SURVIVOR SERIES AIRCREW FLOTATION VEST PACKING INSTRUCTIONS Applicable Part Numbers: AMTC-V1126-BL SURVIVOR LITE AMTC-V1130-BL SURVIVOR (With Extraction Harness) Capewell Aerial Systems LLC Connecticut 105 Nutmeg Road South South Windsor, CT 06074 P: 860.610.0700 www.capewell.com Capewell Aerial Systems LLC Virginia 4298 Jeb Stuart Highway Meadows of Dan, VA 24120 P: 276.952.2006 www.capewell.com
TABLE OF CONTENTS 1. INTRODUCTION 3 1.1 Survivor Vest Components 4 1.2 Survivor Bladder Components 6 2. PREFLIGHT INSPECTION 7 3. FITTING PROCEDURE 9 3.1 Survivor Lite Vest Fitting Procedure 9 3.2 Survivor with Harness Fitting Procedure 11 4. MAINTENANCE 12 5. STORAGE 12 6. SERVICE LIFE 12 7. ANNUAL INSPECTION 14 8. FUNCTIONAL INSPECTION 18 9. BLADDER PACKING INSTRUCTIONS 19 APPENDIX A. SPARE PARTS LIST 31 The following symbols are used throughout this manual: WARNINGS indicate a procedure or situation that may result in serious injury or death if instructions are not followed correctly. CAUTIONS indicate any situation or technique that will result in potential damage to the product, or render the product un safe if instructions are not followed correctly. NOTES are used to emphasize important points, tips, and reminders. 2
1. INTRODUCTION: The Survivor Aircrew Vest is Capewell s latest in vest and flotation design. This new design series integrates the vest and flotation collar into one assembly providing an extremely low profile light weight vest. The vests are made of robust, fire resistant cloth providing superior wear resistance and flash fire protection. Current available models are: AMTC-V1126-XX AMTC-V1130-XX Survivor Lite (No built in harness) Survivor (Hoisting harness version) NOTE: XX denotes color. When ordering specify BL for black or FG for green The bladder provides a minimum of 44 pounds of buoyancy using one 40g, 1/2 inch thread CO2 cylinder actuated manually. There are two versions of the Survivor Bladder: Single cell bladder with permanently mounted FAA commercial inflation valve. This version has one oral inflation tube and inflates manually with CO2. Dual cell bladder with replaceable military type inflation valve. This version has one cell which inflates manually with CO2 and a back up cell inflated orally. This version has two oral inflation tubes; one black and one red. The red oral inflation tube is for back up cell. Dual bladder does not include locator light or whistle unless requested. WARNING: You must use a 40 gram CO2 inflation cylinder with half inch threads. Failure to use proper cylinder will prevent bladder from reaching design shape, decrease buoyancy, and damage valve. 3
1.1 Survivor Vest Components Survivor Lite COMPONENT LIST Survivor, with Extraction Harness FRONT VIEW Burst Zipper Hoisting Loops Vest Closure Zipper Burst Zipper Closure Pin and Loops Beaded Inflation Handle Leg Straps Hoistable Leg Straps Not Hoistable 4
1.1 Survivor Vest Components (Continued): Survivor Lite COMPONENT LIST Survivor, with Extraction Harness BACK VIEW Tether / MURA Attachment Loop Rear Torso Adjustment Straps Back Panel With Waist Belt Height Adjustment Slots Waist Strap Front Waist Buckle Leg Straps Hoistable Leg Straps Not Hoistable 5
1.2 Survivor Bladder Components Survivor Locator Light (1) Oral Inflation Tube (2) Note: Single cell models will have one oral inflation tube. Double cell models will have two. 40g CO2 Cylinder (3) 1/2 inch thread Reflective Tape (4) Survival Whistle (5) CO2 Inflation Valve (6) NOTE: Military models will have a legacy model 840 replaceable inflation valve. Single cell vests have a permanently mounted FAA approved inflation valve. Main Bladder Cell (7) 1 7 2 5 4 3 6 6
2. Preflight Inspection: It is the responsibility of the air crewman to inspect the Survivor Flotation Vest and collar before flight operations. Perform a preflight inspection prior to each flight and at intervals not to exceed 30 days. If damage is found during an inspection, the vest must be grounded until repaired. 2.1 Inspect the vest and collar cover for: Cuts, tears, and abrasion damage Open seams and loose or broken stitching Contamination damage Hardware for cracks and corrosion 2.2 Ensure that the beaded inflation handle is attached with the one snap, that the other end of the inflation handle is stowed in handle stowage pocket, and the closure pin is fully engaged in all closure loops. 2.3 Ensure that the flotation collar quick burst zipper is completely closed and no zipper teeth are broken, missing, or separated. Closure pin should be engaged in all vest closure loops Ensure quick burst zipper is fully engaged around entire length with no broken or separated teeth. Beaded Inflation handle secured with snap and stowed in handle stowage pocket 7
2. Preflight Inspection (Continued): 2.4 If vest has built in harness inspect all webbing and load bearing stitches. Inspect for: Cuts, tears, and abrasion damage Open seams and loose or broken stitching. No more than three stitches broken in a line are allowed. Repair must be done by manufacturer or authorized Aviation Life Support Equipment (ALSE) Technician. Contamination damage Hardware for cracks and corrosion 2.5 Check that CO2 inflation cylinder is present by squeezing vest on wearer s front left side. If no cylinder present remove vest from service until replaced. END OF PREFLIGHT INSPECTION 8
3. Fitting Procedures: 3.1 Survivor Lite Vest Fitting The Survivor Lite vest is a very simple vest to adjust. Follow the steps below to ensure a proper fit. Step 1. Don vest by pulling over arms and up to shoulders. Step 2. Fasten front chest buckle Step 3. Close vest by zipping front zipper Step 4. Make sure vest is not riding up on back of neck and pull adjustment strap for a snug fit 9
3.1 Survivor Lite Vest Fitting (Continued): Step 5. Roll excess webbing towards adjustment buckle and secure with velcro webbing keeper. Step 6. Clip leg straps to back D rings and route end with adjuster through legs. Step 7. Clip leg straps to front D rings. Make sure end with adjuster is on front D ring. Step 8. Pull straps snug and wrap excess webbing around keep and secure around leg strap as shown. NOTE: Leg straps are optional but highly recommended to hold flotation in proper position. 10
3.2 Survivor Vest with Harness, Fitting The Survivor Vest with extraction harness is a fully hoist capable with built in harness system. Therefore, the Survivor vest with harness requires a more complex fitting procedure. It is important to follow the steps below to achieve a proper fit. Step 1. Don vest by pulling over arms and up to shoulders and fasten front torso strap. Step 2. Pull torso strap excess until snug around waist. Step 3. Roll excess torso strap towards buckle and secure around strap with velcro keeper as shown. Step 4. Close vest by zipping front zipper to the top. 11
3.2 Survivor Vest with Extraction, Fitting (Continued) Step 5. Measure one fist down from nape of neck to rear flotation collar seam as shown and adjust vest off back of wearer s neck. NOTE: It is important that rear of flotation collar is off wearers neck. This prevents neck pain and fatigue. Step 6. Once vest is in proper position relative to the neck, adjust rear torso straps snug. Roll excess towards buckle and secure with velcro keeper strap. Step 6. Connect leg straps to cobra buckle female on front of vest. Pull excess until straps are snug. END OF FITTING PROCEDURE Step 7. Roll excess webbing towards buckle and secure to leg straps using velcro keeper strap. 12
4. Maintenance Maintenance of the Survivor flotation collar consists of cleaning, service, and minor repair. The air crewman s responsibility for maintenance is limited to inspecting the outside components of the collar. Service and repairs shall be completed only by an authorized ALSE technician or the manufacturer. Remove the bladder to wash the vest. See sections 7, 8, and 9 of this guide for functional and packing instructions. CAUTION: There are no repairs authorized on flotation bladders other than replacement of CO2 valve. 5. Storage Store your Survivor aircrew vest on a plastic or wooden clothing hanger away from direct sunlight in a dry, well ventilated place. Do not store your vest near sources of heat such as a radiator, or in a warm, humid environment where mold or mildew can contaminate the vest. Do not drag vest on rough surfaces such as concrete or pavement. 6. Service Life Capewell suggests a service life of 7 years for flight vests and rescue harnesses. After 7 years of use Aerial recommends replacement of vests, bladders, and harnesses. 13
7. Annual Inspection An inspection should be performed annually to ensure the Survivor flotation collar will perform when needed. Only qualified personnel are to perform and log this inspection. The inspection can also be performed by the manufacturer. If damage is found during an inspection the vest must be grounded until repaired. Repairs are limited to replacement of snaps and inflator replacement if equipped with removable inflator valve. All other repairs must be completed at the manufacturer. A functional test should be performed every third year. If a functional test is required, skip to section 7. Consumables: Replacement CO2 bottle, 40 gram, 1/2 thread. Green safety clip, 1 each. 7.1 Lay vest on flat surface clear of any contamination for puncture hazards. 7.2 Carefully remove inflation handle and closure pin from closure loops without actuating CO2 cylinder. Open quick burst zipper by gently pulling slider around full length of zipper to opposite side. Unfold bladder and lay flat on packing surface. Open zipper all the way around to opposite side 14
7. Annual Inspection (continued): 7.3 Remove CO2 inflation cylinder and inspect cylinder for corrosion, damaged threads, and compromised strike plate. 7.4 Cycle inflation valve lever a few times while watching valve punch post inside valve thread access. make sure post inside valve is not blunted or bent. 7.5 Make sure inflation lanyard is securely tied to lever using a bowline knot with square knot on end, and lanyard is properly routed through last eyelet of bottom bladder vest mounting tab. NOTE: There are two types of inflation valves available on the Survivor series vest. See below for examples of each. Replaceable CO2 Valve Permanent mounted FAA type 15
7. Annual Inspection (continued): CAUTION: Inflate vest only with clean, dried, filtered air regulated to no more than 40 PSI. Unfiltered air can introduce contaminants into the bladder. Over 40 PSI shop air pressure may damage bladder. 7.6 Perform leak test by inflating the bladder to 2.0 PSI using the oral inflation tube. Dual Cell Bladder Single Cell Bladder 7.7 Let flotation collar sit for 2 hours undisturbed in an environmentally controlled area with a constant temperature. CAUTION: If pressure drops more than.4 PSI, submerge the Survivor bladder in water or use leak detection compound to determine where leakage is occurring. If leakage occurs around inflator, replace inflator and gaskets and perform leak test again. If no determination can be made or bladder is leaking through internal bladder bulkhead (double cell only), return Survivor to manufacturer for evaluation. 7.8 Check pressure through oral inflation tube and record in vest maintenance record. Pressure should drop no more than.4 PSI. 16
7. Annual Inspection (continued): 7.9 Evacuate all air from the bladder cell through oral inflation tube using a shop vacuum. To aid in air removal Aerial offers our bladder evacuation hose adapter with single hole (AMTC-M2033) NOTE: It is important that all trapped air be removed from bladder before packing. This provides a low profile, tight pack. 7.10 If inspecting a double celled bladder, repeat steps 6.6 through 6.9 for remaining cell. 7.11 Make sure inflation valve lever has been reset. Then reinstall 40g CO2 Cartridge by screwing in to inflation valve hand tight. Install green safety clip. Replaceable CO2 valve PROCEED TO SECTION 9 FOR BLADDER PACKING FAA permanent mounted valve 17
8. Functional Inspection: A functional inspection should be performed every third year to ensure the Survivor flotation collar will perform when needed. It is the responsibility of qualified ALSE technicians to perform and log this inspection. The inspection can also be performed by the manufacturer. If damage is found during an inspection, the vest must be grounded until repaired. Repairs are limited to replacement of snaps and inflator replacement, All other repairs must be completed at the manufacture. Functional inspection is as follows: 8.1 A functional can be performed with an individual wearing the Survivor vest or on a table. 8.2 Pull inflation handle down and away from the bladder to inflate flotation collar as shown below. This can be done with either hand. NOTE: The Survivor bladder should fully inflate within 10 seconds. 8.3 Adjust pressure to 2.0 PSI using oral inflation tubes. 8.5 Return to section 7.7 and complete FUNCTIONAL COMPLETE 18
9. Bladder Packing Instructions: Repack the Survivor bladder on a large, flat clean surface big enough to accommodate the bladder when it is spread flat with no air. Orientation references the wearer s right and left 9.1 Find zipper slide on bottom of wearer s left. Pull the slide all the way around the neck to the wearers right side to end of zipper. 9.2 Starting on the wearers right side fold bladder inward towards vest closure zipper. Make small fold along bottom approx. 1 inch. Make sure water activated battery (if equipped) is parallel to vertical bladder line as shown below. 19
9. Bladder Packing Instructions (Continued): 9.3 Fold bladder back over away from vest closure zipper as shown below. 9.4 Fold bladder back over towards vest closure zipper as shown below. Make sure water activated battery (if equipped) is placed between folds at point of red arrow below. 20
9. Bladder Packing Instructions (Continued): 9.5 While holding folds in place, fold bladder cover panel over bladder towards vest closure zipper. Mate bladder cover zipper ends into slide and begin to close the quick burst zipper as shown below. 9.6 Continue zipping the burst zipper up towards collar and stop at point shown below. 21
9. Bladder Packing Instructions (Continued): 9.7 Fold neck material under once and then back over on itself with the locator light (if equipped) facing up and towards the inner part of the cover as shown below. 9.8 Move bladder closure zipper up to about even with locator light. Then make identical fold on other side of bladder neck as shown below. 22
9. Bladder Packing Instructions (Continued): 9.9 Fold back of neck over till fold line is even with outer back edge of bladder cover as shown below while maintaing left side folds in place. 9.10 Fold back of neck over itself towards back outer edge as shown below. 23
9. Bladder Packing Instructions (Continued): 9.11 Make one more small fold back towards neck of collar. 9.12 Close zipper all the way around the back of the neck and over shoulder area. Stop at point indicated by arrow below. 24
9. Bladder Packing Instructions (Continued): 9.13 Make sure inflation lanyard is connected to actuator arm on replaceable valve and to loop on permanent mounted valve. Ensure the lanyard is routed through guide grommet hole on bottom bladder mounting tab. Replaceable CO2 Valve Permanent Mounted FAA valve 9.14 Make sure new 40g CO2 Cylinder is installed with cover, inflation valve lever is reset and green safety clip is in place. Replaceable CO2 Valve Permanent Mounted FAA valve 25
9. Bladder Packing Instructions (Continued): 9.15 Fold bladder over CO2 assembly towards wearer s left making sure that inflation lanyard is free and clear with no obstructions to inflation pull. 9.16 Now fold bladder over on itself one more time as shown below. Again make sure that inflation lanyard is free and clear and no obstructions to inflation pull. 26
9. Bladder Packing Instructions (Continued): 9.17 Install survival whistle on bladder elastic securing loop as shown below if equipped. 9.18 While holding folds in place continue closing the quick burst zipper slide down the front of the wearers left side until completely closed. 27
9. Bladder Packing Instructions (Continued): 9.19 Install vest closure pin attached to beaded inflation handle by starting and the bottom front of the wearers left side and routing through closure loops alternating bladder side to zipper side loops until pin is completely seated in all loops as show in pictures below. There are a total of seven loops. NOTE: It is important that all loops be engaged by closure pin. 28
9. Bladder Packing Instructions (continued): 9.20 Before snapping inflation handle in place, make sure quick burst zipper pull loop is stowed around snap stud as shown below. Then snap inflation handle into place making sure inflation lanyard is stowed in cover and not tangled. 9.21 Stow other end of beaded inflation handle in stowage pocket as shown below. Close hook and loop closure at bottom of vest. 29
9. Bladder Packing Instructions (continued): 9.22 Close quick burst zipper end cover on wearers right side making sure end of quick burst zipper is packed inside cover. Close hook and loop closure along bottom of vest. PACKING COMPLETE 30
APPENDIX A. SPARE PARTS TABLE: Item Description Aerial Part # 40 Gram CO2 cylinder, 1/2 inch thread 77202 Inflation Valve Safety Clip for FAA valve Inflation Valve Safety Clip, Replaceable Valve V87400 FAA 8452AMA ORDERING INFORMATION: Capewell Aerial Systems 4298 Jeb Stuart Hwy Meadows of Dan, VA 24120 Main plant: 276.952.2006 www.capewell.com SERVICE LIFE: The service life of this vest is rated at 7 years. After 7 years from date of manufacture, vest shall be replaced. 31