section 1.5 and leak test suit.
Section 1.3
Figure 14-A

15
15-A Example of broken
zipper teeth.
15-B Example of broken
zipper slide
15-C Example of broken
zipper slide.

16
16-A Inspect ination
tube to ensure air
tight bond.
16-B Inspect head
support attachment
area.
16-C Inspect tube and valve
to ensure they are
open and operable.

17
17-A Example of damaged
reective tape.
Replace both pieces.
17-B Example of damaged
gloves. (Return for
repair on immersion
suits)
17-C Inspect foot and
sole for proper
adhesion.

18
18-A Example of cut
in suit.
18-B Example of seam
with torn threads.
18-C Example of bag with
tear and broken snaps.