Survitec Group Crewsaver Crewfit 290N User manual

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
Page
of 51
1
R29965
SERVICE MANUAL
CREWFIT 290 LIFEJACKET
Survitec House, Lederle Lane, Gosport,
Hants. PO13 0FZ, England.
Tel: [phone] Fax: [phone]
email: crewsa[email protected]
Web: www.crewsaver.com
R29965

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
Page
of 51
2
No.
Issue 2
Issue 3
Description
Page 4 - change in procedure for accessing manuals on the
website.
Section 8.1.3.3 - change of procedure for replacing CO
2
cylinders on Hammar mechanisms.
Section 5.10 and Section 6.4 - Expired L6 Lights to be
replaced by CSL Lights.
CSL Light added to Parts List
New Packing drawings for Standard model.
References to 290 Advanced model removed.
References to Fire Resistant model added.
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
Sept 2014
April 2016
Service Bulletins and Amendments Register

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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
3.1 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 290N lifejacket without any current
derivatives.

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
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 Crewfit 290N is a single chamber Level 275 PFD (Inflatable lifejacket).
1.2.2. The lifejacket is CE approved to BS EN ISO 12402-2.
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, a Standard automatic firing mechanism or a
Hammar hydrostatic mechanism, and uses a 60 gr. CO cylinder.
2
1.2.6. This lifejacket comes in two different versions, the waist belt version and integral deck safety harness
version. The standard Crewfit 290 has a zip and velcro cover closure system.
1.2.7 The outer cover is made from a hard wearing material. The colour of the outer cover of the standard Crewfit
290N is normally red or blue. It can also be supplied with an industrial Heavy Duty cover or a Fireproof cover
with a unique wrap around system to protect the zip and velcro.
1.2.8 This lifejacket has permanently fitted dual crutch straps and dual lifting beckets.
1
Section

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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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
Dual Lifting Becket - fitted
Light - fitted
Spray Hood - fitted
Dual Thigh straps - fitted
Fall Arrest Harness
Closure method
Alternative covers
Crewfit 290N
290N
275N
Red or blue
-
-
X
60g
According to
Customer
Choice
X
X
N/A
X
X
X
X
Optional
Optional
X
N/A
Zip and Velcro
Heavy Duty, Fire Resistant
-
1
Section

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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1
Section
1.4.1 General Features - Crewfit 290 Non Harness
LLOYDS REGISTER
APPROVED,
AUTHORISED BY MCA
ADULT
43+KG
0191/10
LLOYDS REGISTER
APPROVED,
AUTHORISED BY MCA
ADULT
43+KG
0191/10
Polyester Cover
with Zip and Velcro
Closure
SS40 Buckle
40mm Stainless Steel
Contour Buckle
25mm Side Release
buckles
25 mm Side
Release Buckles
40mm Polyester Belt
40mm Polyester
Belt
25mm Polypropylene
Crutch Straps
25mm Polypropylene
Crutch Straps
40mm Polypropylene
Back Strap / Inflation
Chamber Retainer
40mm Polypropylene
Back Strap / Inflation
Chamber Retainer
Heat Seal 275N logo

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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1.4.2 General Features - Crewfit 290 Harness
1
Section
Stainless Steel D
ring
LLOYDS REGISTER
APPROVED,
AUTHORISED BY MCA
ADULT
43+KG
0191/10
LLOYDS REGISTER
APPROVED,
AUTHORISED BY MCA
ADULT
43+KG
0191/10
Polyester Cover
with Zip and Velcro
Closure
50mm Stainless Steel
Contour Buckle
25mm Side
Release buckles
25 mm Side
Release Buckles
50mm Nylon Belt
50mm Nylon Belt
25mm Polypropylene
Crutch Straps
25mm Polypropylene
Crutch Straps
40mm Polypropylene
Back Strap / Inflation
Chamber Retainer
40mm Polypropylene
Back Strap / Inflation
Chamber Retainer
50mm Stainless Steel
Square Link and Three
Bar Buckle
Heat Seal 275N logo

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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JERK TO
INFLATE
JERK TO
INFLATE
LLOYDS REGISTER
APPROVED,
AUTHORISED BY MCA
ADULT
43+KG
0191/#
Aluminised cloth
with Zip and Velcro
Closure
Aluminised cloth flap
covering the Zip and Velcro
SS40 Buckle
25 mm Side Release
Buckles
40mm Polyester Belt
25mm Polypropylene
Crutch Straps
40mm Polypropylene Back
Strap / Inflation Chamber
Retainner
40mm Stainless Steel
Contour Buckle
40mm Polyester Belt
Hammar Lanyard and
toggle
40mm Polypropylene Back
Strap / Inflation Chamber
Retainer
1.4.2 General Features - Crewfit 290 Fire Resistant
1
Section

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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1.5.1 Donning Instructions - Crewfit 290N
1
Section
DONNING YOUR CREWFIT 290N LIFEJACKET
ADJUSTING AND FITTING YOUR LIFEJACKET

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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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

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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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 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

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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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
Crewsaver Vemnturi Vacuum System
Clean and dry air supply
1 off ball pein hammer
450mm wide bag sealer (3mm element)
Back pressure test kit
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

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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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:
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
R29965R29965

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
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2.6 Lifejacket Servicing Tool Kit
2
Section 2
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)

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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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 for the Crewfit 290 Standard and Fig 3.2 for the Crewfit 290 Advanced.
WARNING: All defects should be noted onto the service record sheet.
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.
3.1.2.2 If a Hammar operating mechanism is fitted, remove using the special Hammar operating
head “Service Key". See Fig 3.5. Place to one side 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

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
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3
Section
Fig. 3.1.1 Fig. 3.1.2
Fig. 3.1.3 Fig. 3.1.4
Fig 3.1 Unpacking the Crewfit 290 Standard
LLOYDS REGISTER
APPROVED,
AUTHORISED BY MCA
ADULT
43+KG
0191/10
LLOYDS REGISTER
APPROVED,
AUTHORISED BY MCA
ADULT
43+KG
0191/10

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
Issue No: 3
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Fig. 3.3.2Fig. 3.3.1
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.
Fig 3.3 Halkey Roberts Operating Head
Fig. 3.3.3
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.
Section
3

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
Date: November 2016
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3
Section
Fig. 3.4.3 Fig. 3.4.4
Fig. 3.4.2Fig. 3.4.1
Fig 3.4 United Moulders 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. Check the date stamp on the cylinder and discard
if expiry date is before the date of the next annual
service or the capsule has been fired and replace with a
new automatic firing capsule upon reassembly.
Please note: The operating head may not match the images above but the processes are always the same.

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
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Fig 3.5 Hammar Operating Head
1
1.
Place the lifejacket 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. 3.5.1 Fig. 3.5.2
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.
Fig. 3.5.3 Fig. 3.5.4
Section
3

Crewsaver - Servicing Manual : Crewsaver Crewfit 290N Lifejacket
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4.1 Cleaning Lifejackets
4.1.1 The current standard cover of the Crewfit 290N is made from a polyester fabric with a polyurethane
coating that can be cleaned with care. The cover of the Crewfit 290N Advanced is made from a PU
coated nylon material. 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 (if fitted) 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 and
allowed 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