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Crewsaver CREWFIT 150N Service Manual
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Crewsaver CREWFIT 150N Service Manual

Lifejacket
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Crewsaver -
Servicing Manual : Crewsaver Crewfit 150 Lifejacket
Date: November 2016
Issue No: 15
SERVICE MANUAL
CREWFIT 150N 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.com
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  • Page 1 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket SERVICE MANUAL CREWFIT 150N 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.com Date: November 2016...
  • Page 2 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Service Bulletins and Amendments Register Date Description Issue 12 Section outlining the scope of the Manual June 2011 added on Index page. Issue 13 February 2013 Details of all Automatic Heads, Capsules and Indicator Clips used.
  • Page 3 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Scope This manual covers primarily the servicing of the Crewfit range of 150N lifejackets. The elements contained within the manual also cover other types of lifejacket as listed below. Training will have been given in these lifejackets and if any aspect is critical to its operation this will be shown in this manual.
  • Page 4 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.

  • Page 5: Data Sheet

    Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 1.3.1 Data Sheet Crewfit 150N Lifejackets Features: 160N Chamber Buoyancy: 150N Buoyancy Category: Red, Blue or Black Cover Colour MCA (UK) Approved SOLAS Approved CE Approved Cylinder size According Standard Automatic...
  • Page 6 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 1.3.2 Data Sheet Crewfit 150N Junior Lifejackets Features: 100N Chamber Buoyancy: 150N Buoyancy Category: Red or Navy Cover Colour MCA (UK) Approved SOLAS Approved CE Approved Cylinder size Standard Automatic...
  • Page 7 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 1.4.1 General Features - Crewfit 150 Non Harness Red PU Coated Polyester 40mm Black Polyester Back-strap Crewsaver Badge 40mm Black Polyester belt 40mm Sliding Bar Belt Adjustment Buckle Screen print...
  • Page 8 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 1.4.2 General Features - Crewfit 150 Harness Red PU Coated Polyester 50mm Black Nylon Harness Crewsaver Badge 50mm Black Nylon belt Screen print Firing Head pull toggle Square Link D-Ring &...
  • Page 9 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 1.4.3 General Features - Crewfit Junior Non Harness Red PU Coated Polyester 25mm Black Polypropylene Back Strap/ Crutch Strap Crewsaver Badge 40mm Black Polyester belt 40mm Sliding Bar Belt Adjustment Buckle...
  • Page 10 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 1.4.4 General Features - Crewfit Short Non Harness Red PU Coated Polyester 40mm Black Polyester Back-strap Crewsaver Badge 40mm Black Polyester belt Screen print Firing Head pull toggle SS40 Buckle...
  • Page 11 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 1.5.1 Donning Instructions - Crewfit 150 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 12 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 1.5.2 Donning Instructions - Crewfit 150 Harness Don the lifejacket like a normal jacket The shoulder straps should then be positioned down the centre of the back. Fasten the interlocking front buckle as shown.

  • Page 13: Service Stations

    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 14: General Care

    Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section General Care 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.
  • Page 15 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.) Note: Prior consent to carry out any repairs must be pre-approved by Crewsaver.
  • Page 16 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Crewsaver 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...
  • Page 17 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 2 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 18 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 - Crewsaver Mk5 Automatic operating head removal. c.) Automatic Operation: Fig 3.6 - United Moulders Mk3 Automatic operating head.
  • Page 19 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 3.1 Unpacking the Crewfit 150 Lifejacket Fig. 3.1.1 Fig. 3.1.2 Fig. 3.1.4 Fig. 3.1.3 Date: November 2016 Page Issue No: 15 f 52...
  • Page 20 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 3.2 Unpacking the Crewfit Junior Lifejacket Fig. 3.2.1 Fig. 3.2.2 Fig. 3.2.3 Fig. 3.2.4 Fig. 3.2.5 Fig. 3.2.6 Date: November 2016 Page Issue No: 15 f 52...
  • Page 21 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 3.3 Halkey Roberts Operating Head Fig. 3.3.1 Fig. 3.3.2 Unscrew the 33 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 22 Crewsaver Mk5 Automatic Capsule - Yellow. This capsule has been withdrawn and should not be found fitted to any Lifejacket. If any are found they MUST be replaced with Crewsaver Mk5i Automatic Capsule - Sales Code 10012. Date: November 2016...
  • Page 23 United Moulders Mk5i Automatic Capsule - Black. Fitted to all Lifejackets manufactured from 2012 onwards. Sales Code 10017. Indicator Clip. Fitted to all Crewsaver and United Moulders Mk5 Automatic Heads EXCEPT the current yellow UM Mk5 head (Sales Code 11044). Sales Code 10111. Indicator Clip.
  • Page 24 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 3.4 Crewsaver Mk5 Operating Head Fig. 3.4.1 Fig. 3.4.2 Unscrew the Automatic firing capsule from the end of the Unscrew the 33 gram cylinder (23 gram for Junior operating head. This should only be done after the test versions) from the automatic operating head.
  • Page 25 If fitted with the old design manifold and a new auto head is needed then the jacket must be returned to Crewsaver for a new inflation chamber to be fitted or, depending on the general condition of the cover, the jacket must be declared as Beyond Economic Repair.
  • Page 26 Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 3.6 United Moulders Mk3 Operating Head JACKETS FITTED WITH THE Mk3 OPERATING HEAD AS ILLUSTRATED ABOVE SHOULD BE RETURNED TO CREWSAVER WHO WILL DETERMINE WHETHER A REPLACEMENT Mk5 OPERATING HEAD CAN BE FITTED. Date: November 2016 Page...
  • Page 27 The servicing procedures for the two heads are the same with the following exceptions: The top and bottom sealing ‘O’ rings are the same for both heads but the cylinder ‘O’ ring seal on the Crewsaver Mk5 head is replaced by a cutter ‘O’ ring on the UM Mk5 head.
  • Page 28 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 3.8 Hammar Operating Head Fig. 3.7.1 Fig. 3.7.2 Locking ring Place the lifejacket on a smooth, Insert metal key as shown in 2a and turn the key counter-clockwise flat surface and wipe off any water.
  • Page 29 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Cleaning Lifejackets 4.1.1 The current standard cover of the Crewfit 150 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.

  • Page 30: Gas Cylinders

    Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 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 31 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 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 32 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 33 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 5.9.5 More recent jackets may be fitted with the Crewsaver CSL Water Activated Light. Visually inspect the light for signs of damage to: 5.9.5.1. The switch. 5.9.5.2. the cable. 5.9.5.3. the lens and its mounting or housing.
  • Page 34 As a final test grasp the Inflation Tube and gently try to rotate it. The measurements taken must be 3.00mm. or greater. If a measurement is less than 3.00mm the jacket must be returned to Crewsaver for the inflator to be replaced. Date: November 2016...
  • Page 35 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section 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 36 6.3.2.4 If the mechanism fails to pass 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 returned. Please do not discard.
  • Page 37 6.5.1. Testing Procedure for lights fitted to lifejackets. The following sea lights have been fitted to Crewsaver Commercial and Leisure lifejackets. All light units used have a detailed expiry date, after which the light should be carefully disposed of. 6.5.1.1 Daniamant L6 The Daniamant L6 can be tested using the switch located on the right side (as looked at).

  • Page 38: Outer Cover

    Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Outer Cover 7.1.1 No repairs are permitted to the outer cover. Inflation Chamber 7.2.1 No repairs are permitted to the inflator fabric or its assembly, due to the construction of this lifejacket.
  • Page 39 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 40 Section 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, Para 5.1 identifies broken or pulled stitches.
  • Page 41 Expel the air from the chamber by inverting the dust cap on the oral tube. Lifejackets may also be deflated using the Crewsaver Venturi Vacuum System. For the part number, refer to Section 9. 8.1.3 Assemble the Operating Mechanism to the inflator.
  • Page 42 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket 8.1.3.2.10 Fit the gas cylinder to the firing mechanism by hand then check using the torque wrench and head adaptor from the tool kit (4Nm). The operating head is gripped in one hand and the cylinder tightened using the torque wrench with the cylinder tightening tool held in the other hand.
  • Page 43 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 8.2 Halkey Roberts Operating Head F i g . 8 . 2 . 1 Following the inspection and testing procedures for Halkey Roberts Manual operating heads as detailed in Section 5 and 6.
  • Page 44 Fig. 8.3.2 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. On Junior versions of the Crewfit refit the anti-tamper device over the capsule.
  • Page 45 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 8.3 Crewsaver Mk5 Operating Head Fig. 8.3.5 Check the bottom O-ring seal is in place. Before fitting the operating head onto the manifold, check that the Schrader valve is fitted.
  • Page 46 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 8.4 Hammar Operating Head Fig. 8.4.1 Fig. 8.4.2 Fig. 8.4.3 Green Indicator Water inlet valve Caution: Do Not turn Single center shaft point indicator Check that the indicator is green.
  • Page 47 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 8.5 Crewfit 150 Packing Instructions Fig. 8.5.1 Fig. 8.5.2 Lay Lifejacket out flat as shown in Diagram 1. Fold Fold lapels B and C across the front of the inflator at down the collar flap (A), line up the velcro the dotted lines shown.
  • Page 48 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 8.6 Crewfit 150 Zipped Packing Instructions Fig. 8.6.1 Fig. 8.6.2 Lay Lifejacket out flat as shown in Diagram 1. Fold Fold lapels B and C across the front of the inflator down the collar flap (A), line up the velcro at the dotted lines shown.
  • Page 49 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 8.7 Crewfit 150 Short Packing Instructions Lay the jacket out as shown. Fold the bottom of Fold the two inner lobes D and E in over the inflation the inflators A and B under and fold the collar C tube and cylinder cover.
  • Page 50 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 8.8 Crewfit Junior 150 Packing Instructions Fig. 8.8.1 Fig. 8.8.2 Fold the lifting becket, C, over the top of the Lay Lifejacket out flat as shown in Diagram 1. Fold inflator.
  • Page 51 Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Fig 8.8 Crewfit Junior 150 Packing Instructions Fig. 8.8.5 Fig. 8.8.6 Fold the top of the inflator, K, upwards then fold The Crewfit Junior is shown above, correctly the corners L and M, over diagonally and fasten packed with the manual pull toggle visible.

  • Page 52: Parts List

    Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket Section Parts List Product Description Part Number 33 gram CO Cylinder 12040 23 gram CO Cylinder 12020 Crewsaver Mk5i Auto Capsule 10012 Halkey Roberts Manual Head 10550 Manual Head Retaining Clip...