Page 1
Document No. 9102 SERVICE MANUAL 5323 Highway Avenue Jacksonville, FL 32254 USA Third Edition International (+001) 904 503 9733 Fax 904 503 9719 www.reveresurvival.com Page 1 TITLE PAGE...
Page 3
DOCUMENTING A REVISION Record the Revision No. and Revision Date. Remove the old sheet and replace it with the revised copy. Record the Insert Date and then initial in the Inserted By column. Revisions made ONLY by Revere Supply, Inc. INSERTED INSERTED REV.
Page 4
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 RR - 2...
Page 5
Revere Supply Co., Inc., Jacksonville, FL 32254 T. 904.786.0033 F. 904.786.0890 LETTER OF TRANSMITTAL 9102 Holders of Manual No. Coastal Compact Title: Service Manual Revision No.: Date: 05/2013 Signed: Date: 05/29/2013 Director of Technical Services Pages: Added (A) Pages Affected...
Page 6
Revere Supply Co., Inc., Jacksonville, FL 32254 T. 904.786.0033 F. 904.786.0890 LETTER OF TRANSMITTAL Pages: Added (A) Pages Affected Revision Highlights Replaced (RP) Removed (RM) Changed image Revised wording 8-14 Replaced lubricant type 8-18 Revised wording 8-23 Changed part numbers...
Page 7
Revere Supply Co., Inc., Jacksonville, FL 32254 T. 904.786.0033 F. 904.786.0890 LETTER OF TRANSMITTAL 9102 Holders of Manual No. Coastal Compact Title: Service Manual Revision No.: Date: 01/2011 Signed: Date: 02/18/11 Director of Technical Services Pages: Added (A) Pages Affected...
Page 8
Revere Supply Co., Inc., Jacksonville, FL 32254 T. 904.786.0033 F. 904.786.0890 LETTER OF TRANSMITTAL Pages: Added (A) Pages Affected Revision Highlights Replaced (RP) Removed (RM) CHAPTER 7 7-1, 7-10 Added canopy to component repair CHAPTER 8 Added canopy to component setup...
Page 9
SERVICE BULLETIN All service bulletins which are incorporated into this manual are required to be recorded in this list. All updates to this list will be made by the owner of the manual. SERVICE DATE OF DATE TITLE/DESCRIPTION REV. No. BULLETIN No.
Page 10
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 SB - 2...
Page 11
This service bulletin is to advise service stations of the change in valves, firing heads and cylinders for the Coastal Compact liferafts. Starting from July, 2014 all Coastal Compact rafts produced by Revere will now be equipped with the following valves...
Page 12
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 VALVE IDENTIFICATION Thanner OTS-45 Mirada A-52030 Mirada B-51994 FIRING HEAD 95-41115-103 (M70) OPERATING INSTRUCTIONS 3/8-18 NPSM See Chapter 8 – Assembly and Packing, Inflation Valve Disassembly & Rebuilding Process for instructions on servicing the 41115 inflation valve.
Page 13
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 95-43013-101 CYLINDER ADAPTOR FOR THANNER DK-99S OPERATING HEAD DISASSEMBLY, REPAIR, AND REASSEMBLY The following instructions are copied from Thanner QA doc. No. 2057 The adaptors are part of the THANNER inflation systems for life rafts and constructed for marine and aviation use.
Page 14
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 REMOVE THE CYLINDER VALVE: Remove the cylinder valve using a 30mm spanner tool. Use suitable spanners only, to avoid damage of the valves. With the cylinder completely discharged and clamped firmly to the vice bench, remove the filling head.
Page 15
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 IMPORTANT: To tighten or loosen the DK99S adaptor it is essential to use the tool 99-120. Place the new diaphragm holder into the valve and screw the holder carefully into the valve with your finger.
Page 16
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 NOTE 3: Inspect the condition of the filling tool and the 0-rings. If damaged, replace the o-rings (see page 3). It is important the O-rings are not warn or compressed. If damaged it will reduce opening of the diaphragm holder and through, the charging facilities as well.
Page 17
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 Close off charging gas supplies to the filling head. Depressurize the filling head by carefully releasing the charging hose connection. Remove the charging hose from the filling head and remove the filling head from the adapter by hand.
Page 18
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 SPECIAL TOOLS, FIXTURES AND MATERIALS: The following are required during filling: Aluminum protection cap Filling tool complete. Tool for diaphragm holder Spare diaphragm holders TBA Permanite GT P.F.T.E, Technical alcohol SCHEDULE OF OVERHAUL PERIODS: Adapter: On condition or maximum 5 years.
Page 19
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 NOTE: The filling temperature must not exceed +65°C. Higher temperature will cause a higher dome of the membrane disc! The pressure difference across the diaphragm holder during charging should not exceed 30 bar = 430 psi.
Page 20
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 IMPORTANT! No matter what kind of charging set up is used, it is important the process starts slowly to avoid pressure choke! IMPORTANT! During the charging procedure the temperature in the cylinder valve/filling head must not exceed +65°...
Page 21
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 FIRING HEAD 95-43012-101 (DK-99S-1) OPERATING INSTRUCTIONS TECHNICAL DESCRIPTION: The DK-99S is based on a stored spring force. By pulling out the release toggle the knife is released and penetrates a diaphragm and releases the content of the cylinder.
Page 22
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 CAUTION: Never attach a released DK99 to a fully charged cylinder! DISMANTLING A RELEASED DK-99S: The released DK-99S is taken off by means of a 30mm spanner (14-151) – turned counter- clockwise.
Page 23
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 SERVICE AFTER WATER RELEASE: The DK-99S is taken off and disassembled. All parts should be dried, cleaned and re-greased before assembly and resetting. Inspect the cutting knife. If the edges are damaged, replace the knife.
Page 24
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 99-050 OUTLET CONNECTIONS: Service of the DK-99S includes a visual inspection of the threads for damage. Banjo connections may need new a-rings and circlips. The a-rings must be greased with silicone grease. The hose unions are tightened with maximum 40Nm.
Page 25
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 ACCESSORIES: Resetting Tool 90-038 Circlip Tool LT 14 U Grease Aero Shell 14 Silicone Grease 4 Compound Protection Cap for 3/8” outlet 005-661 30mm open spanner Commercial 24mm open spanner Commercial...
Page 26
5323 Highway Avenue Jacksonville, FL 32254 (T) 904.503.9733 (F) 904.503.9719 SERVICE BULLETIN NO. 09/16 NOTE: The valve must not be re-tightened after installation. If a leakage appears between the fabric and the relief valve, the valve must be taken apart and reinstalled until tight. IMPORTANT: If using the closing cap, be careful the cap is not fitted to the valve during packing.
Page 27
(F) 904.786.0890 SERVICE BULLETIN NO. 09/16 TRANSMITTAL This page transmits the issue of the above numbered Revere Service Bulletin, which consists of this transmittal sheet plus 16 pages. Title: Revere Coastal Compact Liferafts – Gas Inflation System Service Bulletin Number 09/16 has technical approval by Revere Survival Inc.
Page 29
LIST OF EFFECTIVE PAGES PAGE PAGE PAGE TITLE ISSUE DATE PAGE TITLE ISSUE DATE Title Page May 29/13 June 2/08 May 29/13 Revision Record RR-1 Jan 18/11 2-10 Jan 18/11 RR-2 June 2/08 2-11 Jan 18/11 2-12 Jan 18/11 Service Bulletin SB-1 June 2/08 2-13...
Page 30
PAGE PAGE PAGE TITLE ISSUE DATE PAGE TITLE ISSUE DATE 4-16 May 29/13 May 29/13 4-17 May 29/13 June 2/08 4-18 June 2/08 Jan 18/11 Cleaning Jan 18/11 Section 5 June 2/08 Jan 18/11 June 2/08 May 29/13 June 2/08 May 29/13 June 2/08 8-10...
Page 31
PAGE PAGE ISSUE DATE PAGE TITLE ISSUE DATE 8-40 Jan 18/11 11-11 May 29/13 8-41 Jan 18/11 11-12 May 29/13 8-42 Jan 18/11 11-13 May 29/13 8-43 Jan 18/11 11-14 Jan 18/11 8-44 Jan 18/11 11-15 May 29/13 8-45 Jan 18/11 11-16 May 29/13 8-46...
Page 32
PAGE PAGE ISSUE DATE PAGE TITLE ISSUE DATE 12-16 May 29/13 12-17 May 29/13 12-18 May 29/13 Appendix A May 29/13 Jan 18/11 May 29/13 9102 EP - 4...
Page 33
LIST OF ASSOCIATED PUBLICATIONS None Listed June 2/08 9102 AP - 1...
Page 34
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 AP - 2...
Page 35
LIST OF ABBREVIATIONS/SYMBOLS DEFINITION ABBREVIATION Degrees ° Percent Calories cal. Centigrade/Celcius Cubic Centimeter(s) Centimeter Centimeters of Mercury cm Hg Cubic Inch Farenheit Figure Fig. Foot or Feet Gram Gram per Square Centimeter g/cm Inch (s) Inches of Mercury inHg Inside Diameter Kilogram Kilogram per Square Centimeter kg/cm...
Page 36
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 AB - 2...
TABLE OF CONTENTS DESCRIPTION SECTION – PAGE No. Introduction Description, Data, and Operation Disassembly Testing and Fault Isolation Cleaning Service Inspection and Check Repair Assembly and Packing Storage Tools, Equipment, and Materials 10-1 Illustrated Parts List 11-1 Spare Parts 12-1 Appendix A May 29/13 9102...
Page 38
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 TC - 2...
INTRODUCTION General Manual Breakdown Shop Verification Warnings, Cautions, and Notes Layout of Manual List of Effective Pages Record of Revision Associated Publications June 2/08 9102 1 - 1...
Page 40
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 1 - 2...
Page 41
Revere Supply Company. MANUAL BREAKDOWN Shop Verification The sections within this manual have been verified at the Revere Supply Company facility by actually performing all functions such as disassembly, assembly, and testing. Warnings, Cautions, and Notes...
Page 42
List of Effective Pages The list of effective pages details all the pages that are contained in the manual and indicates the issue dates of those pages allowing the manual content to be checked for completeness and accuracy. This list is included in the preliminary pages of this manual. Record of Revision When required, the pages of this manual will be amended, approved, and re-issued as a revision.
The Coastal Compact liferafts’ self-inflation system is initiated manually and is stored in a valise for rapid, easy access by passengers and crew in the event of an emergency. Note: Revere Coastal Compact liferafts are emergency life-saving devices and are not intended for any other use. Warning: Revere Coastal Compact liferafts are NOT for offshore use.
Page 46
FIGURE 1 – COASTAL COMPACT (4 PERSON) (4 person capacity shown. Description comparable to 2 and 6 person capacity) Jan 18/11 9102 2 - 4...
DESCRIPTION OVERVIEW Coastal Compact Life Rafts are designed for coastal use and are available in 2, 4, and 6 person capacities. They are not for offshore use. The Coastal Compact 4 and 6 person rafts are composed of one large independent buoyancy tube, a single layer floor, 2 ballast pockets, a righting handle, and a boarding stirrup.
DETAIL Standard Equipment The Coastal Compact Liferafts are equipped with the following items and features (Fig. 1): Painterline Pulling on this 20ft. (6m) line will activate the inflation system and begin raft deployment. It can also be used as a mooring line after activation. (IPL Fig. 1, Item 70). Knife A floating raft knife features a sharp blade recessed into a handle to minimize the possibility of damage to the raft.
Page 49
Bailer Used for the removal of excess water from the interior of the raft. 10. Handpump Provided to top off the buoyancy tubes in the event of a puncture or leak. 11. Canopy Constructed from orange urethane coated nylon, the canopy protects survivors from sun and harsh weather.
Page 51
FIGURE 3 – GAS INFLATION SYSTEM May 29/13 9102 2 - 9...
Page 52
DATA Capacity 2, 4, and 6 Person Color Buoyancy tubes: Yellow Ballast bags: Yellow/Orange Valise: Yellow Raft Tube Diameter Coastal 2: 8.5in. (21.59cm) Coastal 4: 10.5in. (26.67cm) Coastal 6: 11.71in. (29.74cm) Frequency of Service Inspection Coastal 2: 2 years after purchase Annually after initial inspection Coastal 4: 2 years after purchase...
Inflation System Coastal Compact 2 Person 323-460 Cylinder, 460g CO filled Coastal Compact 4 Person 327-071 Cylinder, DOT3AL1800, 71 cu. in. Coastal Compact 6 Person 327-102 Cylinder, DOT3AL1800, 102 cu. in. Specifications for Valise packed Coastal Compact Rafts. INFLATED DIM.
OPERATION It is CRITICAL that the valise is not thrown overboard without FIRST having been secured to a strong point on the ship or aircraft. If this instruction is not observed, the valise may be lost, and/or personnel may be pulled overboard with it. Caution: DO NOT attempt to unpack and inflate the liferaft on the deck of the vessel or in the cabin of the aircraft;...
DISASSEMBLY General Procedures June 2/08 9102 3 - 1...
Page 60
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 3 - 2...
Page 61
GENERAL It will be necessary at normal service and overhaul periods (See Section 2 – Data) to remove the packed liferaft from the vessel or aircraft. Ensure the working area is clean and dry, free from sharp projections, and large enough to fit the liferaft. The work surface should be smooth, preferably constructed of linoleum or PVC covering.
Page 62
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 3 - 4...
Page 63
PROCEDURES Remove the packed liferaft in its valise from the vessel or aircraft. Caution: Do not pull or jerk the painterline as this may cause operation of the inflation system. Inadvertent activation of the inflation system may cause personal injury or damage to raft components. Remove the liferaft from the valise as follows: Pull open the fasteners on the valise.
Page 64
FIGURE 1 – DISCONNECTING PAINTERLINE LOOP (Shown below with Coastal Compact 4) FIGURE 2 – DISCONNECTING THE CABLE LOOP Jan 18/11 9102 3 - 6...
Page 65
FIGURE 3 – DISCONNECTING THE CYLINDER NECK LOOP Jan 18/11 9102 3 - 7...
Page 66
FIGURE 4 – UNFOLD RAFT/DISENGAGE THE CYLINDER Jan 18/11 9102 3 - 8...
TESTING AND FAULT ISOLATION General Test Record Chart Preparation Leakage Test Procedures General Inflatable Chambers a. Arch Tube Function Tests General Light Topping-Off Valves Pressure Relief Valves Inlet Check Valves Gas Cylinder and Inflation Valve Cylinder Valve Inflation Test Fault Isolation/Troubleshooting Jan 18/11 9102 4 - 1...
Page 68
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 4 - 2...
GENERAL This section contains instructions for minimum performance testing of the Coastal Compact Liferafts. The performance test provides a functional equipment check to establish the ability of the systems and components to perform required design function or before the reinstallation of rafts removed from service.
Page 70
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 4 - 4...
TEST RECORD CHART Keep records of ALL inflation tests. Make blank copies of this form and fill out charts when needed. LEAKAGE TEST RECORD – COASTAL COMPACT LIFERAFT TYPE No. SERIAL No. INSPECTED BY: CHECKED BY: PACK LIFERAFTS WITHIN 48 HOURS OF TEST, UNLESS STORED UNDER APPROVED CONDITIONS RE-TEST if not operationally packed within 30 days of test Date __________ Date __________...
Page 72
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 4 - 6...
PREPARATION Keep record of ALL inflation tests. Copies of Test Record Charts are provided in the previous section. Make blank copies and store at the end of the Section. Protect liferafts from draughts and direct sunlight as temperature affects pressure. Keep at hand a solution of mild liquid soap (NOT detergent) and water, and a plentiful supply of clean, dry, lint-free cloth.
Page 74
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 4 - 8...
LEAKAGE TEST PROCEDURES GENERAL The Coastal Compact’s main buoyancy chamber will be tested for leaks. All test results should be recorded on the Coastal Compact Test Record Chart (See Table A). INFLATABLE CHAMBERS (AIR HOLDING TEST) Using an inflation tool (Part No. 95-41128-101) and clean, dry shop air, inflate the buoyancy chamber to until the pressure relief valve (PRV) opens.
Page 76
10. Check the floor for rips or tears. If a rip is located, please refer to Chapter 7 – Repair. 11. Once the repairs are completed, retest failed chamber. 12. If the chamber passes its air retention test or if repairs have been made, please refer to Chapter 8 –...
Page 77
Refer to Table B for correction quantities due to changes in barometric pressure or temperature over the test period. BUOYANCY TUBES - HIGH PRESSURE Change in Barometric Pressure, P (inHg) Raft Tube Pressure Correction (psi) -.30 -.1470 -.25 -.1225 -.20 -.0980 -.15 -.0735...
Arch Tube To test the arch tube’s inflatable cell for leaks, inflate the arch tube orally until the cell becomes firm. To inflate, flip the replaceable black dust cap off from the top of the red oral tube. Either blow air into the oral tube (See Figure 2) until the arch tube is firm or first fill the arch tube halfway up with compressed air at a low pressure (<10psig) and top off by blowing into the oral tube.
FUNCTION TESTS GENERAL A full function test is not required for normal service. The following items listed will need to be assessed for proper operation and restored if they are non-functional. Refer to Chapter 7 – Repair for repair/replacement instructions for failed components. LIGHT Check the unit expiration date.
The actual gross weight of the cylinder plus valve assembly must be at least 100 grams greater than the Minimum Gross Weight marked on the cylinder. If not, replace the cylinder. The Coastal Compact 2 cylinders cannot be refilled. They are disposable after being discharged.
Hydrostatic Test The Coastal Compact 4 & 6 cylinders are to be periodically tested in accordance with the requirements of the Department of Transportation (DOT). This test is to be performed every five (5) years from date of purchase coinciding with cylinder valve inflation testing. Note: DOT requires that before recharging, that a cylinder has been hydrostatically tested within the last 5 years.
FAULT ISOLATION The table below is given to facilitate the locations of troubles in the event of malfunction during the function test, their probable causes, and corrective action. In addition to using this table, visually check the liferaft and equipment for evidence of damage or signs of failure. Fault Probable Cause Corrective Action...
CLEANING General Procedures Liferafts Valise June 2/08 9102 5 - 1...
Page 86
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 5 - 2...
Page 87
GENERAL This section contains instructions on cleaning the Coastal Compact Liferafts. When deemed necessary, periodic inspection and cleaning should be performed. The working area must be free from chemicals, corrosives, and solvents. CLEANING MATERIALS Caution: Use only cleaning agents used in Table A. ITEM No.
Page 88
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 5 - 4...
Page 89
PROCEDURES Warning: All solvents: Flammable; Keep away from naked lights. Use solvents only in a well ventilated atmosphere. Do not splash into eyes and avoid breathing in the vapors. Use a barrier cream on hands and wash them after using solvents. Liferafts Wash the liferaft with a solution of mild liquid soap (Item 1) and water.
Page 90
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 5 - 6...
SERVICE INSPECTION AND CHECK General Gas Inflation System Valise Pack June 2/08 9102 6 - 1...
Page 92
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 6 - 2...
Page 93
GENERAL The liferaft is to be inspected two (2) years after the date of manufacture and annually after the initial inspection. This will insure that the inflatable chamber will maintain the specified pressure, that the inflation system functions efficiently, and that all components and associated equipment are maintained in a serviceable condition.
Page 94
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 6 - 4...
Page 95
GAS INFLATION SYSTEM Warning: The charged gas cylinder can become a lethal projectile if discharged to atmosphere when not fitted with a cap. Always fit a recoil cap to a cylinder valve outlet when handling a fully charged cylinder. Inspect non-return valves for visual defects and security. Weigh the cylinder (minus the diffuser caps) and check it against the weight marked on the cylinder.
Page 96
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 6 - 6...
Page 97
VALISE PACKS Inspect valise for: • Cleanliness, freedom from splits, tears, or other obvious signs of damage. • Legibility of all marks and labels. June 2/08 9102 6 - 7...
Page 98
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 6 - 8...
Sewing repairs to the valise. If repairs beyond the limits of the conditions described in previous statements, it is recommended that the raft be returned to Revere Supply Company. Clean all repaired disassembled parts prior to re-assembly according to procedures described in the Cleaning Chapter of this manual.
Page 102
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 7 - 4...
The adhesive to be used for repairs is supplied in a 4oz. can with brush top. (Part No. 95-306-004) Only the specified adhesive shall be used for the repair of liferafts manufactured by Revere Supply Company. Using unspecified adhesives may have unexpected side effects resulting in premature failure.
PREPARATION OF COATED SURFACES Polyurethane-proofed surfaces Caution: VERY IMPORTANT – The heavy duty polyurethane coating on the material used for the buoyancy chambers/floor must have the surface contamination completely removed by thoroughly cleaning the coated surfaces with solvent MEK (Methyl Ethyl Ketone). Petroleum or Toluene type cleaning solvents are ineffective on this material and must not be used.
APPLYING ADHESIVE For the purposes of repair the words ‘tacky’ and aggressive tack are defined as follows: (1). When the word ‘tacky’ is used, it means that if the fingers are lightly dragged across the adhesive, it tends to pull off the base fabric or the previous coat. (2).
REPAIRING TORN AREAS While many of the seams in the Coastal Compact Liferafts are glued with a strong adhesive, others are of welded construction. Once welded, these seams cannot be opened. A correctly welded seam is such that no discernable interface between the two polyurethane surfaces will remain.
Revere Supply Company cannot offer partial or complete panel/tube replacement. It will be necessary to replace the liferaft should significant damage occur to the panels or tubes. Repair Limits for External Patches Patching of the buoyancy tubes is permitted, but there must not be more than 10 patches per panel, and the area of the 10 patches together must not exceed 25% of the panel area.
COMPONENT REPAIR Pressure Release Valve Dismantling the pressure relief valve is not permitted. Unscrew the valve and replace. Topping-Off Valve Unscrew the valve and replace. Inlet Check Valves Unscrew the valves and replace. Inflation Valve See Chapter 8 – Assembly for inflation valve rebuilding. Canopy The canopy is a non-repairable item.
Page 109
FIGURE 1 – PATCHES AND TAPE APPLICATION June 2/08 9102 7 - 11...
Page 110
FIGURE 2 – PATCH APPLICATION OVER SEAM May 29/13 9102 7 - 12...
Page 111
Keep records of all repairs. Make blank copies of this form and fill out charts when needed. REPAIR RECORD LIFERAFT TYPE No. SERIAL No. REPAIRS REQUIRED PART DAMAGE FORM OF REPAIR INSP. BY Buoyancy Tube Floor Inflation Equipment Topping-Off Valve Pressure Relief Valve Fixed Inlet Check Valve Light...
Page 112
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 7 - 14...
ASSEMBLY AND PACKING General Component Setup A. Handpump and Bailer B. Sea Anchor C. Painterline D. Light E. Knife F. Inflation Valve/Cylinder G. Canopy Inflation Valve Disassembly & Rebuilding Process Procedures Jan 18/11 9102 8 - 1...
Page 114
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 8 - 2...
GENERAL This section describes the proper procedures for assembly and repacking of all Coastal Compact Liferafts. Before beginning the assembly, the work area must be clean, dry, and free from sharp projections. Work should be done on a smooth surface, preferably linoleum. Throughout preparation and packing of the liferaft and its associated equipment, all ties are to be bowlines unless stated otherwise.
Page 116
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 8 - 4...
Connect both the bailer and the handpump to the raft lifeline using 48in. long x 1/16in. diameter nylon cord (IPL Fig. 1, Item 130) on the Coastal Compact 2 and 4 person rafts. Use the 60in. long x 1/16in. diameter nylon cord (IPL Fig. 1, Item 220) on the Coastal Compact 6 person raft. Tie with bowline knots.
Inflation Valve/Cylinder Remove cotter pin from inflation valve. Place Valve Foam Cover (IPL Fig. 1, Items 160/160A) over inflation valve and tape down securely. (See Fig. 2F) Canopy Completely deflate the arch-tube (IPL Fig. 5, Items 50/50A). To deflate, remove the black dust cap from the top of the red oral tube.
See section 2.1-2.3 for removal and replacement. DO NOT disassemble and rebuild the M100 inflation valve for the Coastal Compact 2. All disassembly/rebuild illustrations are shown for the 41115 inflation valve only.
Page 122
1.1 Torque Settings The settings listed in table below list the required torque settings for the 41115 Series inflation system. Refer to this table when tightening inflation system components that require a specific setting. Tighten to the minimum setting in the specified range first. If leakage occurs, discharge the assembly and tighten to the maximum setting.
Page 123
1.3.2 Inflation Valve Illustrated Disassembly / Rebuilding Process All components can be removed using a socket wrench, but most will only require a standard Note: or open-ended wrench. If using a socket (A 6pt socket is recommended to minimize dings to the hex edges), rotate the fitting to be removed to this cut-out.
Page 124
Step 4: Remove the Fill Fitting Poppet (IPL Fig. 4, Item 40) and Washer (IPL Fig. 4, Item 70) from Fill Fitting Housing. Step 5: Using a socket wrench, remove the Safety Disk Retainer (IPL Fig. 4, Item 110), Disk, and Washer (IPL Fig.
Page 125
Use an O-Ring pick to remove the O-Rings Step 8: from: • Fill Fitting Cap • Safety Disk Retainer • Piston Inspect all components for damage and Step 9: corrosion, replace as necessary. Clean all components of old grease and dirt, use cotton swabs to clean ports.
Page 126
1.4 Inflation Valve Reassembly Prepare the Inflation Valve for rebuilding. Items List: • Rebuild Kit (Part No. 95-41120-101) • DC-111 O-Ring Lubricant • DC-55 O-Ring • Wrenches and Sockets • Torque Wrench • Loctite 1.4.1 Only organizations that are equipped with the latest technical data, tools and fixtures are permitted to perform inflation valve rebuilding activities.
Page 127
1.4.2 Inflation Valve Illustrated Reassembly / Rebuilding Process Step 1: After applying lubrication to the O-rings, install them in the Fill Fitting Cap, and Safety Disk Retainer as necessary. Step 2: Being sure the Safety Pin hole is facing upwards, install the Piston Housing (IPL Fig. 4, Item 140) and Pull Lanyard (IPL Fig.
Page 128
Step 5: Install the Safety Disk (IPL Fig. 4, Item 100). Step 6: Replace Safety Disk Retainer (IPL Fig. 4, Item 110) and torque to the settings in Table A. Step 7: Install Sealing Washer (IPL Fig. 4, Item 70) into Fill Fitting Cavity.
Page 129
Step 9: Install Fill Fitting Cap (IPL Fig. 4, Item 160) and hand tighten. Step 10: Apply thread sealant Loctite to Outlet Fitting before installing. Torque according to settings listed in Table A. June 2/08 9102 8 - 17...
Page 130
1.5 Inflation Valve Installation - 41115 Figure 1.5 Inflation Valve Installation - 41115 1.5.1 Inspect inflation valve threads for cleanliness and damage. 1.5.2 Apply a thin film of 95-DC-111 lubricant to inflation valve O-ring. 1.5.3 Inspect cylinder threads and O-ring Groove for cleanliness and damage. Carefully screw Inflation Valve into Cylinder.
Page 131
1.6 Charging the Cylinder 1.6.1 The inflation system is charged with Carbon Dioxide. Cylinders must only be charged by properly trained technicians. 1.6.2 Verify proper installation of Inflation Valve, install Diffuser Caps on outlet connectors. 1.6.3 Remove Fill Fitting Cap. 1.6.4 Above figures show a picture of the "Charge Adaptor", proper installation of the charging hose using the Charge Adaptor and Quick Disconnect, and a simple Charging Station.
Page 132
After the cylinder is charged to the correct weight (See Table B) and is torque to the correct value (See Table A), a leak test must be administered. 1.7.1 Using Revere Leak Test Solution (Part No. 50-CO2-LEAK), pour approximately 2oz. into a 4in. X 6in. poly bag to enclose the entire valve and neck of cylinder. Use 1in. masking tape (or equivalent), secure the poly bag over the neck of the cylinder.
Page 133
2.1 Torque Settings The table below lists the required torque setting for the M100 Series inflation system. Tighten within the specified range. Table C, Torque Settings Component Torque Setting Inflation Valve to Cylinder – M100 25-26 lbf.ft (33.90-35.26 Nm) 2.2 Inflation Valve Installation – M100 Figure 1.6 Inflation Valve Installation 2.2.1 Inspect inflation valve threads for cleanliness and damage.
Page 134
2.3 Removal of Inflation Valve from Cylinder 2.3.1 Use ratchet and crows foot to remove Inflation Valve from Cylinder. 2.3.2 Check threads for condition. Inflation Valves with worn threads must be discarded and replaced. 2.3.2.1 June 2/08 9102 8 - 22...
Page 135
PROCEDURE Note: It is recommended that the liferaft be packed by two men. Place the liferaft on a platform or in an open area with enough room to maneuver the liferaft and valise during packing. Locate the topping-off (inflate/deflate) valve. Using a vacuum adapter (Part No. 95-41129-101) connected to a vacuum source, evacuate all air from the compartment.
Page 136
TABLE D FOLDED DIMENSIONS RAFT MODEL (L x W x H) in. Coastal Compact 2 19.5 x 10.0 x 5.0 Coastal Compact 4 16.5 x 13.0 x 5.0 Coastal Compact 4 with canopy 16.5 x 13.0 x 6.0 Coastal Compact 6 20.0 x 13.0 x 7.0...
Page 137
FIGURE 3 – TOPPING-OFF (INFLATE/DEFLATE) VALVE FIGURE 4 – ATTACHING THE CYLINDER June 2/08 9102 8 - 25...
Page 138
FIGURE 5 – STORAGE OF COMPONENTS Jan 18/11 9102 8 - 26...
Page 139
FIGURE 6A – CC2 FOLDING DIAGRAM STEP 1 Note: Refer to Chapter 2 – Description, Table A for the L x W x H dimensions shown in the following folding diagrams. June 2/08 9102 8 - 27...
Page 166
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 9 - 2...
Page 167
GENERAL This section describes the proper storage procedures for Coastal Compact Liferafts. Rafts should be stowed where they can easily be reached in an emergency. Valise packed rafts can be kept on deck for short periods of time only but should be stowed in a location where they are not continuously exposed to direct sunlight, weather, or water spray.
Page 168
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 9 - 4...
Page 169
TOOL, EQUIPMENT, AND MATERIALS General Tool List May 29/13 9102 10 - 1...
Page 170
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 10 - 2...
Page 171
GENERAL This section contains a listing of all tools, equipment, and materials used to service the Coastal Compact liferafts. Images of all the tools can be found in Chapter 12 - Spare Parts. To keep your tools in proper working order, take care of them by: Inspecting and adjusting daily •...
Page 172
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 10 - 4...
Page 173
TOOL LIST TOOL/EQUIPMENT/MATERIAL PART NUMBER SECTION 3 – DISASSEMBLY Wrench Diffuser Cap, -5 95-301-017 SECTION 4 – TESTING AND FAULT ISOLATION Manometer (0-10 psig)) Thermometer (hang on manometer) Rubber Tubing (1/8in. x 3/8in. i/d x 1/2in. o/d) (3m of 9mm i/d, 12mm o/d) for manometer connection Inflation Tool w/ Ball Valve, Quick-Connect End 95-41128-101 Deflation Tool, 3/8in.
Page 175
ILLUSTRATED PARTS LIST (IPL) Introduction Numerical Parts List Detailed Parts List Image List May 29/13 9102 11 - 1...
Page 176
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 11 - 2...
Page 177
Items with the same part number but different quantities per assembly will be assigned a suffix as a variant of the original part number, e.g. 10 and 10A. PART NUMBERING Revere Supply Company part number. ILLUSTRATIONS A view of each assembly, exploded as necessary to show the component parts is provided. Each illustration is assigned a figure number.
Page 178
NOMENCLATURE CONTINUED ‘Replaced By’ means that the part in the part number column is replaced by and is interchangeable with the part number shown in the notation. ‘Replaces’ means that the part in the part number column replaces and is interchangeable with the part number shown in the notation.
Page 179
Image List at the end of this section. 10. VENDOR CODES AND ADDRESSES A part manufactured by a different company other than Revere Supply is identified by a Vendor Code, following the nomenclature. Vendor Codes are in accordance with the Federal Supply Codes for Manufacturers for American Vendors, and NATO Codes for UK Vendors.
Page 180
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 11 - 6...
Page 181
NUMERICAL PARTS LIST No equivalent substitutes are to be used for listed items without the prior written consent of Revere Supply Company. Revere Supply Company will not accept responsibility for any equipment malfunction where unauthorized substitutions have been used. The Numerical Index is an alpha-numeric list of all part numbers included in the Detailed Parts List.
Page 182
THIS PAGE INTENTIONALLY LEFT BLANK June 2/08 9102 11 - 8...
Page 185
PART No. FIG – ITEM No. UNITS PER ASSY. 95-41163-103 5-60A 95-41162-101 1-200 95-41162-103 1-200A 95-41169-101 1-190 95-41171-101 1-210 95-41193-101 1-100 May 29/13 9102 11 - 11...
Page 186
THIS PAGE INTENTIONALLY LEFT BLANK May 29/13 9102 11 - 12...
Page 187
DETAILED PARTS LIST No equivalent substitutes are to be used for listed items without the prior written consent of Revere Supply Company. Revere Supply Company will not accept responsibility for any equipment malfunction where unauthorized substitutions have been used. May 29/13...
Page 188
FIGURE 1 – LIFE RAFT ASSEMBLY Jan 18/11 9102 11 - 14...
SPARE PARTS LIST Introduction Image List Tool Image List May 29/13 9102 12 - 1...
Page 206
THIS PAGE INTENTIONALLY LEFT BLANK May 29/13 9102 12 - 2...
Page 207
This section provides an illustrated parts breakdown for the purpose of ordering replacement parts. It should not be used for any other purpose. An image of each part is provided. Each image has a corresponding Revere Supply Company part number and description of the item.
Page 208
THIS PAGE INTENTIONALLY LEFT BLANK May 29/13 9102 12 - 4...
Page 209
IMAGE LIST Description Part Number Vinyl Tape 1, White 10-TAPE-1 Raft Tube Fabric, PU 10-302-001 (Yellow) Canopy Fabric 10-302-006 (Orange) May 29/13 9102 12 - 5...
Page 210
Description Part Number Certificate and Sticker 50-REV3002 Painterline Assembly 95-36-43009-101 Handpump 95-301-001 PRV Plug 95-301-014 May 29/13 9102 12 - 6...
Page 211
Description Part Number Key Ring 95-301-028 Repair Cement 95-306-004 Thread, Red Nylon 95-311-004 Nylon Cord, 1/16in. 95-313-004 May 29/13 9102 12 - 7...
Page 212
Description Part Number Locator Light 95-319-001 Cylinder 460g CO 95-323-460 Pressure Release Valve 95-324-003 Fixed Inlet Check 95-325-002 May 29/13 9102 12 - 8...
Page 213
Description Part Number Topping Off Valve 95-326-003 Inflation Valve, Model 100 95-326-004 Cylinder, DOT3AL1800 90-327-071 71in Cylinder, DOT3AL1800 90-327-102 102in May 29/13 9102 12 - 9...
Page 214
Description Part Number Sea Anchor 95-41027-101 Cylinder Holder 95-41034-101 Extension Strap Label, 95-41047-1 Cylinder/Valve Assembly Bailing Bucket 95-41065-101 May 29/13 9102 12 - 10...
Page 215
Description Part Number Inflation Instructions 95-41103-1 Valise CC2 95-41101-101 Valise CC4 95-41101-103 Valise CC4 with canopy 95-41104-109 Valise CC6 95-41101-113 May 29/13 9102 12 - 11...
Page 216
Description Part Number Valve Foam Cover CC2 95-41111-1 Valve Foam Cover 95-41111-1 CC4 and CC6 Inflation Valve Model 41115 95-41115-101 Coastal Compact 95-41119-1 Owner's Manual May 29/13 9102 12 - 12...
Page 217
Description Part Number Canopy Kit Pack CC4 95-41162-101 Canopy Kit Pack CC6 95-41162-103 Canopy Buckle Strap 95-41169-101 Knife, Low Profile 95-41193-101 May 29/13 9102 12 - 13...
Page 218
THIS PAGE INTENTIONALLY LEFT BLANK May 29/13 9102 12 - 14...
Page 219
TOOL IMAGE LIST Description Part Number Quick Connect 40-338-005 Valve Charging Stem Bleed Down Tool 40-338-007 Quick Disconnect Valve 40-338-006 Charging Body May 29/13 9102 12 - 15...
Page 220
Description Part Number Hand Roller 80-338-003 O-Ring Lubricant 95-DC-55 O-Ring Lubricant 95-DC-111 Diffuser Cap 5 95-301-017 (Brass) May 29/13 9102 12 - 16...
Page 221
Description Part Number Socket, 1-3/8 in. 45-338-008 Inflation Tool 95-41128-101 Deflation Tool 95-41129-101 3/8 in. May 29/13 9102 12 - 17...
Page 222
THIS PAGE INTENTIONALLY LEFT BLANK May 29/13 9102 12 - 18...
Page 223
A 3-page version of the certificate is provided to every service station. Completion of this form is required at every service. Copies of the form will then be sent to the appropriate group as follows: White: Vessel Canary: Service Station Pink: Revere Supply Company May 29/13 9102 A - 1...
Page 224
THIS PAGE INTENTIONALLY LEFT BLANK Jan 18/11 9102 A - 2...
Page 225
1901 RECREATIONAL LIFERAFT RE-INSPECTION CERTIFICATE This is to certify that this liferaft has been inspected and serviced in accordance with the REVERE SURVIVAL INC. servicing manuals. MODEL: __________________________ SIZE (circle one) 2 4 6 8 S SERIAL NO: ____________________________ DOM: _____/_____/_____ DATE OF PREVIOUS INSP: ______/_____/______DATE OF NEXT INSP: _____/_____/______...
Need help?
Do you have a question about the Coastal Compact 2 and is the answer not in the manual?
Questions and answers