Am-Safe Inc.

1043 N. 47th Ave.

Phoenix, Arizona 85043
Phone: (602) 850-2850
Fax: (602) 850-2812

Restraint System
Assembly

Part No.
4005-SERIES
Abbreviated Component
Maintenance Manual
With illustrated parts list

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 ABBREVIATED COMPONENT MAINTENANCE MANUAL
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PROPRIETARY NOTICE

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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MATERIALS HAZARD RATING CODE

Am-Safe Inc. uses the National Fire Protection Association system to identify the different levels of
hazards that are caused by the use of a given material. A Hazard Code identifies three effects of a
material on a person: health (eat, drink, touch, and breathe), fire (when and how it burns), and reactivity
(chemical explosions). Also, each material is given a storage group for safety.

Each code has three numbers and one letter (for example, 130D) as shown in the Hazard Code symbol
below. The three numbers show the hazard levels for health, fire, and reactivity, in that sequence. The
range of each number is 0 to 4. The higher the number, the more dangerous the hazard. You must be
careful with any material that has a Hazard Code with a 2, 3, or 4. The one letter (A thru E) in the code
identifies a specific storage group that is applicable for the material.

If applicable, the materials used for the procedures in this manual are given a Hazard Code. More data
on the health and fire levels is shown in on page H-2. Get specific data on a material from the data
sheet supplied by the manufacturer of the material.

POSITION 3
POSITION 2 REACTIVITY
FIRE (YELLOW)
(RED)

POSITION 1
HEALTH
(BLUE) POSITION 4
STORAGE
(WHITE)
POSITION 1: HEALTH HAZARD POSITION 2: FIRE HAZARD
0 No important hazard 0 Will not burn
1 Irritant−Use with caution 1 Must increase the temperature above 93.4 °C to
2 Hazardous−Prevent continued exposure, burn
inhalation, and contact 2 Must increase the temperature above 37.8 °C to
3 Dangerous hazard−Use protective clothing burn
together with protection to breathe 3 Fire and explosion hazard at ambient
4 Very bad hazard−Do not breathe vapor or come temperature
in contact with liquid without approved special 4 Highly dangerous fire and explosion hazard
protection
POSITION 3: REACTIVITY HAZARD POSITION 4: STORAGE
0 Usually stable A Acids
1 Unstable if heated B Alkalis, cyanides
2 Violent chemical change is possible C Oxidizing agents
3 Dangerous explosion is possible D Chlorinated hydrocarbons, flammable liquids,
4 Very bad explosion hazard−quickly go out of materials that are not flammable
the area if materials are exposed to fire E Neutral salts and others

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HEALTH HAZARD RATING IN POSITION 1

Rating Description Effect of Exposure
4 Very bad health Very short exposures could cause DEATH or CRITICAL REMAINING
hazard INJURY even after fast medical treatment. Do not breathe the vapor or
come into contact with the liquid without approved protection.
3 Dangerous Short exposures could cause DANGEROUS TEMPORARY OR
health hazard REMAINING INJURY even with fast medical aid. Use approved
clothing.
2 Hazardous Intense or continued exposure could cause TEMPORARY DISABILITY
OR POSSIBLE REMAINING INJURY unless medical aid is given
immediately.
1 Irritant May cause IRRITATION on exposure. Only SMALL REMAINING
INJURY would be the result without medical treatment. Safety glasses
must be worn.
0 No important Not hazardous for usual conditions. Special personal protection is not
health hazard necessary.
FIRE HAZARD RATING IN POSITION 2
Rating Description Effect of Exposure
4 Very flammable Any liquid or gaseous material that is a liquid under pressure with a
flash point below 22.8 °C. Also materials that can form explosive
mixtures with air, such as dusts or combustible solids, and pressurized
small drops of flammable or combustible liquid. PREVENT ALL
SOURCES OF IGNITION. NO SMOKING PERMITTED!
3 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!
2 Moderately Materials that must be warm or in an area open to high temperatures
combustible before ignition can occur. This rating is applicable to liquids having a
flash point above 37.8 °C but below 93.4 °C. Be very careful when near
a source of heat.
1 Lightly Materials that must be hot before ignition can occur. This rating
combustible 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.
0 Will not burn 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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RECORD OF REVISIONS

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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TABLE OF CONTENTS

Subheading Page

DESCRIPTION AND OPERATION 11

TESTING AND FAULT ISOLATION 15

AUTOMATIC TEST REQUIREMENTS (ATLAS) NOT APPLICABLE

DISASSEMBLY 17

CLEANING 19

CHECK 21

REPAIR 25

ASSEMBLY (Including Storage) 27

FITS AND CLEARANCES NOT APPLICABLE

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT 29

ILLUSTRATED PARTS LIST 31

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INTRODUCTION

How to Use this Manual

The instructions in this manual give the data necessary to do all recommended maintenance functions to
put the Restraint System in serviceable condition. Standard maintenance procedures that technicians are
thought to know are not given in this manual.

Refer to the Table of Contents for a list of subheadings in this manual. The Table of Contents identifies
those subheadings that are not applicable, that require no special instructions, or that are scheduled for a
subsequent revision.

We recommend that the tests in TESTING AND FAULT ISOLATION be done before the unit is
disassembled. These tests can tell the condition of the Restraint System or the most probable cause of any
malfunction. Should any malfunction occur, repair as necessary.

To decrease the length of sentences and titles, complete part numbers are not always shown in this
manual. A piece of the part number can show applicability to a specific assembly or component. Complete
part numbers are always given in the parts list subheading. Refer to the introduction in the ILLUSTRATED
PARTS LIST (or CATALOG) to find how to use that subheading.

Related publications that are referred to in this manual are identified in the list that follows:

Document Publication No.

Abbreviations for Use on Drawings and in Text* ASME Y1.1 (1989)
Standard Letter Symbols for Units of Measurement* ANSI/IEEE Std 260
(1978)

*Available from the American National Standard Institute, New York, NY

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Verification of these technical instructions is done by performance or by simulation of the necessary

procedures. Checks of the manual by the engineering staff make sure the instructions and description data
agree with the applicable engineering specifications and drawings and are accurate and sufficient. The level
of verification for this manual is as shown:

Subheading Level of Verification

Testing and Fault Isolation By performance, December 1, 1999

Disassembly By performance, December 1, 1999
Assembly By performance, December 1, 1999

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
g Standard gravity
RF Reference callout

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DESCRIPTION AND OPERATION

1. Description (See Figure 1.)

The Restraint System consists of the following major assemblies:

• Shoulder Harness Assembly / Dual Inertia Reels

• Left-Hand (LH) Lap Belt Assembly
• Right-Hand (RH) Lap Belt Assembly

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 hard-
mounted 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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Restraint System Assembly

Figure 1

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2. 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: Refer to the installation instructions supplied by the seat manufacturer.

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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2. E. Fastening

Fasten the belts and straps as follows:

(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.

F. Release

NOTE: Do not allow the shoulder straps to be wound up unrestrained.

(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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TESTING AND FAULT ISOLATION

1. Task– Testing on Aircraft and Shop Test

Use the following procedures to make an analysis of the performance of the restraint system while
on the aircraft. Table 102 is a fault isolation guide, which has been keyed to the test procedures.
Use it to isolate malfunctions that occur when you do the test.

A. Equipment and Materials

No equipment or materials required

B. Inspection Intervals

(1) Concurrently with on-aircraft seat inspection or if pulled from aircraft to determine
airworthiness.
(2) When malfunction is reported for failing requirements described in paragraph 1.

C. Procedure

(1) Follow procedures as dictated in table 101

(2) If restraint fails any tests in table 101, remove restraint for further evaluation
or overhaul by Am-Safe

Test No. Procedure Limits

1.0 Initial Test
1.1 Insert all connectors into rotary buckle. Connectors engage.
1.2 Release connectors by rotating the rotary buckle cover All but one of the connectors
clockwise. release. The buckle cover should
return to the closed position.
1.3 Repeat step 1.1 then release connectors by rotating the All but one of the connectors
rotary buckle cover counterclockwise. release. The buckle cover should
return to the closed position.
1.4 Put the inertia reel assembly in a simulated mounting
position
1.5 Slowly pull the shoulder harness webbing all of the way Webbing extends.
out of the inertia reel assembly.
Observe webbing for freedom of reel action and general Webbing should not exhibit
appearance. excessive web fray or any cuts.
1.6 Slowly let the webbing retract into the inertia reel Webbing retracts.
assembly.
1.7 Repeat steps 1.5 and 1.6 four times. The harness webbing extends
and retracts smoothly.

Restraint System Test

Table 101

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Test Procedure Limits

No.
1.8 Hold the inertia reel assembly and withdraw The locking system should lock
approximately 25% of webbing from the reel and rapidly and the webbing should not
accelerate the webbing until the system locks. extend.
1.9 Slowly let the webbing retract into the inertia reel Webbing retracts.
assembly.
1.10 Repeat steps 1.8 and 1.9 four times. The locking system should lock
and the webbing should retract.

Restraint System Test

Table 101 (cont.)

2. Procedure for Fault Isolation

When a Test Fails:

A. 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.

Test No. Where Probable Cause of Failure Repair Task

Failure Occurs

1.2 Damaged locking-end connector Replace belt portion.

Damaged rotary buckle Replace rotary buckle or belt portion
with rotary buckle.
1.3 Damaged locking-end connector Replace belt portion.
Damaged rotary buckle Replace rotary buckle or belt portion
with rotary buckle.
1.5 Damaged inertia reel assembly or webbing Replace Shoulder Harness or strap.
1.6 Damaged inertia reel assembly Replace Shoulder Harness.
1.7 Damaged inertia reel assembly Replace Shoulder Harness.
1.8 Damaged inertia reel assembly Replace Shoulder Harness.
1.9 Damaged inertia reel assembly Replace Shoulder Harness.
1.10 Damaged inertia reel assembly Replace Shoulder Harness.
Restraint System
Table 102

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DISASSEMBLY

1. 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. Equipment and Materials

See SPECIAL TOOLS, FIXTURES AND EQUIPMENT.

Note: Equivalent alternatives are permitted for the equipment and materials in this list.

• Standard hand tools

• Locking key (P/N T504898-1)
• Spring plate 3 x 0.5 x 0.008 in (7.62 x 1.27 x 0.02 cm) - Make locally

3. Procedure

NOTE: Refer to ILLUSTRATED PARTS LIST (IPL figure 1) for parts locations.

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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C. 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) For installation instructions refer to the ASSEMBLY section in this manual.

Locking key
(T504898-1)
Webbing PHOENIX, AZ. USA

REWORK BY AMSAFE
ONLY

Lock bar
Disassembly
Figure 2

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CLEANING

1. 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. Equipment and Materials

WARNING BEFORE YOU USE A CLEANING MATERIAL, YOU MUST KNOW THE
HAZARD CODE AND OBTAIN THE NECESSARY PROTECTION. REFER
TO THE PAGE ABOUT HAZARD CODES FOR MATERIALS IN THE
FRONT OF THIS MANUAL.

NOTE: Equivalent alternatives are permitted for the equipment and materials in this list.

Isopropyl Alcohol - Optional source, HAZARD CODE 130D

Mild Soap – Optional source (household dishwasher liquid soap, household laundry detergent)

Lint-free cloth - Optional source

Sponge or soft brush - Optional source

3. Procedure

CAUTIONS: 1. THE RESTRAINT SYSTEM MUST NOT BE MACHINE-WASHED, BECAUSE THE

WEBBING WILL SHRINK AND ITS PERFORMANCE CHARACTERISTICS WILL BE
CHANGED SIGNIFICANTLY.

2. THE RESTRAINT SYSTEM MAY BE DRY-CLEANED. HOWEVER, THE WEBBING

WILL LOSE ITS ABRASION-RESISTANCE COATING AFTER EACH CLEANING
AND ITS SERVICE LIFE WILL THEREFORE BE DECREASED.

3. REFER TO THE “CHECK” SECTION OF THIS MANUAL TO DETERMINE

WHEN THE WEBBING OF A RESTRAINT SYSTEM MUST BE REPLACED BY
AM-SAFE OR AN AM-SAFE APPROVED REPAIR STATION.

4. WHEN CLEANING THE RESTRAINT SYSTEM, CARE MUST BE TAKEN TO

KEEP AWAY FOREIGN MATTER AND CLEANING MEDIA FROM THE
HARDWARE ASSEMBLIES.

5. NO SOAP OR WATER IS TO BE USED ON METAL PARTS.

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3. A. Cleaning the webbing.

(1) Attach pieces of cloth to cover the metal fittings

(2) Either:

(a) Dry-clean the webbing, (see cautions) or

(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) Inspect the dry Restraint System.

B. 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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CHECK

1. 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. Equipment and Materials

None.

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) Make sure all parts are satisfactorily attached.

B. Webbing

NOTE: Slight wear of the webbing is permitted. However, excessive web

wear that has progressed to cut or worn edges must be replaced, as
described below.

(1) Examine webbing for:

• Cut or worn edges
• Damaged stitching
• Broken fabric threads
• Tears
• Excessive chafe marks
• Excessive wear
• Excessive fusing

(2) Replace webbing if any of the following are observed:

• A limited amount of “frayed” webbing will retain sufficient strength necessary to meet the
required strength. Frayed webbing is defined as broken filaments from either the warp
(longitudinal) yarns or the filler (transverse) yarns. The number of broken filaments should
not be sufficient to obscure the identity of any yarn when viewed from a distance of about 8
inches.

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• Any web that is cut or torn on the edge should be replaced.

• 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) Examine labels for legibility.

3. C. Fittings

NOTES: 1. Burrs, nicks, and scratches are material that is raised

above the normal surface. This material must be
removed to make sure that the parts will fit together
correctly.

2. Dents must not damage the finish or functional

operation of any parts.

(1) Examine fitting for:

• Burrs, nicks, or scratches
• Cracks
• Dents
• Corrosion

D. Rotary Buckle and connectors

(1) Examine rotary buckle and connectors for:

• Burrs, nicks, or scratches
• Cracks
• Dents
• Corrosion

E. Reel Assembly

(1) Examine reel assembly for:

• Burrs, nicks, or scratches
• Cracks
• Dents
• Corrosion

(2) Make sure movable parts operate correctly.

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4. Inspection for Continued or Renewed Airworthiness

A. 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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REPAIR

1. Task

The primary repair of the Restraint System is replacement of defective parts, and replacement or repair of
defective subassemblies. Disassemble the unit only to the level necessary to make repairs. When new
parts are necessary, refer to ILLUSTRATED PARTS LIST (IPL) for the correct part numbers, quantities,
and hardware that attaches.

CAUTION: THE RESTRAINT SYSTEM MAY NOT BE DISASSEMBLED BEYOND THE LEVEL
INDICATED IN THE “DISASSEMBLY” SECTION. FURTHER REPAIR BEYOND THE
LEVEL INDICATED BELOW 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.

2. Equipment and materials

WARNING BEFORE USING A MATERIAL, KNOW THE HAZARD CODE AND

GET THE NECESSARY PROTECTION. REFER TO THE PAGE
ABOUT HAZARD CODES FOR MATERIALS IN THE FRONT OF
THIS MANUAL.

NOTE: Equivalent alternatives are permitted for the equipment and materials in this list.

Abrasive cloth (Federal Specification P-C-451) – Optional source

Crocus cloth (Federal Specification P-C-458) – Optional source

Epoxy Paint (Color no. 37038 per Fed-Std 595) – Optional source, HAZARD CODE 230D

Epoxy Primer (Military Specification Mil-P-23377) – Optional source, HAZARD CODE 230D

3. Procedure

CAUTIONS: 1. REPLACEMENT OF DAMAGED METAL PARTS ON THE RESTRAINT SYSTEM

ASSEMBLY IS NOT PERMITTED.

2. REPAIR OF DAMAGED WEBBING ON THE RESTRAINT SYSTEM IS NOT

PERMITTED.

(1) 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) Clean the parts when the repair is complete.

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ASSEMBLY (Including Storage)

1. 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. Equipment and Materials

NOTE: Equivalent alternatives are permitted for the equipment and materials in this list.

3. Procedure

NOTE: Refer to ILLUSTRATED PARTS LIST fig. 1 for parts locations.

A. Attach connector halves to rotary buckle assembly.

(1) Insert connector of connector half into correct slot of rotary buckle assembly.

(2) Push connector into slot until connector becomes locked in position.

B. Attach straps from harness assembly to rotary buckle assembly.

(1) Insert connector of each strap into correct slot on rotary buckle assembly.

(2) Push connector into slot until it is held in position.

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3. C. Attach the replacement shoulder strap to inertia reel. Refer to figure 3.

NOTE: To remove the Shoulder Strap from the inertia reel, refer to the DISASSEMBLY section.

WARNING THE FOLLOWING OPERATION IS TO BE CARRIED OUT WITH GREAT CARE.

BEFORE YOU REPLACE THE DAMAGED PART OR RE-INSTALL THE SHOULDER
STRAP, YOU MUST GET NECESSARY PERSONAL PROTECTION EQUIPMENT

(1) 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.

Replacem ent strap Pin (476211-9)

Assembly
Figure 3

(4) Carefully remove the Locking key (T504898-1) from the inertia reel and allow the webbing to
retract slowly.

4. 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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SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

This subheading gives all the tools, fixtures, and equipment specified in other subheadings. They are
necessary to do the maintenance on the Restraint System. The applicable subheading shows the materials
used during maintenance. Am-Safe provides the data that follows so you can get all of the equipment listed,
or you can substitute equivalent equipment.

To replace strap Sub-heading

Replacement strap P/N Supplier name
used on P/N used on
4005-207-XXXX*
(Contains one 4005-209-XXXX* 4005-1-01X-XXXX* Am-Safe Inc. (USA) or
Assembly
shoulder strap, one pin 476211-9 and 4005-1-02X-XXXX* Am-Safe LTD (UK)
one T504898-1 locking key)

* 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)

ƒ T504898-1 Locking Key, Material: .060 +/- .002 inches thick, stainless steel: type 304

Locking Key
Figure 4

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This equipment can be fabricated locally per Figure 5.

• Steel spring plate 0.008 in (0.02 cm.) thickness.

0.5 IN
(1.27 CM)

3.0 IN (7.62 CM)

Spring Plate
Figure 5

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ILLUSTRATED PARTS LIST

1. Introduction

The ILLUSTRATED PARTS LIST provides illustrations and detailed parts list for the use in identifying
and requisitioning replaceable parts in disassembly order.

2. Part Number Structure

The top assembly part number consists of the following information. For more information contact Am-
Safe customer service.

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A. 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.

• 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.

C. The Units Per Assembly shows the quantity of each part used in the next higher assembly.

4. 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. The abbreviations in this parts list agree with ASME Y1.1.

B. These abbreviations are not standard:

RF - This identifies reference callout.

LH - Left hand
RH - Right hand

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Restraint System Assembly

Figure 6

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UNIT
FIG. PART AIRLINE STOCK EFF
1234567 NOMENCLATURE PER
ITEM NUMBER NO. 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 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
- 1E 4005-1-061* RESTRAINT SYSTEM (RH) RF
A,E,
5 4005-211* 1
.LAP BELT (LH) G
5A 4005-212* .LAP BELT (RH) B,F,H 1
A,C,
10 4005-203* 1
..BUCKLE HALF (LH) E,G
B,D,
- 10A 4005-204* 1
..BUCKLE HALF (RH) F,H

…BUCKLE ASSEMBLY (LH FIXED) A,C,

15 502214-401 1
E,G
B,D,
- 15A 502214-403 1
…BUCKLE ASSEMBLY (RH FIXED) F,H
+ 20 4005-201* ..CONNECTOR HALF 1
25 4005-205** .SHOULDER STRAP 2
- 30 4005-207** SHOULDER STRAP REPLACEMENT RF
KIT (W/ PIN AND LOCKING KEY)
- ITEM NOT ILLUSTRATED

* -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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UNIT
FIG. PART AIRLINE STOCK EFF
1234567 NOMENCLATURE PER
ITEM NUMBER NO. CODE
ASSY

+ WHEN ORDERING CONNECTOR HALVES INDICATE THE TOP ASSEMBLY RESTRAINT PART NUMBER.

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