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Crewsaver VOYAGER 275N Service Manual

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Servicing Manual: Crewsaver Voyager 275 Lifejacket
Project No: 00154
SERVICE MANUAL
VOYAGER 275N LIFEJACKET
Date: November 2016
Issue No: 2
Survitec House, Lederle Lane, Gosport,
Hants. PO13 0FZ, England.
Tel: +44 (0) 1329 820000 Fax: +44 (0) 1329 236218
email: crewsaver@survitecgroup.com
Web: www.crewsaver.co.uk
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  • Page 1 Servicing Manual: Crewsaver Voyager 275 Lifejacket Project No: 00154 SERVICE MANUAL VOYAGER 275N LIFEJACKET Survitec House, Lederle Lane, Gosport, Hants. PO13 0FZ, England. Tel: +44 (0) 1329 820000 Fax: +44 (0) 1329 236218 email: crewsaver@survitecgroup.com Web: www.crewsaver.co.uk Page Date: November 2016...
  • Page 2 Servicing Manual: Crewsaver Voyager 275 Lifejacket Project No: 00154 Service Bulletins and Amendments Register Description Date Issue 2 Section outlining the scope of the Manual added on Index page. Reference to Venturi Vacuum System added (sections 6.1.2, 8.1.3 and Parts List).

  • Page 3: Table Of Contents

    Servicing Manual: Crewsaver Voyager 275 Lifejacket Project No: 00154 Scope This manual covers the servicing of the Voyager 275N lifejacket without any current derivatives. Index Section 1 Introduction Product Description Data Sheet General Features Donning Instructions Section 2 Service Station Guidelines...

  • Page 4: Introduction

    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.

  • Page 5: Data Sheet

    Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Data Sheet Voyager 275N Lifejacket Features: 290N Total Chamber Buoyancy: 275N Buoyancy category: Orange Cover Colour MCA (UK) Approved SOLAS Approved CE Approved Cylinder size According Standard Automatic to customer...

  • Page 6: General Features

    Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 1.4.1 General Features - Non-Harness Hammar Plastic Press Studs Orange PVC coated polyester, flame retardant 40mm Black Polyester Back Strap Crewsaver Badge 40mm Black Polyester Waist Belt Solas Approved Retro Reflective Tape...
  • Page 7 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 1.4.2 General Features - Non-Harness Auto Plastic Press Studs Orange PVC coated polyester, flame retardant 40mm Black Polyester Back Strap Crewsaver Badge 40mm Black Polyester Waist Belt Solas Approved Retro Reflective Tape...

  • Page 8: Donning Instructions

    Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 1.5.1 Donning Instructions - Voyager 275 Non-Harness Don the lifejacket like a normal jacket The backstrap should then be positioned down the centre of the back. Fasten the interlocking front buckle as shown.

  • Page 9: On Receipt Inspection

    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...

  • Page 10: General Care

    Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 General Care 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.

  • Page 11: Lifejacket Servicing Record Sheet

    N.B. In case of difficulty contact Crewsaver direct (Not sewing machines, cabinets or tables - these parts may be sourced locally). Note: Prior consent to carry out any repairs must be pre-approved by Crewsaver. All repairs to stitching must be in accordance with this manual.
  • Page 12 Servicing Manual: Crewsaver Voyager 275 Lifejacket Project No: 00154 CERTIFICATE NUMBER: LIFEJACKET SERVICING SCHEDULE W/O Number: TYPE CUSTOMER VESSEL LAST SERVICED BY DATE OF LAST SERVICE SERIAL NUMBER/S: COMMENTS COMMENTS CHAMBER INSPECTION INFLATION MECHANISM GENERAL CONDITION OPERATING MECHANISM CORD MATERIAL...
  • Page 13 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section 2 Project No: 00154 Lifejacket Servicing Tool Kit Cylinder Torque Strap Calibrated Socket Driver (Tighten Cylinder) UML Mk5 Auto Socket Calibrated Socket Driver Turned Socket (Remove & Replace Locking Nuts For UML & HR)
  • Page 14 3.1.3.2 Where other operating mechanisms are fitted, refer to: a.) Manual Operation: Fig 3.4 - Halkey Roberts operating head removal. b.) Automatic Operation: Fig 3.3 - Crewsaver Mk5 Automatic operating head removal. C.) Automatic Operation: Fig 3.5 - United Moulders Mk3 Automatic operating head.
  • Page 15 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Fig 3.1 Unpacking the Lifejacket Fig. 3.1.1 Fig. 3.1.2 Fig. 3.1.3 Fig. 3.1.4 Page Date: November 2016 Issue No: 2 of 36...
  • Page 16 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section 3 Project No: 00154 Fig 3.2 Hammar Operating Head Fig. 3.2.1 Fig. 3.2.2 Locking ring Place the lifejacket (PFD) on a Insert metal key as shown in 2a and turn the key counter-clockwise smooth, flat surface and wipe off (2b) between black locking ring and labelled yellow cap.
  • Page 17 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Fig 3.3 Crewsaver Mk5 Operating Head Fig. 3.3.2 Fig. 3.3.1 Unscrew the Automatic firing capsule from the end of the Unscrew the 60 gram cylinder from the automatic operating head. This should only be done after the test operating head.
  • Page 18 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Fig 3.4 Halkey Roberts Operating Head Fig. 3.4.1 Fig. 3.4.2 Unscrew the 60 gram cylinder from the manual firing head. Check Unscrew the valve retaining nut from the top of to see if the cylinder has been used.
  • Page 19 Project No: 00154 Fig 3.5 United Moulders Mk3 Operating Head JACKETS FITTED WITH THE Mk3 OPERATING AS ILLUSTRATED ABOVE SHOULD BE RETURNED TO CREWSAVER WHO WILL DETERMINE WHETHER A REPLACEMENT Mk5 OPERATING HEAD CAN BE FITTED. Page Date: November 2016...
  • Page 20 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Cleaning Lifejackets 4.1.1 The current standard cover of the Voyager 275 has a PVC coated polyester outer cover that can be cleaned with care. In the event that contamination is such that the materials are inherently damaged refer to section 7.
  • Page 21 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Outer Cover Inspection 5.1.1 Visually inspect the cover material for wear, abrasion, pulled threads, contamination, cuts and holes. 5.1.2 If necessary the cover may be washed. Refer to Section 4.
  • Page 22 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Mouth Inflation Valve 5.4.1 Visually inspect for damage. 5.4.2 Test in accordance with Section 6. Remedial Action: These items are not repairable. Refer to Section 9 for replacement part. Inflation System 5.5.1...
  • Page 23 5.7.1 Visually inspect all buckles used on the webbings for signs of damage or corrosion. Remedial Action: No repairs are allowed. In the case of damage being found, return the Lifejacket to Crewsaver. Labelling/Markings 5.8.1. Check all Markings and Labelling are clear and legible.
  • Page 24 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Inflation Chamber 6.1.1. Air Holding Test. 6.1.1.1 Connect through a suitable Tee piece and adaptor, the oral tube with the oral valve in the open position, to a graduated water manometer (or a similar digital device for measuring back pressure).
  • Page 25 6.3.2.4 If the mechanism fails to pass this repeat test replace the complete unit. Refer to Section 9 for part Number of the replacement part. NOTE: all failures of this test must be reported to Crewsaver. Crewsaver may require the failed units to be returned, please do not discard.
  • Page 26 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Outer Cover 7.1.1 No other repairs are allowed on the outer cover. NO REPAIRS AT ALL ALLOWED ON CSR JACKETS. Inflation Chamber 7.2.1 No repairs are permitted to the inflator fabric or its assembly, due to the construction of this lifejacket.
  • Page 27 Lifejackets. Worn, broken or cracked stitches are to be over sewn by 25mm in each direction past the extent of the fault, use only approved thread. (Refer to Crewsaver) In the Case of the Crutch Strap Replace Damaged Unit. Refer to Section 9 for Part No. of the replacement part.
  • Page 28 Project No: 00154 Repair Parameters - Stitching All repairs to stitching must be carried out by a company deemed fit to perform the repair by Crewsaver prior to the work commencing. Stitching repairs should be performed when the visible inspection as detailed in section 5, Identifies broken or pulled stitches.
  • Page 29 Fit new top gasket. 8.1.3.1.5 Tighten the retaining nut onto the body using the Calibrated torque driver provided in the Crewsaver servicing tools. Note: Retaining nut must be tightened to between 2.5 and 2.7 Nm. 8.1.3.1.6 Firmly screw the cylinder adaptor by hand into the head 8.1.3.1.7...
  • Page 30 8.1.3.2.4 Tighten the retaining nut onto the body using the Calibrated torque driver provided in the Crewsaver servicing tools. Note: Retaining nut must be tightened to between 2.5 and 2.7 Nm. 8.1.3.2.5 Firmly screw the cylinder adaptor by hand into the head 8.1.3.1.6 Connect the cylinder adaptor to the pressure test unit...
  • Page 31 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Fig 8.1 Hammar Operating Head Fig. 8.1.1 Fig. 8.1.2 Fig. 8.1.3 Green Indicator Water inlet valve Caution: Do Not turn Single center shaft point indicator Check that the indicator is green.
  • Page 32 Fig. 8.2.2 Fit the new firing capsule onto the operating head. Capsules fitted on the Crewsaver Mk5 head are navy blue in colour. The capsule should be screwed tight to the end. Make a note of the batch number and manufacture date on to the service record sheet.
  • Page 33 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Fig 8.2 Crewsaver Mk5 Operating Head Fig. 8.2.5 Check the bottom O-ring seal is in place. Before fitting the operating head onto the manifold, check that the schraeder valve is fitted. If fitting a new schraeder valve use a calibrated torque driver set to 0.32 - 0.36 Nm.
  • Page 34 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section 8 Project No: 00154 Fig 8.3 Halkey Roberts Manual Operating Head Fig. 8.3.1 Following the inspection and testing procedures for Halkey Roberts Manual operating heads as detailed in Section 5 and 6. Fit the retaining clip or pin. Both the green retaining u-shaped clip and the green retaining pin, perform the same job, either may be fitted.
  • Page 35 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Fig 8.4 Voyager 275 Packing Instructions Fig. 8.4.1 Fig. 8.4.2 Fold down the collar flap (C), and line up the velcro Lay Lifejacket out flat as shown in Diagram 1. Fold and fasten.
  • Page 36 Servicing Manual: Crewsaver Voyager 275 Lifejacket Section Project No: 00154 Parts List Product Description Part Number 60 gram CO Cylinder 1 0470 Crewsaver Mk5 Auto Capsule 1 0012 Halkey Roberts Manual Head 1 0550 Manual Head Retaining Clip 1 0210...