Crewsaver VOYAGER 275N Service Manual Download

Page: 1 / 36

Servicing Manual: Crewsaver Voyager 275 Lifejacket

Project No: 00154

Date: November 2016
Issue No: 2

Page

of 36

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: [email protected]

Web: www.crewsaver.co.uk

R29965

Summary of Contents for VOYAGER 275N

Page 1: ...ject No 00154 Date November 2016 Issue No 2 Page of 36 1 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 2: ... No Issue 2 Description 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 CSL Light updated to show new switch Back pressure testing of the operating head added Date November 2016 Service Bulletins and Amendments Register ...

Page 3: ...n 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 Voyager 275N lifejac...

Page 4: ...ng 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...

Page 5: ...er size Standard Automatic Hammar Automatic Manual Firing head Manual Override Oral inflation tubes Pressure relief valves Heavy Duty cover Whistle fitted Retro reflective tape Lifting Becket fitted Light fitted Spray Hood Thigh straps Fall Arrest Harness Closure method Alternative covers Voyager 275N Lifejacket 290N 275N Orange X 60g According to customer choice X X N A N A X X X Optional Optiona...

Page 6: ...s Studs 40mm Black Polyester Back Strap Crewsaver Badge Solas Approved Retro Reflective Tape 40mm Black Polyester Waist Belt SS 40 Buckle Heathcoat Mesh 1 Section 1 4 1 General Features Non Harness Hammar Orange PVC coated polyester flame retardant Spanish Gold PU Coated Nylon Solas Approved Retro Reflective Tape 60g CO Cylinder 2 20mm Velcro Hook 20mm Velcro Loop Oral Tube 40mm Black Polyester Re...

Page 7: ...ctive Tape 60g CO Cylinder 2 USE ONLY CREWSAVER 60g CO2 Disposable Cylinder FOLD UNDER FOLD UNDER 20mm Velcro Hook 20mm Velcro Loop Oral Tube 40mm Black Polyester Retaining Strips Mk5 Firing Head and Capsule Plastic Press Studs 40mm Black Polyester Back Strap Orange PVC coated polyester flame retardant Crewsaver Badge Solas Approved Retro Reflective Tape 40mm Black Polyester Waist Belt SS 40 Buckl...

Page 8: ... 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 lanyard down if manual inflation is required 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 1 Section 1 5 1 Donning Instructions Voyager 275 Non Harness 2 3 4 5 ...

Page 9: ...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 QAcriteria in the Crewsav...

Page 10: ...such as oil or diesel fuel may be sponged off immediately with clean water and allow 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 inflatable stole with pure soap solution only Rinse in clean water immediately inflate an...

Page 11: ...Servicing Tool Kit A fine screw driver or tool suitable for removing gaskets Hammar inflator body bench clamp Hammar cylinder torque clamp Loctite 222 Adhesive Boning tool Roller Brushes Scissors or 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...

Page 12: ... MANIFOLDS Schrader VALVES CYLINDERS LIGHT CYALUME POCKET BUDDY LINE RQ INFLATION MECHANISM COMMENTS OPERATING MECHANISM CORD AUTOMATIC CAPSULE WASHERS RETAINING NUT RETAINING CLIP TOGGLE RQ SPRAY HOOD COMMENTS FABRIC ATTACHMENT VELCRO REPAIRED ITEMS COMMENTS TYPE CUSTOMER RQ WEBBINGS COMMENTS WAIST BELT HARNESS BACK STRAP LIFTING BECKET CROTCH STRAP BUCKLES STITCHING ON OFF RELIEF VALVE TEST RESU...

Page 13: ...on 2 2 6 Lifejacket Servicing Tool Kit Cylinder Torque Strap UML Mk5 Auto Socket Manometer Valve Extraction Tool Pressure Measuring Adaptor Inflation Adaptor Turned Socket Calibrated Socket Driver Tighten Cylinder Calibrated Socket Driver Remove Replace Locking Nuts For UML HR Calibrated Torque Driver Schraeder Valve ...

Page 14: ... 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 3 1 3 2 1 Automatic Only Unscrew the Automatic Capsule if fitted from the operating mechanism Place to one side for testing a...

Page 15: ...cing Manual Crewsaver Voyager 275 Lifejacket Project No 00154 Date November 2016 Issue No 2 Page of 36 15 Fig 3 1 Unpacking the Lifejacket 3 Section Fig 3 1 1 Fig 3 1 2 JER K TO INF LAT E Fig 3 1 3 Fig 3 1 4 ...

Page 16: ...black locking ring and labelled yellow cap The black locking ring will now turn counter clockwise Fig 3 2 1 Fig 3 2 2 Cap 3a 3b 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 in...

Page 17: ...the 60 gram cylinder from the automatic operating head Once the cylinder has 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 theAutomatic...

Page 18: ...e valve retaining nut from the top of the firing head using a 9 16 socket or spanner Check for corrosion discard if corroded Remove the top sealing gasket washer and discard This must be replaced with a new part upon reassembly 3 Section Fig 3 4 Halkey Roberts Operating Head Fig 3 4 3 Remove the operating head from the manifold which is welded to the inflator fabric Remove the bottom gasket sealin...

Page 19: ...154 Date November 2016 Issue No 2 Page of 36 19 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 Section 3 ...

Page 20: ... 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 Allow 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...

Page 21: ...e stole material for wear pulled threads contamination or signs of mistreatment 5 2 2 Visually inspect all welds 5 2 3 Visually inspect all webbings in accordance with Section 5 6 5 2 4 Visually inspect the whistle and its attachment to the lifejacket for mistreatment defects and fraying of the cord and its attachment 5 2 5 Test Lifejacket in accordance with Section 6 5 3 1 Visually examine 5 3 1 ...

Page 22: ...leased Remedial Action In the event that the Operating Mechanism fails any of the above inspection procedures the complete unit shall be replaced No Repairs are allowed Refer to Section 9 for the part number of the relevant replacement part 5 5 2 Visually inspect the Operation of the Automatic Capsule on the automatic Operating Head 5 5 2 1 Check plug is in place at the base of the capsule 5 5 2 2...

Page 23: ...abelling Markings 5 9 Lights if fitted 5 9 1 There are many lights available and all have a means of testing the light Each light will have an expiry date printed on the light Below is the example of an L6 light with manual operation and a description on testing 5 9 1 2 Inspect the light for any signs of damage If there are chips or cracks the light must be replaced 5 9 1 3 Check that the light is...

Page 24: ...6 2 103 50 0 1406 0 1378 137 90 13790 13 79 2 1 58 19 4 276 1476 5 108 68 0 1476 0 1447 144 80 14480 14 48 2 2 60 96 4 479 1546 8 113 85 0 1547 0 1516 151 69 15169 15 17 2 3 63 73 4 683 1617 1 119 03 0 1617 0 1585 158 59 15859 15 86 2 4 66 50 4 886 1687 4 124 20 0 1687 0 1654 165 48 16548 16 55 2 5 69 28 5 090 1757 8 129 38 0 1758 0 1723 172 38 17238 17 24 2 6 72 05 5 294 1828 1 134 55 0 1828 0 17...

Page 25: ... move or the firing pin is not clearly moving the operating head must be replaced Refer to Section 9 for part number 6 3 2 Operational Test for Crewsaver Mk5 Automatic Operating Heads to be performed when capsules have expired 6 3 2 1 Remove the operating mechanism from the lifejacket and remove the cylinder 6 3 2 2 Assemble the expired capsule onto the body of the operating mechanism 6 3 2 3 Plac...

Page 26: ...No repairs permitted For the Part No of the replacement part refer to Section 9 7 3 2 Please ensure cylinders are disposed of in accordance with local regulations Treat empty cylinders as steel for recycling purposes 7 4 1 No repairs permitted For the Part No of the replacement parts refer to Section 9 7 4 2 Replacement of the Oral valve may be achieved by 7 4 2 1 Carefully removing the defective ...

Page 27: ...on 9 for the Part No of the replacement part 7 6 1 No cuts are allowed in the webbing of any of these components No repairs are permitted on Harness 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 t...

Page 28: ...epairs to broken stitches should be over sewn following the same line of stitching ensuring that the stitching continues for a minimum of 20mm past the repair section each end must be back tacked twice aii Repairs to pull threads should be repaired by first trimming the lose ends and then repeating the process as detailed above aiii Any repairs carried out must be made using the correct thread ava...

Page 29: ...echanisms See Fig 8 3 8 1 3 1 1 A new firing retaining pin clip upper and lower manifold gaskets must be fitted Refer to Section 9 for Part Numbers 8 1 3 1 2 Fit new lower gasket 8 1 3 1 3 Locate operating head onto manifold 8 1 3 1 4 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 ...

Page 30: ...i and release the control to its vertical position 8 1 3 1 7 There may be a slight decrease in pressure over the first 2 seconds as the unit stabilises Leave for 10 seconds and check for any further decrease in pressure shown on the gauge 8 1 3 1 8 Release the pressure by turning the control to deflate 8 1 3 1 9 If there had been any decrease in pressure remove the cylinder adaptor remove the oper...

Page 31: ...th these questions then proceed as follows If NO get a new cap Fig 8 1 3 Hold the gas cylinder through the fabric of the lifejacket Fig 8 1 4 Position the replacement cap with the water inlet valve pointing to the right and press it FIRMLY onto the inflator body and sealing ring Fig 8 1 5 While pressing FIRMLY onto the inflator body turn the BLACK locking ring clockwise into the locked position Pu...

Page 32: ...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 If the lifejacket is fitted with a United Moulders Mk5 head a M5i firing capsule must be fitted These are black in colour Fig 8 2 2 Fig 8 2 1 Check that the cylinder sealing gasket in the end of the oper...

Page 33: ...orque driver set to 0 32 0 36 Nm Then place the operating head onto the manifold so that the cylinder is pointing upwards Fig 8 2 5 Fig 8 2 6 Sealing O Ring Check the O ring seal is in the recess on the top face of the operating head With the top O ring in place fit the retaining nut The retaining nut should be screwed into place using a torque wrench or driver fitted with a 9 16 socket The wrench...

Page 34: ...ew schraeder valve ensure it is only finger tight Then place the operating head onto the manifold so that the cylinder threaded opening is facing the cylinder elastic away from the bottom of the inflator With the top gasket in place fit the retaining nut The retaining nut should by screwed in to place using a torque wrench or driver fitted with a 9 16 socket The wrench or driver should be set to b...

Page 35: ... under at the dotted lines shown Fold down the collar flap C and line up the velcro and fasten Locate lifting becket D and fold this up on top of the inflator Fold lapels E and F across the front of the inflator at the dotted lines shown Fold sides G and H inwards and fasten the velcro Secure the press studs K and L at the top Fold under the velcro flaps I and J and fasten to the velcro at the bac...

Page 36: ...l Cap 11012 Hammar Back Plate 11013 Whistle 10677 L6 Light 10219 Crutch Straps pair 10032 Mouth Inflation Valve 10208 Mouth Inflation Valve Cap 10151 Schraeder Valve 10049 Cover Fabric for minor repairs Orange 5 5 R77500 Cover Fabric for minor repairs Orange 2 5 R78900 15mm Loop Velcro R74751 15mm Hook Velcro R74752 32mm Elastic R74300 8 Plait Polyester Cord White for Whistle R71000 8 Plait Polyes...

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