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Restraint System
Assembly
Part No.
4005-SERIES
Abbreviated Component
Maintenance Manual
With illustrated parts list
PAGE 1 OF 35
June 20, 2003
Rev. 8
25-11-36
PRINTED IN USA
This document and the information disclosed herein are the proprietary data of Am-Safe Inc.
Neither this document nor the information contained herein shall be used, reproduced, or disclosed
to others without the written authorization of Am-Safe Inc., except to the extent required for
installation or maintenance of recipient's equipment.
NOTICE FREEDOM OF INFORMATION ACT (5 USC 552) AND
DISCLOSURE OF CONFIDENTIAL INFORMATION GENERALLY (18 USC 1905)
Am-Safe Inc is furnishing this document in confidence. The information disclosed herein falls within
exemption (b) (4) of 5 USC 552 and the prohibitions of 18 USC 1905.
The Am-Safe Inc. Commercial And Government Entity (CAGE) code: 0FWE1
TSO NOTICE
The conditions and test required for TSO approval of this article are minimum performance
standards. It is the responsibility of those desiring to install the article either on or within a specific
type or class of aircraft to determine that the aircraft installation conditions are within the TSO
standards. The article may be installed only if further evaluation by the applicant documents an
acceptable installation and is approved by the administrator.
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POSITION 3
REACTIVITY
(YELLOW)
POSITION 2
FIRE
(RED)
POSITION 1
HEALTH
(BLUE)
POSITION 4
STORAGE
(WHITE)
No important hazard
IrritantUse with caution
HazardousPrevent continued exposure,
inhalation, and contact
Dangerous hazardUse protective clothing
together with protection to breathe
Very bad hazardDo not breathe vapor or come
in contact with liquid without approved special
protection
Usually stable
Unstable if heated
Violent chemical change is possible
Dangerous explosion is possible
Very bad explosion hazardquickly go out of
the area if materials are exposed to fire
A
B
C
D
E
Acids
Alkalis, cyanides
Oxidizing agents
Chlorinated hydrocarbons, flammable liquids,
materials that are not flammable
Neutral salts and others
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Description
Effect of Exposure
Dangerous
health hazard
Hazardous
Irritant
No important
health hazard
Description
Effect of Exposure
Very flammable
Highly flammable
Liquids and solids that can start to burn in almost all conditions of
ambient temperature. Liquids with a flash point at or above 22.8 C but
below 37.8 C. Control all sources of ignition. NO SMOKING!
Moderately
combustible
Lightly
combustible
Materials that must be hot before ignition can occur. This rating
includes materials that will burn in air in an area open to a temperature
of 815 C for 5 minutes or less. Liquids and solids have flash point at or
above 93.4 C.
Any material that will not burn in air in an area open to a temperature of
815 C for 5 minutes.
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For each revision to this ACMM, because of the limited number of pages a complete reissue of the
ACMM will accomplish the changes to the content with each page showing the reissue date.
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Page
11
15
NOT APPLICABLE
DISASSEMBLY
17
CLEANING
19
CHECK
21
REPAIR
25
27
NOT APPLICABLE
29
31
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PAGE 8 OF 35
June 20, 2003
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Publication No.
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Level of Verification
Am-Safe Inc. will revise this manual as necessary to give current data. The sources for data supplied in this
manual include engineering drawings and change orders released as of December 1, 1999
Abbreviations
Weights and measurements in this manual are in both U.S. and S.I. (metric) values. The letter symbols for
units of measurement and the abbreviations are the same as shown in ANSI/IEEE Std 260 and ASME Y1.1,
except as identified below.
Abbreviation
Definition
LH
Left Hand
RH
Right Hand
Standard gravity
RF
Reference callout
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The Inertia Reels are subassemblies of the Shoulder Harness Assembly. The shoulder harness and
belts come together at a common attachment point (Rotary Buckle). Clockwise or counterclockwise
rotation of the rotary buckle releases the shoulder harness and all but one belt at the same time. Dash
number of the Restraint System determines the fixed position of the buckle (right or left). Also note that
the shoulder harness can be separately released by pushing forward on a black tab (plate) located on
top of the rotary buckle.
All of the Restraint System belts and straps are made from nylon or polyester webbing. The locking-end
of the lap belts are fitted with sewn-in connectors. The ends of the lap belt, which attach to the seat or
airframe are fitted with sewn-in end-fittings. Leading particulars for the Restraint System are listed in
Table 1.
Identification plates and unit markings are located on each assembly. The Restraint System is hardmounted directly on the seat or aircraft structure in accordance with the installation instructions supplied
by the seat manufacturer.
Use.............................................................................................................Personnel Restraint
Type ......................................................................................................................Restraint System
Shoulder Harness Assembly:
Type ............................................................................................................ Dual Inertia Reels
Locking Actuation Force ................................................................................. 1.25 +/- 0.25.g.
Webbing ..........................................................................................................................Nylon
Maximum Length .......................................................................................... 62.0 in (157 cm)
Lap Belt:
Maximum Length ........................................................................................ 49.00 in.(124 cm)
Rated Strength (minimum).....................................................................3000 lbs. (1360.8 kg)
Webbing .........................................................................................................................Nylon
Leading Particulars
Table 1
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PAGE 12 OF 35
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Operation
The Restraint System is intended for use by the flight-crew and flight attendant as a safety belt. The
system is specially designed to restrain a human body (seat occupant) during all flight attitudes and
landings. The lap belts can be used separately or with the shoulder harness. The Shoulder Harness
Assembly is attached to the seat or airframe by the inertia reels. The lap belts are attached to the seat
or airframe with sewn-in end fittings.
NOTE:
A.
Shoulder Straps
The shoulder harness has a left- and right-hand strap. The upper end of each shoulder strap is
separately secured to an automatic inertia reel. When the shoulder straps are unfastened, their
respective inertia reels roll up each portion. The shoulder straps can be removed for replacement
or to install the restraint onto the seat. Refer to the DISASSEMBLY section in this manual.
B.
Inertia Reels
When the Restraint System is in use, the inertia reels allow unrestricted movement in the seat.
The reels extend and retract the shoulder harness as required. If a sudden acceleration force is
applied to the shoulder harness, the inertia reel and shoulder strap will automatically lock. The
occupant in the seat is automatically held by the shoulder harness. When the shoulder harness is
relieved of the force, the locking action of the inertia reel is released and unrestricted movement
within the seat is once again permitted. For identification purposes the inertia reels are fitted with
an equipment identification decal.
C.
Lap Belts
There is a right- and left-hand lap belt portion. The lap belts are equipped with an adjuster
assembly for length adjustment. For identification purposes the lap belts have a sewn on cloth
label.
D.
Rotary Buckle
The rotary buckle has a housing with five slotted sockets. Each socket has a specially designed
pawl, which latches and holds the connectors of the shoulder harness and lap belts. The pawl for
either the left- or right-hand lap belt is designated at the factory so the rotary buckle will remain
attached to the connector. If necessary, the fixed lap belt may be removed by inserting a thin
spring plate in the slot to force the pawl downward. See SPECIAL TOOLS, FIXTURES AND
EQUIPMENT.
You can release the remaining connectors by rotating the three-vane disc 45 in either direction.
The shoulder harness can be separately released by pushing forward on the black tab located
between the shoulder harness fittings.
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E.
Fastening
Fasten the belts and straps as follows:
F.
(1)
In the seated position, grasp the rotary buckle with one hand and position it over the
center of the body. Use the other hand to bring over the connector of the opposite belt.
Insert the connector into the lateral slot directly opposite the fixed connector of the rotary
buckle.
(2)
Adjust the length of the lap belts so that the rotary buckle takes up a central position and
that the lap belts pass over the pelvis.
(3)
Tighten belts by pulling on the free end of webbing at the adjusters. Loosen belts by
rotating the buckle cover 45.
(4)
Withdraw the shoulder straps from the inertia reels and insert the connectors into the
upper slots of the rotary buckle.
Release
NOTE:
(1)
Turn the rotary disc of the buckle approximately 45 in either direction to release the
connectors.
(2)
If the lap belts are to remain attached to the rotary buckle, push on the black tab on top of
the rotary buckle to release the shoulder harness.
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C. Procedure
(1)
(2)
Test No.
Procedure
Limits
1.0
Initial Test
1.1
Connectors engage.
1.2
1.3
1.4
1.5
Webbing extends.
1.6
Webbing retracts.
1.7
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Procedure
Limits
1.8
1.9
Webbing retracts.
1.10
Find the number of the test in table 101 where the failure occurs.
B.
Use the fault isolation procedure in table 102 to isolate the malfunction. All fault isolation
procedures are keyed to the Test No. column of Table 101.
C.
Refer to the ILLUSTRATED PARTS LIST (IPL) figure 1 for complete item data when repair or
replacement of parts is necessary.
Repair Task
1.5
1.6
1.7
1.8
1.9
1.10
1.3
Restraint System
Table 102
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Task
Before you disassemble the Restraint System, use TESTING AND FAULT ISOLATION to examine its
condition or to find the most probable cause of its malfunction. This is to prevent disassembly that is not
necessary. Do only those procedures of disassembly that are necessary to remove defective parts and
to correct malfunctions.
CAUTION: THE RESTRAINT SYSTEM MAY NOT BE DISASSEMBLED BEYOND THE LEVEL
INDICATED BELOW. FURTHER REPAIR OF THIS SYSTEM MAY ONLY BE CARRIED
OUT BY AM-SAFE INC. (USA), AM-SAFE LTD. (UK) OR AN AM-SAFE-APPROVED
REPAIR STATION. AM-SAFE INC. IS NOT RESPONSIBLE FOR DAMAGE OR
MALFUNCTIONS RESULTING FROM ANY UNAUTHORIZED ATTEMPT TO REPAIR
OR DISASSEMBLE THE RESTRAINT SYSTEM.
WARNING THE FOLLOWING OPERATION IS TO BE CARRIED OUT WITH GREAT CARE.
BEFORE YOU REPLACE THE DAMAGED PART, YOU MUST GET NECESSARY
PERSONAL PROTECTION EQUIPMENT
2.
3.
Procedure
NOTE:
A.
Turn the handle on the rotary buckle assembly to release the straps that are not locked.
B.
Release the locked connector half from the rotary buckle assembly. (If necessary)
(1)
Put the spring plate behind the connector of the fixed connector half.
(2)
Insert the spring plate in the slot on the rotary buckle assembly to release the pawl.
(3)
Remove the connector half and the spring plate from the rotary buckle.
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Remove the shoulder strap from harness assembly for seat installation or strap replacement.
NOTE: For seat installation, refer to the installation instructions supplied by the seat
manufacturer.
(1)
Pull the webbing out of the inertia reel and insert properly the Locking key (T504898-1)
between the lock bar and the frame assembly as shown in figure 2. Failure to do so may
cause fast unwinding of the return spring and/or personal injury.
Note: If the return spring unwinds by itself for any reason, the entire restraint system should be
sent back to the manufacturer for service.
(2)
Using standard hand tools push the pin out of the shaft and remove the pin from the web
loop. Remove strap from reel assembly.
(3)
Locking key
(T504898-1)
Webbing
REWORK BY AMSAFE
ONLY
Lock bar
Disassembly
Figure 2
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Task
To clean the Restraint System, remove dirt and unwanted oil and grease. This helps the Restraint
System to last longer and prevents corrosion of the metal parts. The webbing is to be cleaned with fresh
water and a mild soap. The metal fittings are cleaned with a cloth moistened with isopropyl alcohol.
After cleaning the assemblies, protect them from moisture, dirt, or other contamination. Keep them
protected until you do a visual check and return the Restraint System to service.
2.
NOTE:
Equivalent alternatives are permitted for the equipment and materials in this list.
Procedure
CAUTIONS:
3.
4.
5.
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A.
B.
(2)
Either:
(a)
(b)
Hand-wash the webbing: gentle scrub with a soft brush and cold soapy solution is
permissible.
(3)
Dry the Restraint System in an area that has a good flow of air. Do not dry the Restraint
System in sunlight or near any source of heat.
(4)
Cleaning hardware.
WARNING WHEN USING ISOPROPYL ALCOHOL, FOLLOW THE DIRECTIONS AND
WARNINGS GIVEN BY THE MANUFACTURER. AVOID ANY CONTACT WITH THE
WEBBING MATERIAL.
(1)
Clean the hardware with a lint-free cloth moist with isopropyl alcohol.
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Task
Use visual checks to find damaged or worn parts and parts that show signs of near failure. If you find
and correct possible conditions of failure, you can prevent failures in the aircraft and make the
equipment more reliable.
2.
3.
Procedures
A.
General
(1)
Make sure that the Restraint System is clean and does not contain:
Dirt
Oil or grease
Other unwanted particles or substances.
(2)
B.
Webbing
NOTE:
(1)
(2)
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The amount of fray should be limited to an amount that is less than 10% of the width of the
webbing and not to exceed 8 inches in length.
Webbing with more than 15 broken yarns in locations other than the edge.
Webbing that is frayed or distorted sufficiently to cause improper operation of any portion of the
restraint system.
A total of 15 stitches can be torn in a stitch pattern before the webbing needs replacement.
(3)
3.
C.
Fittings
NOTES:
(1)
2.
E.
D.
1.
Reel Assembly
(1) Examine reel assembly for:
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General
Inspection of the restraint is in accordance with the on condition principle and is governed by an
inspection and servicing schedule. The restraint may remain in service until defects are found
upon inspection or in use.
As a minimum, Am-Safe recommends a yearly inspection of the restraint. The continued use is
subject to the routine inspection interval of the airframe by conducting a functional inspection check
of the restraint in accordance with the procedures listed in the TESTING and FAULT ISOLATION
and CHECK sections of this CMM. The service life is subject to the periodic inspection while in
service and depends on the service environment in which it is used and the degree of use over the
installation period. This subsequently places the responsibility for the continued airworthiness of
the restraint on the installer/operator since the flight times, usage, and operating environment will
vary by operator. The frequency of the inspection interval should be adjusted appropriately by the
installer/operator to ensure the continued airworthiness of the restraint. If the restraint is no longer
usable based on the inspection for continued or renewed airworthiness, it must be discarded or
returned to Am-Safe or an Am-Safe approved repair station for overhaul/repair.
B.
Inspection Intervals
- Concurrently with the airworthiness inspection of the airframe.
- When the equipment has sustained damage or whenever malfunctions occur.
- When the equipment is transferred to another owner or for any special reason.
- When the equipment has been over-stressed or if over-stress is suspected. Visual inspection of
the restraint will not always reveal the extent of the damage caused by over-stress/crash
impact/severe loading conditions. In order to ensure that the original design performance and
structural integrity is maintained, the user should remove and replace all restraints within the
aircraft after over-stress/crash impact/severe loading conditions have occurred.
C.
Inspection Responsibility
Inspection of the restraint for continued or renewed Airworthiness must only be performed by the
manufacturer or by agencies specially approved by the aviation authorities.
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NOTE:
Equivalent alternatives are permitted for the equipment and materials in this list.
Use an abrasive cloth to remove minor nicks and scratches from aluminum parts.
(2)
Use crocus cloth to remove minor nicks and scratches from steel parts.
(3)
For painted surfaces, apply a coat of epoxy primer followed by a coat of black epoxy paint.
(4)
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Task
This subheading provides instructions to assemble each subassembly and to put the subassemblies
together to make a Restraint System. Do only those procedures applicable to the level of disassembly
done.
Refer to paragraph 4 for storage instructions.
2.
3.
Procedure
NOTE:
A.
B.
Insert connector of connector half into correct slot of rotary buckle assembly.
(2)
Insert connector of each strap into correct slot on rotary buckle assembly.
(2)
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C.
Insert the shoulder strap with the fold over facing down through the slot of the web guide
and through the shaft.
(2)
Insert and center the pin (476211-9) in the webbing fold over.
(3)
Pull on the connector end of the strap to tighten and secure in place the shoulder strap. The
fold must be kept inside the shaft.
Pin (476211-9)
Assembly
Figure 3
(4)
4.
Carefully remove the Locking key (T504898-1) from the inertia reel and allow the webbing to
retract slowly.
Storage
A.
If you must keep the Restraint in storage, keep it in conditions with a temperature range of -22 to
+131 F (-30 to +55 C). You must protect the Restraint from sunlight, dust, moisture, and other
contamination.
B.
After removal from storage, new restraints shall be subject to an inspection check in accordance
with the TESTING and FAULT ISOLATION and CHECK sections of this CMM before installation
into the aircraft.
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4005-207-XXXX*
(Contains one 4005-209-XXXX*
shoulder strap, one pin 476211-9 and
one T504898-1 locking key)
To replace strap
used on P/N
Supplier name
4005-1-01X-XXXX*
4005-1-02X-XXXX*
Sub-heading
used on
Assembly
* Last four digits determine web type and color. Refer to the restraint system top assembly part number or
contact Am-Safe customer service.
NOTE: Equivalent alternatives are permitted for the equipment in this list.
(This equipment can be fabricated locally per the figures 4 and 5)
T504898-1 Locking Key, Material: .060 +/- .002 inches thick, stainless steel: type 304
Locking Key
Figure 4
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0.5 IN
(1.27 CM)
3.0 IN (7.62 CM)
Spring Plate
Figure 5
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Introduction
The ILLUSTRATED PARTS LIST provides illustrations and detailed parts list for the use in identifying
and requisitioning replaceable parts in disassembly order.
2.
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The Detailed Parts List shows assemblies, subassemblies, and detail parts of this unit. The indenture of
sub-unit parts shows their relationship to the unit. Part numbers and name data identify each part.
Assembly and sub-assembly part numbers in this restraint include four numeric characters at the
end of the part number to designate web type and color. In the IPL table the assemblies are
defined with black webbing 2251 black nylon for the lap belt portion, (-2251 is also the
designation when complete restraint assemblies are ordered) and 3192 black nylon for the upper
torso. For any other color, contact AM-SAFE customer service. Item numbers refer to the
accompanying illustration. Use them for locating a part that you find in the Reference Designator
Index, or illustration.
B.
The Eff (Effectivity) Code Column shows the differences between similar units or subassemblies
that are in the same parts list.
C.
4.
If this column is blank, the part goes in all the units shown in that figure.
If this column has a letter in it, that part only goes into the unit or subassembly that relates to
the letter.
If this column has more than one letter, the part goes into each unit or subassembly that
relates to the letters.
The Units Per Assembly shows the quantity of each part used in the next higher assembly.
Identifying Parts
If you do not know a part number, refer to the illustration in which you found the part. Find the item
number of the part and refer to the Detailed Parts List.
5.
Abbreviations
A.
B.
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PAGE 33 OF 35
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PART
NUMBER
AIRLINE STOCK
1234567
NO.
NOMENCLATURE
UNIT
EFF
PER
CODE
ASSY
USABLE ON CODES
CODE A 4005-1-011*
CODE B 4005-1-021*
CODE C 4005-211XXX
CODE D 4005-212XXX
CODE E 4005-1-031*
CODE F 4005-1-041*
CODE G 4005-1-051*
CODE H 4005-1-061*
1
4005-1-011*
RESTRAINT SYSTEM
(LH)
RF
1A
4005-1-021*
RESTRAINT SYSTEM
(RH)
RF
1B
4005-1-031*
RESTRAINT SYSTEM
(LH)
RF
- 1C 4005-1-041*
RESTRAINT SYSTEM
(RH)
RF
- 1D 4005-1-051*
RESTRAINT SYSTEM
(LH)
RF
RESTRAINT SYSTEM
(RH)
RF
1E
4005-1-061*
4005-211*
5A
4005-212*
10
4005-203*
- 10A 4005-204*
15
502214-401
- 15A 502214-403
+
.LAP BELT
(LH)
A,E,
G
.LAP BELT
(RH)
B,F,H
A,C,
E,G
B,D,
..BUCKLE HALF (RH)
F,H
A,C,
E,G
B,D,
F,H
1
1
1
20
4005-201*
..CONNECTOR HALF
25
4005-205**
.SHOULDER STRAP
30
4005-207**
RF
* -2251 FOR BLACK NYLON WEBBING. FOR ANY OTHER COLOR, CONTACT AM-SAFE CUSTOMER SERVICE
** -3192 BLACK NYLON WEBBING. (SEE PAGE 31 PARA. 2.A) FOR ANY OTHER COLOR, CONTACT AM-SAFE
CUSTOMER SERVICE
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PART
NUMBER
AIRLINE STOCK
1234567
NO.
NOMENCLATURE
UNIT
EFF
PER
CODE
ASSY
+ WHEN ORDERING CONNECTOR HALVES INDICATE THE TOP ASSEMBLY RESTRAINT PART NUMBER.
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