AMSAFE 504414 Series User manual

PAGE 1 OF 42
June 9, 2014
Rev. 2
25-20-217
PRINTED IN USA
AmSafe, Inc.
1043 N. 47th Ave
Phoenix, Arizona 85043
Phone: [phone]
Fax: [phone]
Restraint System
Assembly
Part No.
504414-SERIES
Abbreviated Component
Maintenance Manual
With illustrated parts list
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
P/N 504414-SERIES
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PROPRIETARY NOTICE
This document and the information disclosed herein are the proprietary data of AmSafe Inc. Neither this
document nor the information contained herein shall be used, reproduced, or disclosed to others without the
written authorization of AmSafe 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)
AmSafe 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 AmSafe Inc. Commercial And Government Entity (CAGE) code: 35FB9
The technical data in this document (or file) is controlled for export under the Export Administration
Regulations (EAR), 15 CFR Parts 730-774, ECCN: 9A992. Violations of these laws may be subject to fines
and penalties under the Export Administration Act.
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MATERIALS HAZARD RATING CODE
AmSafe 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 4. Get specific data on a material from the data sheet supplied
by the manufacturer of the material.
POSITION 1: HEALTH HAZARD POSITION 2: FIRE HAZARD
0
1
2
3
4
No important hazard.
Irritant Use with caution.
Hazardous Prevent continued exposure,
inhalation, and contact.
Dangerous hazard Use protective clothing
together with protection to breathe.
Very bad hazard Do not breathe vapor or come
in contact with liquid without approved special
protection.
0
1
2
3
4
Will not burn.
Must increase the temperature above 93.4°C to
burn.
Must increase the temperature above 37.8°C to
burn.
Fire and explosion hazard at ambient
temperature.
Highly dangerous fire and explosion hazard.
POSITION 3: REACTIVITY HAZARD POSITION 4: STORAGE
0
1
2
3
4
Usually stable.
Unstable if heated.
Violent chemical change is possible.
Dangerous explosion is possible.
Very bad explosion hazard quickly 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.
POSITION 3
REACTIVITY
(YELLOW)
POSITION 4
STORAGE
(WHITE)
POSITION 1
HEALTH
(BLUE)
POSITION 2
FIRE
(RED)
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HEALTH HAZARD RATING IN POSITION 1
Rating Description Effect of Exposure
4 Very bad health
hazard
Very short exposures could cause DEATH or CRITICAL REMAINING
INJURY even after fast medical treatment. Do not breathe the vapor or
come into contact with the liquid without approved protection.
3 Dangerous
health hazard Short exposures could cause DANGEROUS TEMPORARY OR 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
health hazard Not hazardous for usual conditions. Special personal protection is not 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 PERMITTED!
2 Moderately
combustible
Materials that must be warm or in an area open to high temperatures
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
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.
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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INTRODUCTION
How to Use this Manual
The instructions in this manual give the data necessary to do all recommended maintenance functions to
keep the restraint system in serviceable condition. Standard maintenance procedures that technicians are
thought to know are not given in this manual. Verification of these technical instructions is done by
performance or by simulation of the necessary procedures. AmSafe Inc. will revise this manual as
necessary to give current data.
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.
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 directed.
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.
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
g Standard gravity
RF Reference callout
Record of revisions
For each revision to this ACM, because of the limited number of pages a complete reissue of the ACM will
accomplish the changes to the content with each page showing the reissue date.
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TABLE OF CONTENTS
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Subheading Page
DESCRIPTION AND OPERATION 9
TESTING AND FAULT ISOLATION 11
AUTOMATIC TEST REQUIREMENTS (ATLAS) NOT APPLICABLE
DISASSEMBLY 15
CLEANING 17
CHECK 19
REPAIR 23
ASSEMBLY AND STORAGE 25
FITS AND CLEARANCES NOT APPLICABLE
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT NOT APPLICABLE
ILLUSTRATED PARTS LIST 27
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DESCRIPTION AND OPERATION
1. Description (see Figure 1.)
The restraint system consists of the following major assemblies:
Shoulder Strap
Lap Belt Assy
The restraint system assemblies come together at a common attachment point.
All of the belts and straps are made from nylon webbing. The lap belt is fitted with a fixed buckle and an
adjustable connector. The ends of the lap belts, which attach to the seat or aircraft, are fitted with end
fittings. Leading particulars for the restraint system are listed in Table 1.
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 Strap:
Type.................................................................................................... Automatic Inertia Reel
Locking Acceleration.........................................................................................................2.5g
Lap Belt Assembly:
Rated Strength (minimum)....................................................................... 3000 lbs. (1361 kg)
Leading Particulars
Table 1
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2. Operation
The restraint system is intended for use by the aircraft occupants. 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 strap.
NOTE: Refer to the installation instructions supplied by the seat manufacturer.
A. Shoulder Strap
The shoulder strap is equipped with an inertia reel, which performs length adjustment by reeling
the strap in or out and allows the upper part of the body freedom of movement. Sewn to the other
end of the strap is the connector, which is slid over the rivet on the lap belt for donning.
B. Inertia Reel
When the restraint system is in use, the inertia reel allows unrestricted movement in the seat.
The reel extends and retracts the shoulder harness as required. If a sudden acceleration force is
applied to the shoulder harness, the inertia reel will automatically lock. The occupant in the seat
is 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.
C. Lap Belts
There is a buckle half with a fixed buckle and a connector half with an adjustable connector
especially designed for length adjustment.
D. Fastening
In the seated position, pull the shoulder strap connector and slide it over the rivet on the lap belt
connector. Insert the lap belt connector into the buckle until the latch block audibly engages the recess
in the connector. For shortening the lap belt, pull the free end of the webbing at the connector. For
lengthening the belt, grasp the connector and rotate it approximately 45. Pulling the connector will
lengthen the belt.
E. Releasing
For releasing the lap belt, lift the buckle cover. This action will release the connector, which can then
be withdrawn from the buckle. Place the lap belt portions on the seat to prevent them from being
damaged and soiled.
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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
AmSafe Inc.
Test No. Procedure Limits
1.0 Initial Test (Lap Belt Assy)
1.1 Insert connector into buckle. Connector engages.
1.2 Release connector by lifting the buckle cover. Connector releases. The buckle cover return to the
normal position.
1.3 Repeat step 1.1 and 1.2 four times. The connector engages and releases. The cover returns to
the normal position.
1.4 Adjust webbing in connector half by pulling on the free
end of webbing.
Webbing must adjust and
should not exhibit excessive
fray or any cuts.
1.5 Repeat step 1.4 four times. Webbing must adjust and should not exhibit excessive
fray or any cuts.
Restraint system test Table101
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Test No. Procedure Limits
2.0 Initial Test (Shoulder Strap)
2.1 Slowly pull the shoulder strap webbing all of the way out of the inertia reel assembly. Observe webbing for
freedom of reel action and general appearance.
Webbing extends. Webbing
should not exhibit excessive
fray or any cuts.
2.2 Slowly let the webbing retract into the inertia reel
assembly. Webbing retracts.
2.3 Repeat steps 2.1 and 2.2 four times. The webbing extends and
retracts smoothly.
2.4 Withdraw approximately 25% of webbing from the reel and rapidly accelerate the webbing until the system
locks.
The locking system should
lock and webbing should not
extend.
2.5 Slowly let the webbing retract into the inertia reel
assembly. The webbing retracts.
2.6 Repeat steps 2.4 and 2.5 four times. The locking system should lock and the webbing should
retract.
2.7 Slide the shoulder strap connector over the rivet on the
lap belt connector.
The connector should present
a small resistance and stay in
place. The plastic grommet
must not show signs of
weakness.
2.8 Remove the shoulder strap connector from the rivet of
the lap belt connector.
The connector should present
a small resistance and come
off the rivet. The plastic
grommet must not show signs
of weakness.
2.9 Repeat steps 2.7 and 2.8 four times.
The connector should present
a small resistance and stay in
place. The connector should
present a small resistance and
come off the rivet. The plastic
grommet must not show signs
of weakness.
Restraint System Test
Table 101 (cont.)
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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
Failure Occurs Probable Cause of Failure Repair Task
1.1 Damaged buckle or connector. Replace buckle half or
connector half.
1.2 Damaged buckle or connector. Replace buckle half or
connector half.
1.3 Damaged buckle or connector. Replace buckle half or
connector half.
1.4 Damaged connector or webbing. Replace connector half.
1.5 Damaged connector or webbing. Replace connector half.
2.1 Damaged inertia reel or webbing. Replace shoulder strap.
2.2 Damaged inertia reel. Replace shoulder strap.
2.3 Damaged inertia reel or webbing. Replace shoulder strap.
2.4 Damaged inertia reel. Replace shoulder strap.
2.5 Damaged inertia reel. Replace shoulder strap.
2.6 Damaged inertia reel. Replace shoulder strap.
2.7 Damaged shoulder strap connector.
Damaged lap belt connector or grommet. Replace shoulder strap. Replace connector half.
2.8 Damaged shoulder strap connector.
Damaged lap belt connector or grommet. Replace shoulder strap. Replace connector half.
2.9 Damaged shoulder strap connector.
Damaged lap belt connector or grommet. Replace shoulder strap. Replace connector half.
Fault Isolation
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 AMSAFE INC. (USA), AMSAFE LTD. (UK) OR AN AMSAFE APPROVED REPAIR
STATION. AMSAFE INC. IS NOT RESPONSIBLE FOR DAMAGE OR MALFUNCTIONS
RESULTING FROM ANY UNAUTHORIZED ATTEMPT TO REPAIR OR DISASSEMBLE
THE RESTRAINT SYSTEM.
2. Equipment and Materials
No equipment or materials required.
3. Procedure
None.
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CLEANING
1. Task
Clean the restraint system to 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 230D
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 RESISTANT 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
AMSAFE OR AN AMSAFE 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. A 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 moistened 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) Webbing must be replaced 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.
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.
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C. Fittings.
NOTES: 1. Burrs and nicks are material raised above the normal surface. This material must
not prevent the mating parts from fitting together correctly.
2. Dents must not damage the finish or functional operation of any parts.
(1) Examine fittings for burrs, nicks, cracks, dents or corrosion.
D. Buckle and connector assemblies.
(1) Examine buckle and connector for burrs, nicks, cracks, dents or corrosion.
E. Reel Assembly
(1) Examine reel assembly for burrs, nicks, cracks, dents or corrosion.
(2) Make sure movable parts operate correctly.
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, AmSafe recommends a yearly inspection of the restraint. The continued use of the
restraint 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 ACM. 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, must be discarded or returned to AmSafe or an AmSafe 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.
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