Survitec Group Crewsaver Crewfit Twin 275N User manual

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Date: April 2014
Issue No: 9
Crewsaver - Servicing Manual : Crewsaver Crewfit Twin Lifejacket
SERVICE MANUAL
CREWFIT TWIN LIFEJACKET
Survitec House, Lederle Lane, Gosport,
Hants. PO13 0FZ, England.
Tel: [phone] Fax: [phone]
email: crewsa[email protected]
Web: www.crewsaver.com
R29965

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Issue No: 9
Crewsaver - Servicing Manual : Crewsaver Crewfit Twin Lifejacket
No.
Issue 9
Issue 10
Description
Section outlining the scope of the Manual added
on Index page.
Page 4 - change in procedure for accessing
manuals on the website.
Section 8.1.3.2 - New procedure for fitting
replacement cylinders to Hammar mechanism.
Section 5.4 - Expired L6 Lights to be replaced by
CSL Lights.
CSL Light added to Parts List
Date
June 2011
April 2014
Service Bulletins and Amendments Register
DN: cn=scott.
sanders@surv
itecgroup.com
Date:
2014.05.07
15:43:17
+01'00'

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Issue No: 9
Crewsaver - Servicing Manual : Crewsaver Crewfit Twin Lifejacket
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 Crewfit Twin 275N lifejacket without any current derivatives.

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Crewsaver - Servicing Manual : Crewsaver Crewfit Twin Lifejacket
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 Twin is a twin chamber 275N inflatable lifejacket.
1.2.2. The lifejacket is both SOLAS/MED approved and 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 two individual chambers each providing 150N buoyancy.
To ensure full buoyancy is achieved both chambers must be inflated. Each chamber is fitted with an oral tube to
ensure full buoyancy can be achieved and maintained 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. This lifejacket is inflated by automatic firing mechanisms.
1.2.7. This lifejacket is provided with a light that operates when the lifejacket inflates. It can be fitted with a crutch strap
and a spray hood that conforms to EN394.
1.2.8. This lifejacket comes in two different versions, the waist belt version and integral deck safety harness version
which both have a velcro cover closure. The Crewfit Twin can also be fitted with a fall arrest harness approved to
EN361.
1
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Crewsaver - Servicing Manual : Crewsaver Crewfit Twin Lifejacket
1.3 Data Sheet
Features:
Front Chamber Buoyancy:
Rear Chamber Buoyancy:
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
Hard wearing cover
Whistle - fitted
Retro-reflective tape
Lifting Becket - fitted
Light - fitted
Spray Hood
Thigh straps
Fall Arrest Harness
Closure method
Alternative covers
Crewfit Twin 275N Lifejacket
150N
150N
300N
275N
Orange
X
X
X
33g
X
Optional
N/A
X
X
-
X
X
X
X
X
Optional
Optional
Optional
Velcro
-
1
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1
Section
1.4.1 General Features - Non-Harness
Orange PU Coated Polyester
39mm Polyester
Neck Retainer
50mm x 100mm Solas Approved
Retro Reflective Tape
Light
F R O N T
DOT (UK)
APPROVED
PERSON
OF 32 KG
OR MORE
Spanish Gold PU coated Nylon
Twin Inflator
Whistle
Oral Tube
33gm Cylinder
Mk5 Firing Head
and Capsule
SS40 Buckle
40mm Black Polyester
Back-strap
Crewsaver Badge
40mm Black
Polyester belt
Firing Head
pull tab
Screen print
Sprayhood

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1
Section
1.4.2 General Features - Harness
Orange PU Coated Polyester
39mm Polyester
Neck Retainer
50mm x 100mm Solas Approved
Retro Reflective Tape
Light
F R O N T
DOT (UK)
APPROVED
PERSON
OF 32 KG
OR MORE
Spanish Gold PU coated Nylon
Twin Inflator
Whistle
Oral Tube
33gm Cylinder
Mk5 Firing Head
and Capsule
Stainless Steel Buckles
(Square Link & 3 Bar Buckle)
50mm Black Nylon
Back-strap
Crewsaver Badge
50mm Black
Nylon belt
Firing Head
pull tab
Screen print
Sprayhood

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CREWFIT
FRONT
PERSONS OF
32 KG
OR MORE
CREWFIT
FR O NT
PERSONS OF
32 KG
OR MORE
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
lanyards down if manual
inflation is required).
Pull crutch strap (if fitted)
through in between legs
a n d f a s t e n b u c k l e ,
tension webbing to fit.
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 2
3
5
4
6
1
Section
1.5.1 Donning Instructions - Crewfit Twin Non-Harness

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CREWFIT
PERSONS OF
32 KG
OR MORE
FRON T
LR APPROVED
AUTHORISED
BY MCA
Don the lifejacket like a normal jacket The shoulder straps should then be
positioned down the centre of the
back.
Pull crutch strap (if fitted)
through in between legs and
fa st en buckle , tension
webbing to fit.
Fasten the interlocking
front buckle as shown.
1 2
3 4
CREWFIT
PERSONS OF
32 KG
OR MORE
FRON T
LR APPROVED
CREWFIT
PERSONS OF
32 KG
OR MORE
FRO N T
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
lanyards down if manual
inflation is required).
Adjust the belt length by pulling
the webbing through the stainless
steel front buckle to achieve a
secure fit. And thread through belt
tidy. (As shown above).
5 6
PERSONS OF
32 KG
OR MORE
1
Section
1.5.2 Donning Instructions - Crewfit Twin Harness

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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 (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
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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 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 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 lockable 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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Crewsaver - Servicing Manual : Crewsaver Crewfit Twin Lifejacket
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
Section
2

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2.6 Lifejacket Servicing Tool Kit
UML Mk3 Auto Socket
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)
Section
2

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3.1 Unpacking
3.1.1. Starting at the bottom of the outer cover, unpeel the velcro and open up the lifejacket,
exposing the operating heads and cylinders. See Fig 3.1.
WARNING: Care should be taken not to snag the firing line
3.1.2. Open the zip around the outside of the two inflation chambers by peeling the chambers apart. 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 Following unpacking refer to Fig 3.2 - Crewsaver Mk5 Automatic operating head removal. If
the jacket is fitted with United Moulders Mk3 operating heads, refer to Fig 3.3.
3.1.3.1.1 Unscrew the Automatic Capsule from the operating mechanism. Place to one side
for testing and reassembly later. See Section 6 for details.
3.1.3.1.2 Carefully remove the inflation cylinder by unscrewing it from the operating
mechanism. Retain for further Inspection. Refer to Section 5.
3.1.3.1.3 Remove Operating Mechanisms by unscrewing the retaining nut on the top of the
inflation mechanism. Retain for further Inspection. Refer to Section 5.
3.1.3.2 If Hammar operating mechanisms are fitted, remove using the special Hammar operating
head "Service Key". See Fig 3.4. Place to one side for further inspection. Refer to Section 5.
3.1.4. Remove light and battery 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

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Crewsaver - Servicing Manual : Crewsaver Crewfit Twin Lifejacket
Fig 3.1 Unpacking the Lifejacket
3
Section
Fig. 3.1.1 Fig. 3.1.2
Fig. 3.1.3 Fig. 3.1.4
Fig. 3.1.5 Fig. 3.1.6
F R O N T
DOT (UK)
APPROVED
PERSON
OF 32 KG
OR MORE
F R O N T
DOT (UK)
APPROVED
PERSON
OF 32 KG
OR MORE
F R O N T
DOT (UK)
APPROVED
PERSON
OF 32 KG
OR MORE

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3
Section
Fig. 3.2.3 Fig. 3.2.4
Fig 3.2 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 33 gram cylinders from the automatic
operating heads. Once the cylinders have 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 each
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.
R29965
Fig. 3.2.2
Fig. 3.2.1

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Fig 3.3 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

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3
Section
Fig 3.4 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. 3.4.1 Fig. 3.4.2
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 the same.
Fig. 3.4.3 Fig. 3.4.4

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4.1 Cleaning Lifejackets
4.1.1 The current standard cover of the Crewfit Twin is made from a 300d polyester fabric with a polyurethane
coating 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 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