MUSTANG SURVIVAL ICE COMMANDER, MUSTANG MODEL … · Mustang Survival IC6000 NZ Version Description and Maintenance Instructions 3 May 2002, Rev: -- ii This document is for information

MUSTANG SURVIVAL ICE COMMANDER,

MUSTANG MODEL IC6000 NZ VERSION

DESCRIPTION AND MAINTENANCE INSTRUCTIONS

3 MAY 2002, REV: --

Mustang Survival Canada Mustang Survival-USA

3810 Jacombs Road 3870 Mustang Way

Richmond, BC, V6V 1Y6 Bellingham, WA

Tel: (604) 270-8631 Fax: (604) 270-0489 USA 98226

E-mail: [email protected] Tel: (360) 676-1782 Fax: (360) 676-5014

WEB: www.mustangsurvival.com E-mail: [email protected]

Mustang Survival IC6000 NZ Version Description and Maintenance Instructions

3 May 2002, Rev: --

i TThhiiss ddooccuummeenntt iiss ff oorr iinnff oorrmmaattiioonn ppuurrppoosseess oonnllyy.. IItt iiss nnoott aa ccoonnttrroolllleedd

ddooccuummeenntt aanndd mmaayy nnoott bbee ccoonnssiiddeerreedd ccuurrrreenntt wwhheenn pprriinntteedd..

TABLE OF CONTENTS 1.0 INTRODUCTION...............................................................................................................................1

1.1 GENERAL .................................................................................................................................... 1 1.2 CONTACT.................................................................................................................................... 1 1.3 RIGHTS RESERVED................................................................................................................... 1 1.4 RESPONSIBILITIES .................................................................................................................... 1 1.5 DESCRIPTION............................................................................................................................. 2

2.0 IMMERSION AND ANTI-EXPOSURE CLOTHING .....................................................................4 2.1 HAZARDS .................................................................................................................................... 4 2.2 WET SUITS.................................................................................................................................. 4 2.3 DRY SUITS .................................................................................................................................. 4

3.0 IC6000 NZ VERSION FEATURES ................................................................................................5 3.1 GENERAL .................................................................................................................................... 5 3.2 HYPOTHERMIA PROTECTION.................................................................................................. 5 3.3 TESTING...................................................................................................................................... 6 3.4 ASSEMBLED IC6000 NZ VERSION........................................................................................... 6 3.5 OTHER FEATURES .................................................................................................................... 6

4.0 ASSEMBLY........................................................................................................................................8 4.1 STEP 1 LAYOUT THE BUOYANCY LINER AND OUTER SHELL ............................................ 8 4.2 STEP 2 CONNECT THE BUOYANCY LINER/OUTER SHELL AT THE ANKLES .................... 8 4.3 STEP 3 WRIST SNAP CONNECTIONS ..................................................................................... 8 4.4 STEP 4 CHEST AND NECK SNAP CONNECTIONS................................................................. 8

5.0 DONNING\DOFFING INSTRUCTIONS ........................................................................................9 5.1 STEP 1 SUIT PREPARATION PRIOR TO DONNING ............................................................... 9 5.2 STEP 2 DONNING INSTRUCTIONS .......................................................................................... 9 5.3 STEP 3 CLOSING THE WATERPROOF ENTRY ZIPPER ........................................................ 9 5.4 STEP 4 ADJUSTING THE IC6000 NZ VERSION AFTER DONNING ....................................... 9 5.5 DOFFING PROCEDURE............................................................................................................. 9

6.0 MAINTENENCE AND CARE ........................................................................................................11 6.1 GENERAL .................................................................................................................................. 11 6.2 SEPARATING THE LAYERS .................................................................................................... 11 6.3 CLEANING ................................................................................................................................. 11 6.4 TREATMENT AFTER IMMERSION.......................................................................................... 12 6.5 INSPECTION ............................................................................................................................. 13 6.6 REPAIRS.................................................................................................................................... 18

7.0 SUMMARY.......................................................................................................................................29 8.0 PARTS LIST ....................................................................................................................................30


3 May 2002, Rev: --

ii TThhiiss ddooccuummeenntt iiss ff oorr iinnff oorrmmaattiioonn ppuurrppoosseess oonnllyy.. IItt iiss nnoott aa ccoonnttrroolllleedd


TABLE OF FIGURES Figure 1. IC6000 NZ Version Sizing Information.....................................................................................3 Figure 2. Clo Insulation Graph.................................................................................................................5 Figure 3. Component Locations ..............................................................................................................6 Figure 4. Recommended Zipper Cleaning Fluids and Waxes ................................................................13 Figure 5. Step a. Suit Leakage Test........................................................................................................15 Figure 6. Step b. Suit Leakage Test........................................................................................................15 Figure 7. Step c. Suit Leakage Test........................................................................................................16 Figure 8. Step d. Suit Leakage Test........................................................................................................16 Figure 9. Step e. Suit Leakage Test........................................................................................................17 Figure 10. Step f. Suit Leakage Test.......................................................................................................17 Figure 11. Step g. Suit Leakage Test......................................................................................................18 Figure 12. Parts for Snap Replacement ..................................................................................................20 Figure 13. Step a. Liner Snap Replacement ...........................................................................................21 Figure 14. Step b. Liner Snap Replacement ...........................................................................................21 Figure 15. Step c. Liner Snap Replacement ...........................................................................................22 Figure 16. Step d. Liner Snap Replacement ...........................................................................................22 Figure 17. Step e. Liner Snap Replacement ...........................................................................................23 Figure 18. Step f. Liner Snap Replacement ............................................................................................23 Figure 19. Step a. Shell Snap Replacement ...........................................................................................24 Figure 20. Step b. Shell Snap Replacement ...........................................................................................24 Figure 21. Step c. Shell Snap Replacement ...........................................................................................25 Figure 22. Step d. Shell Snap Replacement...........................................................................................25 Figure 23. Step e. Shell Snap Replacement ...........................................................................................26 Figure 24. Step f. Shell Snap Replacement ............................................................................................26 Figure 25. Step g. Shell Snap Replacement ...........................................................................................27 Figure 26. IC6000 NZ Version Outer Shell (Part Number MA3003) and Index Numbers......................30 Figure 27. Parts List for the IC6000 NZ Version Outer Shell ..................................................................31 Figure 28. IC6000 NZ Version Buoyancy Liner (Part Number MA2200) and Index Numbers...............32 Figure 29. Parts List for the IC6000 NZ Version Buoyancy Liner ...........................................................32 Figure 30. IC6000 NZ Version Accessories ............................................................................................33 Figure 31. Expendables List for the IC6000 NZ Version.........................................................................33


3 May 2002, Rev: --

1 TThhiiss ddooccuummeenntt iiss ff oorr iinnff oorrmmaattiioonn ppuurrppoosseess oonnllyy.. IItt iiss nnoott aa ccoonnttrroolllleedd


1.0 INTRODUCTION 1.1 GENERAL

1.1.1 This manual provides information on the hazards of cold-water immersion, the function and features of the Mustang Survival Ice Commander Model IC6000 NZ Version. Also included are test, maintenance and repair instructions to assist qualified Life Support Equipment Technicians.

1.1.2 Read this manual thoroughly to become familiar with the operation of the zippers, pockets and seals. The lives of crewmembers may depend on the condition of the IC6000 NZ Version. Keep the manual in a convenient location for easy reference in the event that the suit requires inspection, repair or cleaning.

1.1.3 This manual consists of eight sections, each organized into a number of subsections (see the Table of Contents).

1.2 CONTACT

1.2.1 For further information concerning this manual or the suit, contact:

Mustang Survival Corp.

3810 Jacombs Road

Richmond, BC

V6V 1Y6

Tel. (604) 270-8631

Fax (604) 270-0489

E-mail: [email protected]

WEB: www.mustangsurvival.com

1.3 RIGHTS RESERVED

1.3.1 Tug-Tite® is a registered trademark of Mustang Survival Corp.

1.3.2 Velcro is a trademark of American Velcro Inc.

1.3.3 Uniroyal® is a registered trademark of Uniroyal.

1.4 RESPONSIBILITIES

1.4.1 The individual to whom the suit is issued or assigned, following internal training, assumes responsibility for pre and post use inspections and for returning the suit to the Life Support Equipment shop for periodic inspection and testing on required dates.

1.4.2 Each operational organization is responsible for the instruction and survival training of all IC6000 NZ Version users in the following:

a. Fitting of the immersion suit

b. Purpose, use and operation of all accessories

c. Importance and method of visual pre and post use inspections


3 May 2002, Rev: --



1.4.3 The Life Support Equipment shop is responsible for:

a. Inspection upon first issue from the supply depot or contractor

b. Ensuring the suit is complete and serviceable prior to issue

c. Periodic inspection and testing of the suit (see section 6.5)

d. Maintenance, cleaning and repair when required

e. Requisitioning and maintaining stocks of spare parts

f. Maintenance of inspection records for all Mustang Survival IC6000 NZ Version units

1.5 DESCRIPTION

1.5.1 Application

1.5.1.1 Built to endure the extreme operating environments, the IC6000 NZ Version’s two-layer modular system is a result of Mustang’s ongoing commitment to research and development. Crewmembers may use the IC6000 NZ Version when operating in conditions requiring dry suit use. The IC6000 NZ Version is designed for Ice Rescue professionals and aircraft transport passengers, Coast Guards, Search and Rescue Teams and Fire Departments.

1.5.2 Protection

1.5.2.1 Mustang’s patented breathable closed cell (PVC) AirSoft foam not only aids in the moisture management system, but it also provides inherent buoyancy and the basis for hypothermia protection, even in the event of damage to the suit.

1.5.2.2 The Immersion Module uses urethane coated nylon fabric to provide a waterproof barrier to the outside elements.

1.5.3 Durability

1.5.3.1 The IC6000 NZ Version’s Outer Shell is constructed of urethane coated nylon and reinforced, in high abrasion areas, with neoprene knee panels.

1.5.4 Configuration

1.5.4.1 The IC6000 NZ Version provides hypothermia protection and inherent buoyancy using two interconnected modules forming a single system. Each module may be repaired, to a degree, or replaced individually.

1.5.4.2 The Buoyancy Liner is a breathable foam liner, which provides hypothermia protection and buoyancy for flotation. The black 100% polyester inner lining is attached to the 5.0 mm PVC foam flotation material. The liner is removable and is equipped with snap studs at the wrists, ankles, neck and along the front entry of the liner, which form the primary attachment to the shell.

1.5.4.3 The Outer Shell provides watertight integrity and the equivalent protection of a dry suit. All seams are welded to provide watertight integrity without the necessity of taping over sewn seams. The only sewn seams are at the wrists, ankles and hood, where the neoprene joins the shell. The shell provides waterproof coverage from the feet to neck and wrists.

NOTE: Wear appropriate thermal undergarments (such as polypropylene underwear) to enhance the protection afforded by the IC6000 NZ Version and assist in wicking moisture away from the body.


3 May 2002, Rev: --



1.5.4.4 Due to its radically different construction, the suit offers superior flexibility and remains lightweight.

1.5.5 Fit

Figure 1. IC6000 NZ Version Sizing Information

Adult Universal

4’ 11” to 6’ 7” Height

150 cm to 200 cm

110 lbs to 330 lbs Body Weight

50 kg to 150 kg

NOTE: The leg permits entry of a fully clothed leg with, up to, size twelve boots.


3 May 2002, Rev: --



2.0 IMMERSION AND ANTI-EXPOSURE CLOTHING 2.1 HAZARDS

2.1.1 Cold-water immersion is a life-threatening situation, and your survival depends on the clothing you wear. Cold, shock, hypothermia, loss of dexterity and mental sharpness and drowning are your primary concerns. Many strong swimmers drown within yards of safety in cold water. This suggests that many drown because of the rapid shock of immersion, causing immediate hyperventilation, water ingestion, and often heart failure, which may occur in water below 15ºC (59ºF).

2.1.2 Without adequate buoyancy and insulation, individuals rely on swimming ability and endurance for survival. Your strength and endurance are seriously diminished in colder water, reducing your ability to overcome waves, currents, spray, etc.

2.1.3 Hypothermia results when your body loses heat faster than it can be replaced, and can occur in any environment below 37ºC (98.6ºF), our normal body core temperature. Water conducts heat away from our body 240 times faster than air, presenting a high risk.

2.1.4 Shivering is the body’s way of generating heat to replace lost heat. The smallest blood vessels constrict close to the skin, reducing the blood circulation to your hands and feet. Circulation to the body core is also restricted, where needed most, resulting in a loss of dexterity. As the effect of cold increases, muscles weaken and stiffen, leading to the loss of feeling and reduced co-ordination. Your decision-making and thinking processes slow down.

2.1.5 Proper clothing reduces many of these hazards, improving your chances of survival. Clothing should provide insulation from the cold and should not hinder mobility. Ensure buoyancy is provided either inherently in your outfit, or with an additional life preserver, preferably both.

2.1.6 Generally there are two types of immersion protective clothing:

a. Wet suits

b. Dry suits

2.2 WET SUITS

2.2.1 Wet suits allow some water in, but restrict water movement into and out of the suit. Your body heats up the water trapped in the suit. If the openings of the suit become restricted, the warmed water stays inside the suit longer, reducing heat loss. If a wet suit is damaged or torn, the level of protection is reduced.

2.3 DRY SUITS

2.3.1 Dry suits protect you during cold-water immersion by using, in conjunction with garments worn under the suit, the trapped air as an insulation layer from the cold water. Most dry suits utilize seals at the wrists, neck and ankles, unless incorporating gloves and boots. These seals are made from waterproof materials, insulated or non-insulated.


3 May 2002, Rev: --



3.0 IC6000 NZ VERSION FEATURES 3.1 GENERAL

3.1.1 Familiarize yourself with all the features of the suit to maximize its effectiveness. Illustrations are provided as an additional reference.

3.2 HYPOTHERMIA PROTECTION

3.2.1 Immersion in cold water is a danger for anyone working on or near the water. The length of time a person can survive in cold water largely depends on both the water’s temperature and the thermal protection of their protective clothing.

3.2.2 To create the most effective protection against hypothermia, Mustang Survival begins by evaluating the clothing’s immersed Clo value, which depicts the level of thermal insulation a garment provides. Clo is a measurement of insulation, much like the ‘R’ values assigned to fiberglass house insulation. We determine the rate at which heat is lost from the body, as well as the difference in temperature between the skin and the water.

3.2.3 Figure 2 indicates random samples of Immersed Clo values and the corresponding estimation of survival time in cold water (assuming a thin person with a 3.0º C (5.5º F) drop in body core temperature).

3.2.4 The Clo value for the IC6000 NZ Version is 0.94 in calm (stirred) water.

Figure 2. Clo Insulation Graph

NOTE: When using Figure 2, keep in mind that the chart was derived empirically by mathematical modeling and conservatively applied to the tenth percentile (thin) individual in calm (stirred) water.

Estimated Calm Water Survival Time (hours)

Water Temperature


3 May 2002, Rev: --



With the complexity of factors involved, there is no guarantee as to the accuracy of the predicted survival time on an individual case basis.

3.3 TESTING

3.3.1 Each IC6000 NZ Version is tested and proven 100% watertight. Refer to section 6.5.9 for suit leakage test information.

3.4 ASSEMBLED IC6000 NZ VERSION

Figure 3. Component Locations

3.5 OTHER FEATURES

3.5.1 Visibility

3.5.1.1 SOLAS/IMO approved high visibility reflective tape and highly visible Outer Shell.

3.5.2 Hood and Face Seals

3.5.2.1 The attached neoprene thermal hood is required when a crewmember wearing the suit enters the water. The hood, which stays in place in all conditions, offers a watertight fit and the face seal that gives protection from water and wind exposure. The adjustable face seal has elastic qualities, making donning easy.

Reinforced Knees

Wrist Seals

Ice Awl Pockets

Face Seal

Tethering Harness

Insulated Hood

Five Fingered Gloves

Reflective Tape

Non-slip Soles

Tug-Tites®


3 May 2002, Rev: --



3.5.3 Thigh and Ankle Tug-Tites®

3.5.3.1 The thigh and ankle Tug-Tites® are to be tightened during donning to restrict the flow of air to the lower leg. Trapped air in the suit’s lower legs will cause maneuverability problems due to over buoyant legs.

3.5.4 Reinforcements

3.5.4.1 Knees and lower legs are reinforced, and padded, with highly abrasion resistant neoprene (2.5 mm). The seat and elbows are also reinforced with yellow shell fabric for increased durability.

3.5.5 Main Entry Zipper

3.5.5.1 The full-length main entry zipper, located on the Outer Shell (see figure 3), is a heavy-duty zipper with nickel-silver teeth provides a watertight seal when closed. A rubber-coated thong, attached to the zipper slider, assists the wearer in opening and closing the zipper.

CAUTION: Avoid snagging your clothing in the zipper, as this may break the zipper’s seal.

3.5.5.2 The zippers should remain in the open position while the suit is stored. See section 6.4.5 for zipper care procedures and for recommended zipper cleaners and lubricants.

3.5.6 Welded Nylon Outer Shell

3.5.6.1 The high performance urethane coated nylon exterior is waterproof and durable, and makes repairs and cleaning easier.

3.5.7 Non-slip Soles

3.5.7.1 The durable rubber soles provide traction on wet surfaces.

3.5.8 Ice Awl Pockets

3.5.8.1 The sleeve pockets are customized to attach and stow ice awls, and are easily secured with Velcro (ice awls are not included).

3.5.9 Detachable Inner Buoyancy Liner

3.5.9.1 This liner is constructed of closed cell AirSoft foam for maximum flotation and thermal insulation with an uncoated nylon inner lining. The liner can be unsnapped and removed for field repairs and cleaning.

3.5.10 Gloves

3.5.10.1 The palms of the five-fingered gloves, constructed of insulated vinyl, provide abrasion resistance, a better grip, comfort and watertight integrity.

3.5.11 Safety Harness

3.5.11.1 The safety harness, for attachment to individuals requiring help or to an anchor point, is integral and self-adjusting.

WARNING: Do not use this feature to hoist an individual out of the water. Major damage to the suit may occur.


3 May 2002, Rev: --



4.0 ASSEMBLY WARNING: Wear the IC6000 NZ Version with both modules assembled. The modules are

not to be worn independently. A loss of protection and wear resistance will result if worn improperly.

4.1 STEP 1 LAYOUT THE BUOYANCY LINER AND OUTER SHELL

a. Lay out the Buoyancy Liner and the Outer Shell side by side in the same orientation as worn.

NOTE: Check that the Buoyancy Liner faces out.

b. Ensure the Outer Shell’s waterproof zipper is fully opened.

4.2 STEP 2 CONNECT THE BUOYANCY LINER/OUTER SHELL AT THE ANKLES

a. Keeping the bottom flat and straight, insert each leg of the Buoyancy Liner down into each leg of the Outer Shell until it reaches the ankle.

NOTE: Ensure the legs do not twist, maintaining a matching orientation during insertion.

b. After pushing your hand down into the Buoyancy Liner leg, connect each Buoyancy Liner ankle snap to the corresponding Outer Shell ankle snaps.

4.3 STEP 3 WRIST SNAP CONNECTIONS

a. After laying the Outer Shell out flat, push the left arm of the Buoyancy Liner down to the end of the left arm of the Outer Shell.

b. After pushing your hand down into the Buoyancy Liner arm, connect each Buoyancy Liner wrist snap to the corresponding Outer Shell wrist snaps.

NOTE: Ensure that the arms do not twist. Maintain a matching orientation during insertion.

c. Repeat this procedure with the right arm.

4.4 STEP 4 CHEST AND NECK SNAP CONNECTIONS

a. Starting at the base of the row of chest snaps, connect each Buoyancy Liner chest snap to the corresponding Outer Shell chest snap on one side.

b. Repeat for the other side of the chest.

c. Complete the assembly of the Outer Shell to the Buoyancy Liner by starting at the base of the row of chest snaps and connect each Buoyancy Liner chest snap to the corresponding Outer Shell chest snap.


3 May 2002, Rev: --



5.0 DONNING\DOFFING INSTRUCTIONS WARNING: The IC6000 NZ Version must be worn with both modules assembled. The

modules are not to be worn separately. A loss of protection and wear resistance will result if worn improperly.

NOTE: The IC6000 NZ Version may be donned without assistance.

5.1 STEP 1 SUIT PREPARATION PRIOR TO DONNING

a. Ensure the thigh and ankle adjustment straps are fully loosened.

b. Unbuckle the tethering harness.

c. Fully open the waterproof chest zipper.

CAUTION: Use extreme caution when donning the IC6000 NZ Version. Prior to donning, remove all rings, watches, earrings, necklaces and eyeglasses that will cause damage to the suit.

5.2 STEP 2 DONNING INSTRUCTIONS

a. Pick up the IC6000 NZ Version and fold the top back at the waist.

b. Slowly slide your legs in until your toes reach the end of the feet.

c. Gently push one hand through the arm and into the glove. Repeat for the opposite hand.

d. Bring the upper portion of the suit over your back, pulling the hood over the top of the head.

5.3 STEP 3 CLOSING THE WATERPROOF ENTRY ZIPPER

a. Grasping the open end of the waterproof entry zipper with your left hand, begin pulling the zipper slider with your right hand to completely close the waterproof zipper. Zipper lubrication will make this job easier (see section 6.4.5).

WARNING: Failure to completely close the waterproof entry zipper and the relief zipper will result in leakage of water inside the suit and reduction of in-water survival time.

5.4 STEP 4 ADJUSTING THE IC6000 NZ VERSION AFTER DONNING

a. Adjust the face seal flap to a snug but comfortable fit. Do not tighten the face seal to a point of discomfort.

b. Fasten and adjust the tethering harness.

c. Adjust the thigh and ankle Tug-Tite® straps.

5.5 DOFFING PROCEDURE

a. Remove all other equipment donned over the IC6000 NZ Version before proceeding.

b. Wash down the IC6000 NZ Version while wearing it, paying particular attention to the entry slide fasteners. Remove all traces of salt.

c. Loosen the harness and release the face seal, ankle and thigh Tug-Tite® straps.

d. Completely open the front entry zipper.


3 May 2002, Rev: --



CAUTION: Failure to completely open the waterproof entry zipper will result in damage to the suit when it is doffed.

e. Remove your arms from the suit.

f. Remove your legs from the suit.

g. Halfway close waterproof zipper and hang the suit by the harness loop until dry.

h. Once the suit is dry, open the zipper fully.


3 May 2002, Rev: --



6.0 MAINTENENCE AND CARE 6.1 GENERAL

6.1.1 IC6000 NZ Version maintenance is to be performed by a suitable, trained technician at an approved site. Contact Mustang Survival Corp. for more information.

6.1.2 After immersion in water (other than fresh clean water), the suit modules should be either washed or rinsed separately. To increase the life of the garment, it is recommended to wash the suit only when required.

6.1.3 Refer to section 6.3 for cleaning instructions.

6.2 SEPARATING THE LAYERS

a. Disconnect the harness belt, if connected.

b. Reach into the sleeve and undo the three snaps that fasten the Buoyancy Liner to the Outer Shell.

c. Repeat step b. for the opposite wrist.

d. Reach into the leg and undo the four snaps that fasten the Buoyancy Liner to the Outer Shell.

NOTE: Be careful not to pull hard on the Buoyancy Liner, undo each snap individually. Improper unsnapping may lead to suit damage.

e. Repeat step d. for the opposite leg.

f. Reach into one side of the chest and undo the five snaps that fasten the Buoyancy Liner to the Outer Shell.

g. Repeat step f. for the opposite side of the chest.

h. Carefully remove the Buoyancy Liner from the Outer Shell.

6.3 CLEANING

6.3.1 For spot cleaning the Outer Shell when assembled, hand-wash the suit in fresh water (37.8°C/100°F or less) using a mild powdered soap solution, then thoroughly rinse and hang the suit to dry.

CAUTION:

Do not dry clean or use commercial laundry facilities.

Fully close the front entry zipper when spot cleaning to keep the liner dry.

Do not use bleach or other chlorine products.

Do not use fabric softeners.

Do not store in a wet condition.

Do not iron.

Do not dry in front of a radiator or other source of direct heat.


3 May 2002, Rev: --



Do not hang the suit by the hood. Use a strong wood or plastic hanger and support the suit by the Outer Shell, using the hanging loop located inside the Outer Shell neck area to secure the suit while drying.

6.3.2 Removed mud and soil stains from the Outer Shell. Mud stains must be either allowed to dry and then removed with a cloth brush, or sponged clean with cold fresh water. Sponge other stains with cold fresh water. After cleaning, thoroughly air-dry the suit.

6.3.3 Outer Shell

a. Empty the contents of both pockets.

b. Close the entry zipper prior to washing.

c. Machine wash in warm water (37.8°C/100°F) using mild powdered soap. Alternatively, hand wash or sponge down the fabric in warm soapy fresh water, then rinse with clean water.

d. Hang the Outer Shell to air-dry, in a well-ventilated area that is free from direct sunlight, from its boots to allow the water to drain. Do not tumble dry.

e. Refer to section 6.4.5 for metal zipper cleaning guidelines. 6.3.4 Buoyancy Liner

a. Hand wash in warm water using a mild powdered soap.

b. Rinse thoroughly in clean water.

c. Hang to air-dry.

CAUTION: Ensure the Outer Shell and Buoyancy Liner are completely dry before reassembling.

6.4 TREATMENT AFTER IMMERSION

6.4.1 Whenever a suit is immersed in water, it must be treated as specified below and then inspected in accordance with the current authorized servicing schedule.

6.4.2 Fresh Water Immersion

6.4.2.1 Disassemble the layers and rinse thoroughly with clean, fresh water. Hang the Outer Shell and Buoyancy Liner to air-dry, in a well-ventilated area that is free from direct sunlight, from its boots to allow the water to drain. Do not tumble dry.

6.4.3 Salt Water Immersion

6.4.3.1 Disassemble the layers and rinse thoroughly with clean, fresh water. Allow the Outer Shell and Buoyancy Liner to dry naturally, preferably in the open air.

6.4.4 Chlorinated Water Immersion

6.4.4.1 Immersion of the suit in chlorinated water is not recommended. If the suit is immersed in chlorinated water, use the same washing procedure as for salt water immediately following immersion.

6.4.5 Metal Zipper Care

6.4.6 Zipper cleaning is the first step to zipper longevity. Clean the zipper of any mud, sand, salt or foreign elements. Use warm soapy water to remove any heavy deposits.


3 May 2002, Rev: --



6.4.6.1 For the metal entry and zipper, use one of the zipper manufacturers’ recommended cleaning fluids listed in figure 4. After cleaning, use a recommended wax (see figure 4) for zipper lubrication.

Figure 4. Recommended Zipper Cleaning Fluids and Waxes

CARE PRODUCT PRODUCT NAME SUPPLIER Cleaning Fluid Zippy Cool YKK USA Zip Care McNett BDM Fluid BDM UK Lubricating Wax Zippy Cool YKK USA Zip Wax McNett BDM Wax BDM UK

6.4.7 Storage

6.4.7.1 It is important that the IC6000 NZ Version is stored in:

a. A dry area, where normal room temperature is maintained.

b. An area without excessive sunlight and ultra violet rays, and is free of petroleum products, acids and other damaging contaminants.

CAUTION: Never store the suit wet. Never hang the suit from the hood; doing so may result in suit damage.

6.5 INSPECTION

6.5.1 General Suit Examination

6.5.2 Periodically examine your IC6000 NZ Version for visual signs of abrasion or damage. Lay the suit modules on a clean, flat surface. Ensure the suit is dry inside and out. Visually check for small rips, tears, or punctures, which may be repaired by a suitable repair station. Refer major rips, tears, or punctures to Mustang Survival Corp. via the procurement agency for inspection and repair.

NOTE: Proper care of this garment is extremely important for best results and extended service.

6.5.3 Service Life

6.5.3.1 The suit’s service life is determined on condition rather than age. Suits may remain in service indefinitely if properly maintained and all tests and inspections are satisfactory.

6.5.4 Work Area 6.5.4.1 The work area where inspection and maintenance of the suit is performed should be smooth and

flat, where the suit will not snag, tear or otherwise be punctured or damaged and should also be cleared of all non-essential equipment and materials. The working surface should be free of harmful contaminants such as oil, grease, acids or solvents. Work areas, which are subjected to wide temperature variations, should be avoided.

6.5.5 Inspection Intervals

6.5.5.1 The suit should be inspected:

a. On receipt from the supply depot or contractor.


3 May 2002, Rev: --



b. Periodic inspections; depending on the environmental conditions of usage, not to exceed 90 days unless in storage.

c. Before and after use by the individual issued the suit.

d. Whenever the integrity of the suit is in doubt.

6.5.6 Visual Inspection

6.5.6.1 A close visual inspection should be performed prior to issue, by the issuer and the suit user.

6.5.6.2 To perform a close visual inspection, ensure:

a. There is no excessive wear or damage to the material, particularly stiffness, discoloration, burns, tears and frayed edges.

b. There is no separation of the seams, broken or missing stitches.

c. All metal components are intact and free from damage or corrosion.

d. The zipper is intact and operating smoothly.

e. All adjustment straps are adjusting freely and smoothly.

f. All pockets and pocket closures are intact.

6.5.7 Periodic Inspection

6.5.7.1 The suit manufacturer, or a qualified approved technician with the appropriate equipment, should carry out the in-depth periodic inspection (every 90 days).

This inspection includes:

a. Visual inspection

b. Leak testing every second periodic inspection (unless damage is suspected)

c. Zipper inspection

6.5.8 Retro Reflective Tape

6.5.8.1 Check retro reflective tape for condition and adhesion. Replace if necessary, see section 8.0 for a parts list. For best adhesion, a suitable repair station should complete repair.

6.5.9 Suit Leakage Test

6.5.9.1 Have a qualified approved technician test for leaks on periodic inspection, every six months and prior to issue, and when a visual inspection raises any doubt about the integrity of the suit.

6.5.9.2 The following suit leakage test uses Mustang Survival Corp. equipment. Your equipment may differ and, if so, the test should be adjusted accordingly. Contact Mustang Survival Corp. for more information on how to purchase the neck seal and neck clamp plates used in this test.


3 May 2002, Rev: --



6.5.9.3 To perform the suit leakage test on the Outer Shell only:

a. Lay out the IC6000 NZ Version Outer Shell, with the entry zipper fully closed.

Figure 5. Step a. Suit Leakage Test

b. Insert the neck seal plate through the neck seal opening from underneath the neck opening.

Figure 6. Step b. Suit Leakage Test

Neck Seal Plate


3 May 2002, Rev: --



c. Insert a neck clamp plate on top of the neck seal plate, ensuring that the pneumatic couplings are aligned with the holes.

Figure 7. Step c. Suit Leakage Test

d. Carefully seal the neck by clamping the plates together with the lever, and attach the air hose and gauge hose to the appropriate pneumatic couplings.

Figure 8. Step d. Suit Leakage Test

Neck Clamp Plate

Pneumatic Coupling Clamp

Lever

Pneumatic Couplings


3 May 2002, Rev: --



e. Inflate the suit with air that is free of any oil or water.

CAUTION: Do not exceed a pressure of ten inches of water column. Exceeding this pressure may overstress the suit, resulting in damage.

Figure 9. Step e. Suit Leakage Test

f. While inflated, spray the suit section by section with soapy water and look for any signs of leakage (bubbles). Ensure to check the back of the suit for leaks as well. Alternatively, immerse the suit in water and look for bubbles as a sign of damage.

Figure 10. Step f. Suit Leakage Test


3 May 2002, Rev: --



g. Mark the general area of any leaks, if required, with a non-damaging marker. Ensure any detected damage is repaired before the suit is put back into service.

Figure 11. Step g. Suit Leakage Test

h. Hang to dry in a well-ventilated area that is free from direct sunlight. Hang the suit from its boots to allow water to drain. Do not tumble dry.

6.6 REPAIRS

6.6.1 General

6.6.1.1 The protection provided by this dry suit relies very much on its watertight characteristics. It is extremely important that damaged suits are handled in accordance with the following repair requirements.

NOTE: Only qualified personnel should perform Outer Shell repairs.

6.6.1.2 Qualified repair personnel can normally perform repairs to the Buoyancy Liner, with adequate facilities. The manufacturer should do all major repairs, unless otherwise authorized by Mustang Survival Corp. This section provides some information to assist with minor or emergency repairs to the suit and related components.

NOTE: Stitching shall not be used for repair of tears or holes, other than for the Buoyancy Liner.

6.6.1.3 The proper work area is defined in section 6.5.4 of this document.

6.6.2 Inspection Failures

6.6.2.1 These are the recommended repairs for any suit failing inspection:

a. Replace missing, damaged or corroded parts of components.

Marker

Air Leak


3 May 2002, Rev: --



b. Heavily soiled areas shall be cleaned using only mild soap and water with a soft, non-abrasive nylon or synthetic bristle brush. Other cleaning agents or solvents must not be used.

c. Repair worn, broken or missing stitching.

d. Any additional parts or components found to be defective should be repaired or replaced.

6.6.3 Attaching Parts 6.6.3.1 When attaching parts, such as pockets, to the Buoyancy Liner the following general practices

should be followed:

a. Markings must be made carefully only with a non-indelible marker.

b. Fold over the fabric corners and other cut parts corners to prevent fraying.

c. Place the part to be attached into position, and mark the edge of the attachment area.

d. Stitch the part into place (see section 6.6.4).

6.6.4 Stitching

6.6.4.1 All repairs involving sewing shall be done with thread that corresponds to the color of the material being sewn. The thread to be used is outlined in section 8.0.

6.6.4.2 Seam repairs, stitching, and joining of the Buoyancy Liner shall be done using a single needle lockstitch, eight to ten stitches per inch. Securely backstitch all ends of stitching, including breaks in thread, not less than 12 mm (1/2 inch). The seam allowance to be used is 12 mm (1/4 inch) ±3.0 mm (1/8 inch).

6.6.5 Leak Repairs

6.6.5.1 Outer Shell damage may be repaired by patching, see section 6.6.8.

6.6.6 Limits of Repair

6.6.6.1 Use the following guidelines in determining potential for repair of the Outer Shell and Buoyancy Liner.

a. Additional replacement parts are listed in section 8.0.

b. Do not patch the neck or wrist seals.

6.6.7 Repair Materials

6.6.7.1 The full description and part numbers of the materials required for repairs are detailed in section 8.0 of this manual.

6.6.8 Patching NOTE: Return any Outer Shells that have sustained major damage to Mustang Survival

Corp. for damage appraisal and repair. 6.6.8.1 For minor damage to the Outer Shell, such as small holes or tears, purchase an MA2290 Ice

Commander Repair Kit from Mustang Survival Corp.

6.6.9 Lining Fabric

6.6.9.1 To repair a tear in the lining:

a. Cut a patch of black packcloth fabric (this fabric is coated, so its edges will not fray).


3 May 2002, Rev: --



b. Place the patch over the tear. If the foam has been displaced from the suit damage, put it back in place and glue if necessary before sewing the fabric patch.

c. Sew around the perimeter, through the foam.

6.6.9.2 Patching of minor tears and holes on the Buoyancy Liner nylon fabric should conform to the following:

a. Clean the area around the tear of foreign material.

b. Cut a square, or rectangle, in the damaged fabric slightly larger than the hole.

c. Cut a patch of the original material being repaired, exceeding the hole in size by not less than 37 mm (1-½ inch).

d. Apply the fabric patch to the outside of the suit and ensure that the weave corresponds to that of the material surrounding the repair area.

e. Single-stitch the patch to the suit 6.0 mm (¼ inch) from the edge of the hole.

f. Roll an edge of the patch under itself and single-stitch approximately 12 mm (1/2 inch) from the original stitch.

g. Repeat this for each edge of the patch, until the patch is secured.

h. Repair closely grouped small holes or tears with one large patch, rather than several small ones.

i. If the damage extends across a seam, the patch may also extend across the seam.

6.6.10 Snap Replacement Instructions

Figure 12. Parts for Snap Replacement


3 May 2002, Rev: --



6.6.10.1 Liner Snap Replacement Instructions

a. Using a pair of cutting pliers, work the cutting edge underneath the Socket (HD-7214-30) while stretching the foam away from the socket base with your fingers.

Figure 13. Step a. Liner Snap Replacement

b. Cut off Socket (HD-7214-30) while being careful not to cut into the foam.

Figure 14. Step b. Liner Snap Replacement


3 May 2002, Rev: --



c. Load hand pliers with the dies shown.

Figure 15. Step c. Liner Snap Replacement

d. Set the new Mustang Ligne Cap (HD-7213-30) with the pin facing up into the bottom die. Set

the new Socket (HD-7214-30) in to the upper die.

Figure 16. Step d. Liner Snap Replacement


3 May 2002, Rev: --



e. Align pin of Mustang Ligne Cap over hole in foam liner ensemble. Make sure the Cap and Socket are on the proper sides of the foam liner. Press the snap together.

Figure 17. Step e. Liner Snap Replacement

f. The new snap is installed. If the snap rotates not enough force was applied.

Figure 18. Step f. Liner Snap Replacement


3 May 2002, Rev: --



6.6.10.2 Shell Snap Replacement

a. Using a pair of cutting pliers, work the cutting edge underneath the Post (HD-7216-30).

Figure 19. Step a. Shell Snap Replacement

b. Cut off Post (HD-7216-30) while being careful not to cut into the fabric.

Figure 20. Step b. Shell Snap Replacement


3 May 2002, Rev: --



c. Load hand pliers with the dies shown.

Figure 21. Step c. Shell Snap Replacement

d. Set the new Stud (HD-7215-30) with the stud facing up into the top die. Set the new Post (HD-

7216-30) into the lower die.

Figure 22. Step d. Shell Snap Replacement


3 May 2002, Rev: --



e. Align Post over hole in fabric. Make sure the Stud and Post are on the proper sides of the fabric.

Figure 23. Step e. Shell Snap Replacement

f. Press the snap together.

Figure 24. Step f. Shell Snap Replacement


3 May 2002, Rev: --



g. The new snap is installed. If the snap rotates not enough force was applied.

Figure 25. Step g. Shell Snap Replacement

6.6.11 Glove Replacement

a. Remove the Buoyancy Lining and turn the Outer Shell sleeve inside out.

b. Pick out the stitching holding the glove to the sleeve.

c. Using a razor blade cut the tape joining the glove to the suit, being careful not to cut the sleeve.

d. Center the palm of the new glove to the sleeve seam. Ensure that the correct glove is used for the sleeve in question.

e. Cut the replacement glove to the correct length (allow 12 mm, or ½ inch, to be rolled under the seam) and sew the glove liner to the glove 3.0 mm or 1/8 inch from the cut edge.

f. Sew the replacement glove onto the sleeve through the snap cuff. Refer to section 8.0 for the replacement part number.

g. Apply Uniroyal adhesive (#6571) to the top edge (25 mm or 1 inch) of the glove and let dry overnight.

h. Tape over the stitching, overlapping the existing tape on the sleeve, to restore its watertight characteristics. To do so, apply heat to the tape from either a heat-taping machine, or a narrowly applied iron (450º C).

NOTE: Do not damage the glove or suit fabric during the application of heat. Such damage may impair the waterproof characteristics of the suit.

i. Perform a suit leakage test (see section 6.5.9) to ensure the suit is watertight. The leakage test may be local to the sleeve and glove.


3 May 2002, Rev: --



6.6.12 Webbing

6.6.12.1 Webbing that is damaged may be repaired or added to by qualified support technicians. Use the webbing and thread listed in section 8.0 for repairs.

6.6.12.2 For damaged Tug-Tite® strap webbing: fold over itself, if the area is not so large as to restrict donning or movement, and sew for reinforcement. Use a single-needle stitch, back-tacked three or four times to reinforce.

6.6.12.3 For severed Tug-Tite® strap webbing: apply a segment of webbing and sew for reinforcement. Use a single-needle stitch, back-tacked three or four times to reinforce. Ensure the strap is large enough to enable donning and movement.


3 May 2002, Rev: --



7.0 SUMMARY The Mustang Survival Ice Commander Model IC6000 NZ Version is an emergency use dry suit that protects Ice Rescue Professionals and transport passengers in harsh marine environments with cold-water immersion features and flotation. The suit is easily donned, maintained and stored. Qualified approved technicians, with proper equipment, or Mustang Survival Corp. may make suit repairs. A well-maintained suit means survival in emergency situations for which normal clothes were not designed.


3 May 2002, Rev: --



8.0 PARTS LIST This section identifies the materials used in the construction of the Mustang Survival IC6000 NZ Version. These materials are highly recommended for repairs and replacements. Item order quantity is based on their availability. The actual product may not be exactly as shown below.

Figure 26. IC6000 NZ Version Outer Shell (Part Number MA3003) and Index Numbers

2

1

4

3

6

11

10

12

5

7

9

8

14

13


3 May 2002, Rev: --



Figure 27. Parts List for the IC6000 NZ Version Outer Shell

INDEX NUMBER

PART NUMBER

NOMENCLATURE MIN ORDER QUANTITY

1 TA1019 50 MM SOLAS SELF ADHESIVE REFLECTIVE TAPE 1 ROLL (50 MTR)

2 VE930013 50 MM BLACK HOOK FASTENER 1 ROLL (50 MTR)

3 VE931013 50 MM BLACK LOOP FASTENER 1 ROLL (50 MTR)

4 TA1018 50 MM SOLAS REFLECTIVE TAPE 1 ROLL (50 MTR)

5 TA105413 BLACK MELCRO TAPE 1 ROLL (50 MTR)

6 MI50292 INSULATED VINYL GLOVE 6 PAIRS

7 FD2302 2.5 MM NEOPRENE 1 SHEET (1.27 MTR x 2.25 MTR)

8 MI5660 3.0 MM RUBBER MATTING 1 SHEET (.91 MTR x 22.9 MTR)

9 W800013 25 MM BLACK POLYPROPYLENE WEBBING 1 ROLL (50 MTR)

10 HD721530 STUD 20 EA

11 HD721630 POST 20 EA

12 VE900013 BLACK HOOK FASTENER 3/4 IN. 1 ROLL (50 MTR)

13 VE901013 BLACK LOOP FASTENER 3/4 IN. 1 ROLL (50 MTR)

14 FD2303 3.0 MM NEOPRENE 1 SHEET (1.27 MTR x 2.25 MTR)

TH886610 WHITE NYLON THREAD FOR REFLECTIVE TAPE 1 CONE

TH886613 BLACK NYLON THREAD ON BLACK WEBBING 1 CONE


3 May 2002, Rev: --



Figure 28. IC6000 NZ Version Buoyancy Liner (Part Number MA2200) and Index Numbers

Figure 29. Parts List for the IC6000 NZ Version Buoyancy Liner

INDEX NUMBER

PART NUMBER


1 FA300010 AIRSOFT FOAM 1 SHEET (1.2 MTR x 2.4 MTR)

2 TA105513 19 MM ADHESIVE BACKED BIAS TAPE 1 ROLL (200 MTR)

3 HD721330 DOME CAP 20 EA

4 HD721430 SOCKET 20 EA

5 FA102313 UNCOATED BLACK LINING 1 ROLL (20 MTR)

2

1

4

3

5


3 May 2002, Rev: --



Figure 30. IC6000 NZ Version Accessories

PART NUMBER


MA2200 ICE COMMANDER REPLACEMENT LINER 1 EA

MA2001 ICE COMMANDER REPLACEMENT CARRY BAG 1 EA

MA2290 ICE COMMANDER REPAIR KIT 12 EA

Figure 31. Expendables List for the IC6000 NZ Version

PART NUMBER


GL1006 RH149 ADHESIVE GLUE (GLOVES) 1 CAN

(5.28 galls US) GL1011 UNIROYAL #6571 ADHESIVE (FOR NEOPRENE) 1 CAN

(5.28 galls US)

MI5008 AQUASEAL FORMULA ZIPCARE 24 EA

Documents

MUSTANG SURVIVAL ICE COMMANDER, MUSTANG MODEL … · Mustang Survival IC6000 NZ Version Description and Maintenance Instructions 3 May 2002, Rev: -- ii This document is for information