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Crewsaver ERGOFIT 290 Service Manual

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Crewsaver -
Servicing Manual : Ergofit 190N & 290N Lifejackets
Date: November 2016
Issue No: 3
SERVICE MANUAL
ERGOFIT 190 & 290
LIFEJACKETS
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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Summary of Contents for Crewsaver ERGOFIT 290

  • Page 1 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets SERVICE MANUAL ERGOFIT 190 & 290 LIFEJACKETS 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...
  • Page 2 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Service Bulletins and Amendments Register Description Date Issue 2 Page 4 - change in procedure for accessing April 2014 manuals on the website. Issue 3 Manual expanded to include Ergofit 190N Pro and...
  • Page 3 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Scope This manual covers the servicing of the Ergofit 190N and 290N lifejackets without any current derivatives. Index Section 1 Introduction Product Description Data Sheet General Features Donning Instructions Section 2...
  • 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 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section Product Description (Continued) 1.2.1. The Ergofit 290N OC (Ocean) and Ergofit 290N EX are single chamber Level 275 PFDs (Inflatable lifejackets). 1.2.2. The lifejackets are CE approved to BS EN ISO 12402-2.
  • Page 6 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 1.3.1 Data Sheet Ergofit 190N CS Features: 190N Chamber Buoyancy: 150N Buoyancy Category: Black Cover Colour MCA (UK) Approved SOLAS Approved CE Approved Cylinder size According to Standard Prosensor Automatic...

  • Page 7: Data Sheet

    Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 1.3.2 Data Sheet Ergofit 190N Pro Features: 190N Chamber Buoyancy: 150N Buoyancy Category: Black Cover Colour MCA (UK) Approved SOLAS Approved CE Approved Cylinder size According to Standard Prosensor Automatic...
  • Page 8 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 1.3.3 Data Sheet Ergofit 190N OS Features: 190N Chamber Buoyancy: 150N Buoyancy Category: Black Cover Colour MCA (UK) Approved SOLAS Approved CE Approved Cylinder size According to Standard Prosensor Automatic...
  • Page 9 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 1.3.4 Data Sheet Ergofit 290N OC and EX Features: 290N Chamber Buoyancy: 275N Buoyancy Category: Black Cover Colour MCA (UK) Approved SOLAS Approved CE Approved Cylinder size According to...
  • Page 10 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 1.4.1 General Features - Ergofit 190N CS Spray Hood Spray Hood Retaining Webbings velcro to inflation chamber Inflatable Chin Cover: Zipped Support Closure Oral Inflation Tube and whistle Lifting Beckets...
  • Page 11 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 1.4.2 General Features - Ergofit 190N OS and Spray Hood Spray Hood Retaining Webbings velcro to inflation chamber Inflatable Chin Cover: Zipped Support Closure Oral Inflation Tube and whistle...
  • Page 12 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 1.4.3 General Features - Ergofit 290N OC and EX Spray Hood Spray Hood Retaining Webbings velcro to inflation chamber Inflatable Chin Support Cover: Zipped Closure Oral Inflation Tube and whistle...
  • Page 13 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 1.5.1 Donning Instructions - Ergofit 190N CS Don like a normal jacket. Adjust waist belt by Fasten front Zip and buckle. Fasten crutch strap pulling webbing buckles and adjust...
  • Page 14 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 1.5.2 Donning Instructions - Ergofit 190N OS and Ergofit 290N Don like a normal jacket. Adjust waist belt by Fasten crutch strap buckles Fasten the front buckle. pulling webbing forward and adjust straps by pulling for a close secure fit .
  • Page 15 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 1.5.3 Donning Instructions - Ergofit 290N EX Don like a normal jacket. Fasten two front buckles. Adjust waist belt by Fasten crutch strap pulling webbing buckles and adjust forward for a close straps by pulling secure fit .

  • Page 16: Service Stations

    2.2.7 Damaged areas shall be marked using wax based crayon only. Marks shall be made with a small circle 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.

  • Page 17: General Care

    Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 2 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 18 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). Lifejacket Service Record Sheet 2.5.1.
  • Page 19 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 2 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 20 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets 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 21 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section Unpacking 3.1.1 Pull the zips apart exposing the operating head and cylinder. Care should be taken not to snag the firing line. WARNING: All defects should be noted onto the service record sheet.
  • Page 22 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section Fig 3.2 Unpacking the Ergofit (all versions) 1. Open the velcro tab. 2. Pull apart the zip, opening the zip via the quick burst elements, holding the cover either side.
  • Page 23 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section Fig 3.3 UML Prosensor Manual Operating Head Retaining CO cylinder screw Indicator Cylinder sealing O-Ring Pull cord and handle Unscrew the CO cylinder from the manual firing head. Once the cylinder has been removed inspect the cylinder sealing O-Ring .
  • Page 24 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section Fig 3.4 United Moulders Prosensor Automatic Head Retaining CO cylinder screw Automatic capsule Indicators Cylinder sealing O-Ring Pull cord and handle 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.
  • Page 25 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section Fig 3.5 Hammar Operating Head Fig. 3.5.1 Fig. 3.5.2 Locking ring Insert metal key as shown in 2a and turn the key counter-clockwise Place the lifejacket on a smooth, (2b) between black locking ring and labelled yellow cap.
  • Page 26 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section Cleaning Lifejackets 4.1.1 The current standard cover of the Ergofit can be cleaned with care. In the event that contamination is such that the materials are inherently damaged refer to section 7.

  • Page 27: Gas Cylinders

    Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section Outer Cover Inspection 5.1.1 Visually inspect the cover material for wear, abrasion, pulled threads, contamination, cuts and holes. 5.1.2 Carefully examine the zips and the slider for wear, broken teeth or slider and worn or fraying tape.
  • Page 28 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets 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.
  • Page 29 5.6.1.1. Fraying 5.6.1.2. Pulled Threads 5.6.1.3. Broken Stitches Remedial Action: No repairs are allowed. In the case of damage being found, return the Lifejacket to Crewsaver. Buckles 5.7.1 Visually inspect all buckles used on the webbings for signs of damage or corrosion.
  • Page 30 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets 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 31 6.3.1.4 If the mechanism fails to pass this 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 32: Outer Cover

    Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section Outer Cover 7.1.1 No repairs are permitted to the outer cover. Inflation Chamber .2.1 No repairs are permitted to the inflator fabric or its assembly, due to the construction of this lifejacket.
  • Page 33 7.5.1.1 Remove and replace using the calibrated torque driver for UML PS Short valves set to 0.32 - 0.36 Nm. Refer to Section 9 for the Part No. of the replacement part. WARNING: Only fit replacement UML PS Short valves obtained from Crewsaver. 7.5.2 Operating Mechanism.
  • Page 34 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 35 8.1.3.3.2 If a new CO cylinder is required a replacement cylinder ALREADY ATTACHED to an inflator body must be purchased from Crewsaver. 8.1.3.3.3 Insert the cylinder and inflator body into the inflation chamber through the sealing ring, ensure that the cylinder is vertically positioned in the inflation chamber.
  • Page 36 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.2 UML Prosensor Manual Operating Head MANUAL Cylinder sealing O-Ring MANUAL MANUAL Indicator Green Check that the cylinder sealing O-Ring in the end of the operating head has been correctly fitted, or replaced if necessary.
  • Page 37 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.3 United Moulders Prosensor Automatic Operating Head AUTOMATIC Cylinder sealing O-Ring Indicator AUTOMATIC AUTOMATIC green Take the automatic firing capsule and screw onto the operating mechanism in a clockwise direction.
  • Page 38 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 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 39 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.5 Repacking the Ergofit 190N CS, 190N OS and 190N Pro Ensure hood webbing puller is placed above chamber collar and velcro tabs are secured. Fix light activator to...
  • Page 40 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.5 Repacking the Ergofit 190N CS, 190N OS and 190N Pro (cont.) Fold outer left side of chamber over towards the Concertina bottom left side of Chamber. Ensure centre.
  • Page 41 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.5 Repacking the Ergofit 190N CS, 190N OS and 190N Pro (cont.) Tuck chin support inside itself so there is a straight Fold top corners of collar down. Tuck hood in, taking line from corner to corner.
  • Page 42 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.5 Repacking the Ergofit 190N CS, 190N OS and 190N Pro (cont.) FINAL INSTRUCTIONS FOR 190N Pro AND LATER VERSIONS OF 190N OS 190N OS 190N Pro Concertina inner right edge over to fit.
  • Page 43 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.6 Repacking the Ergofit 290N OC Ensure hood webbing puller is placed above chamber collar, and velcro tabs are secured. Fix light activator to its elastic retainer at the back of the collar.
  • Page 44 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.6 Repacking the Ergofit 290N OC (cont.) Concertina bottom edge of chamber. Firing capsule Fold top corners of collar down. Tuck hood in taking should lie on top.
  • Page 45 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.6 Repacking the Ergofit 290N OC (cont.) Fold outer right side of Chamber over towards the Fold up bottom right side of Chamber. centre. Fold back chin support and roll underneath folded Fold the inner edge of the Chamber over towards the chamber.
  • Page 46 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.6 Repacking the Ergofit 290N OC (cont.) Tuck zip ends inside cover so the bottom of the jacket Tuck hood in by curling the tubing inwards. care not looks neat.
  • Page 47 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.7 Repacking the Ergofit 290N EX Ensure hood webbing puller is placed above chamber collar, and velcro tabs are secured. Fix light activator to its elastic retainer at the back of the collar.
  • Page 48 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.7 Repacking the Ergofit 290N EX (cont.) Concertina bottom left side of chamber. Ensure capsule lays Fold outer left side of Chamber over towards the centre. on top of the fabric. On Hammar units, fold as shown.
  • Page 49 Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section 8 Fig 8.7 Repacking the Ergofit 290N EX (cont.) Fold up bottom right side of Chamber. Fold outer right side of Chamber over towards the centre. Release any build up of air using the oral inflation tube.

  • Page 50: Product Description

    Crewsaver - Servicing Manual : Ergofit 190N & 290N Lifejackets Section Parts List Product Description Part Number 60 gram CO Cylinder 12050 38 gram CO Cylinder 12045 United Moulders Mk5i Auto Capsule 1 0017 United Moulders Prosensor Manual Head with...