SUPPLEMENTAL INSTRUCTIONS FOR CONTINUED

AIRWORTHINESS

AMSAFE SEATBELT AIRBAG

V23 SYSTEM

for

CESSNA AIRCRAFT, MODELS 172, 182, 206

Inflatable Restraint System Assembly Series No. 7035

AmSafe Document Number: E508804

AMSAFE PROPRIETARY RIGHTS

This information contained herein is confidential and proprietary to AmSafe. It shall not be reproduced or
disclosed in whole or in part to persons other than those necessary for the user to utilize such information or
used in any manner detrimental to AmSafe’s interests or for the purpose for which such information was
provided without the express, written consent of AmSafe, 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 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 Commercial And Government Entity (CAGE) code: 35FB9
AmSafe Seatbelt Airbag is a registered trademark of AmSafe, Inc. All rights reserved.

1043 N. 47th Avenue, Phoenix, AZ 85043▪ Phone: 602-850-2850 ▪ www.amsafe.com

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SUPPLEMENTAL INSTRUCTIONS FOR CONTINUED AIRWORTHINESS E508804

REVISION HISTORY

Updates and revisions to this manual will be distributed only to Cessna Aircraft and AmSafe Authorized
Service Centers, as necessary. Distribution or notification of these updates to the individual
owner/operator of the affected aircraft will be the responsibility of Cessna Aircraft and AmSafe Authorized
Service Centers.

Access to all applicable and appropriate documentation is available through AmSafe’s web site at
www.amsafe.com. Select and click on “New Customer/Partner Site” link on bottom left of page.

NOTE: REGISTRATION IS BY SERVICE CENTER USER AND PASSWORD ONLY. NO INDIVIDUAL

REGISTRATIONS WILL BE PROCESSED.

First Time User – Select “Register” button and fill in all information. Under “Notes”, indicate Service
Center location and number, if applicable. After registration is accepted, enter user name and password
and click on “Go” button. This will access the client-specific page which contains associated, most-
current AmSafe documents/drawings for the program. Adobe Acrobat (Reader) 5.0 or later version must
be used to view, print, or save a copy of desired document/drawing.

It is requested that all aircraft newly equipped with the AmSafe Seatbelt Airbag System be registered with
AmSafe through the client web page form.

Rev. Prepared Approved Revision Summary Date

NC K. Kleisler W. Gehret Initial Issue 17 Aug 04

A K. Kleisler W. Gehret Updated callouts and buckle belt assy part numbers, Pages 1, 2, 11 Nov 04
5
Added Cable Guide and Installation Kits Parts Breakdown, Page 4
Clarified system functional testing, Page 6
Changed storage section of EMA and Inflator, Page 8
Changed airworthiness limitations section, Pages 14 and 15
B K. Kleisler W. Gehret Updated whole document to include new EMA Assy, Brazilian 29-Aug-05
alternative SAA configurations, and new Model 206 Pilot/Co-Pilot
and Middle Seat only configurations.
Part List Table on pages 6 and 7 was extensively changed to
include above information.
C J. Magish W. Gehret Whole Document revised to add new document access 4-Oct-06
information, requirements, deleted Mesa, AZ address, changed
AmSafe name format with logo, new document name (was
Supplemental Maintenance Manual), added note regarding
requirement to record all functional tests in aircraft log book,
added connector track part number, added Cessna AAIR
installation drawing numbers to Removal and Replacement
section, new RMA contacts and procedures, added information in
Warranty section - second paragraph, and added Appendix A
D J. Magish W. Gehret Page 6 – Corrected part numbers for Brazilian Three-point Airbag 17-Oct-06
Belts and added two configurations of Aux Child End-release
Buckle Assemblies for Model 206 Middle Seats.
E J. Magish W. Gehret Corrected Parts List to accurately include kit – 204 and -205 part 8-Feb-07
numbers.
F F. Armenta W. Gehret Whole document revised airbag name: replaced AAIR with 4-Mar-09
AmSafe Aviation Airbag
Cover Page and Page ii – revised AmSafe website to
www.amsafe.com
Page 2 – updated Figure 1 (V23 System Components)
Page 11 – revised Storage of Spares/Inflator Assembly storage
time to 10 years without renewal.
Page 17 – revised Condemnation/Inflator Assembly storage
period to 10 years without renewal; deleted renewal of inflator.
Page 18 – updated RMA Procedures contact information.
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TABLE OF CONTENTS

DESCRIPTION 1
SYSTEM OPERATION 1
SYSTEM COMPONENTS AND PARTS LIST 1
MAINTENANCE AND INSPECTION 8
Maintenance 8
System Functional Testing 8
Post-Incident Aircraft Documentation Process 8
Inspection 9
Cleaning 10
STORAGE OF SPARES 11
Inflator Assembly 11
Electronics Module Assembly (EMA) 11
Inflatable Restraint System Assembly 11
REMOVAL AND REPLACEMENT 11
Equipment and Materials Required 12
Removal 13
Replacement 15
AIRWORTHINESS LIMITATIONS 17
Inspection Intervals 17
Inoperable AmSafe Seatbelt Airbag System 17
Condemnation 17
Renewal 18
WARRANTY AND RETURN INFORMATION 18
Warranty 18
Returning AmSafe Seatbelt Airbag System Components and RMA Procedures 18
RMA Procedures 18
Packaging and Shipping Requirements – Inflator Assembly 18
Packaging and Shipping Requirements – AmSafe Seatbelt Airbag System Components except the
Inflator Assembly 19
REFERENCE PUBLICATIONS 19

APPENDICES

APPENDIX A – AMSAFE SEATBELT AIRBAG SYSTEM POST-INCIDENT INSPECTION CHECKLIST20

TABLES

Table 1 - Torque Values and Tool Sizes 12

FIGURES

Figure 1 – V23 System Components 2

Figure 2 – Inflator Assy Shipping Cap 2
Figure 3 – V23 System Diagnostic Tool, P/N 508668-201 3
Figure 4 – Guide to Cable Location 4
Figure 5 – Electrical and Hose Connectors of Inflator Assembly 13
Figure 6 – Cable Interface Assembly 14
Figure 7 – Inflatable Restraint System Assembly Connector 15
Figure 8 – Typical EMA Aircraft Forward Installation 16

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INTRODUCTION

DESCRIPTION

This manual contains service and maintenance instructions for the AmSafe Seatbelt Airbag V23 System,
installed on the Cessna Aircraft, Models 172, 182, 206 aircraft. The AmSafe Seatbelt Airbag V23 System
is a self-contained, modular, three-point restraint system that improves protection from serious head-
impact injury during a survivable aircraft crash.

SYSTEM OPERATION

Within milliseconds of an injurious crash event, the EMA’s crash sensor evaluates the crash pulse and
then sends a crash pulse signal throughout the activation circuit. This signal releases the gas in the
inflator, rapidly inflating the airbag within the airbag belt’s cover breaking through the cover’s tearable
seam, and filling the airbag to its fully-inflated state. The inflating airbag will automatically position itself
between the forward monument and the occupant thus providing head protection during the most critical
time of the event. After airbag deployment, the airbag deflates to enable the occupant to egress the
aircraft without obstruction from the airbag.
The crash sensor’s predetermined deployment threshold does not allow inadvertent deployment during
normal operations, such as hard landings, vibration, or turbulence.
To activate the system, join (buckle) the three-point restraint in the same manner as any other three-point
seatbelt. Unbuckling the seatbelt safes the AmSafe Seatbelt Airbag System.

SYSTEM COMPONENTS AND PARTS LIST

The AmSafe Seatbelt Airbag V23 System consists of these core components:
 Inflatable Restraint System Assembly
 Inflator Assembly
 Electronics Module Assembly (EMA)
 Cable Interface Assembly

The Inflatable Restraint System Assembly (1A, 1B, 1C, 1D, 1E, 1F) consists of two primary
subassemblies; the Three-Point Airbag Belt Assy (10A, 10B, 10C, 10D, 10E, 10F) with Safety Cable Tie
(11) and the End-Release Buckle Assy (20A, 20B, 20C, 20D) (see Figure 1). The Inflatable Restraint
System Assembly mounts to aircraft structure using existing mounting points. The End-Release Buckle
Assy provides the electrical connector to the Inflator Assy and the Cable Interface Assembly.

The Inflator Assembly (30) (Figure 1) mounts under the pilot\co-pilot, middle, and rear seats. The Inflator
Shipping Cap (31) makes the inflator a thrust-neutral device and is to be used whenever the inflator is
shipped as a non-installed item.

The Cable Interface Assy (40A, 40B, 40C) connects the EMA (50A, 50B) to two Inflatable Restraint
System Assemblies and also provides a Diagnostic Tool Connector leg (see Figure 1). The Diagnostic
Tool Connector connects to the System Diagnostic Tool to facilitate system functional checks.

The EMA, which contains the system electronics and system power (Lithium-type battery), is mounted to
the aircraft structure.

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Inertia Reel Inflatable Restraint System Assembly

(1A to 1F) – consist of End-Release
Buckle and Three-Point Airbag
Assemblies

Three-Point Airbag Belt

(10A, B, C, D, E, F)

Inflator
Airbag Belt Hose Assembly
(30A, B) End-Release Buckle
Assembly (20A, 20B)
EMA (50A, 50B) (20C, 20D not shown)

Cable Interface
Assembly
(40A, B, C)

Connector for Second Seat

Diagnostic
Connector Leg

Figure 1 – V23 System Components

Inflator Hose
Fitting

Inflator Shipping
Cap - 31

Figure 2 – Inflator Assy Shipping Cap

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V23 System Diagnostic

Tool (60)

Figure 3 – V23 System Diagnostic Tool, P/N 508668-201

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SUPPLEMENTAL INSTRUCTIONS FOR CONTINUED AIRWORTHINESS E508804

Symbol Key
Production Installation Configurations – All Models
EMA

Cable

1 – Standard Equipment 1 1
2 – Optional Equipment 1
1

1 1
Cable Connection
508976-201

Typical Cable Connection 508976-203

Cable Connection
508976-205
1 – Model 182
2 – Model 172
2
Cable Connection
508976-205

After-Market Installation Options – Model 206

Pilot/Co-Pilot Seats, Model 206 Middle Seat, 206 Model – see above for cable location

NOTE: Middle Seat AmSafe Airbag system

configuration to be added to existing Pilot/Co-Pilot
configuration or purchased together with Pilot/Co-
Pilot configuration.

1 1 Middle Seat configuration is not a stand-alone

AmSafe Airbag System placement.

Figure 4 – Guide to Cable Location

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Breakdown of Installation Kit Parts by Model Aircraft

508822-201-XXXX – Pilot/Co-Pilot Seats for Models 172, 182 508822-204-XXXX – Pilot/Co-Pilot Seats for Model 206

7035-1-011-XXXX – Inflatable Restraint System Assembly 7035-1-011-XXXX – Inflatable Restraint System Assembly
(Co-Pilot Seats) (Co-Pilot Seats)
*(7035-1-031-XXXX)
*(7035-1-031-XXXX)
7035-1-021-XXXX - Inflatable Restraint System Assembly 7035-1-021-XXXX – Inflatable Restraint System Assembly
(Pilot Seats) (Pilot Seats)
*(7035-1-041-XXXX)
*(7035-1-041-XXXX)
508794-401 – Inflator Assy, 90 deg. Fitting 508794-401 – Inflator Assy, 90 deg. Fitting
508792-401 – Inflator Assy, 0 deg. Fitting 508792-401 – Inflator Assy, 0 deg. Fitting
1
508358-421 (508358-409) – EMA Assy 508358-421 (508358-409) – EMA Assy
508976-201 – Cable Harness 508976-203 – Cable Harness
509121-1 – Airbag Equipped Label 509121-1 – Airbag Equipped Label
508822-202-XXXX – Pilot/Co-Pilot Sides / Rear Seats 508822-205-XXXX – Pilot/Co-Pilot Sides / Middle Seats
for Models 172, 182, 206 For Model 206
7035-2-011-XXXX – Inflatable Restraint System Assembly 7035-3-011-XXXX – Inflatable Restraint System Assembly
and Child Seat Buckle Half Assembly (Middle Seat – Pilot Side)
(Pilot Side)
*(7035-2-031-XXXX) *(7035-3-031-XXXX)
7035-2-021-XXXX – Inflatable Restraint System Assembly 7035-3-021-XXXX – Inflatable Restraint System Assembly
and Child Seat Buckle Half Assembly (Middle Seat – Co-Pilot Side)
(Co-Pilot Side)
*(7035-2-041-XXXX) *(7035-3-041-XXXX)
508794-401 – Inflator Assy, 90 deg. Fitting 508792-401 – Inflator Assy, 0 deg. Fitting
508358-421 (508358-409) – EMA Assy 508358-421 – EMA Assy
508976-205 – Cable Harness 508976-203 – Cable Harness
509121-1 – Airbag Equipped Label 509121-1 – Airbag Equipped Label
508822-203-XXXX – Pilot/Co-Pilot and Middle Seats
for Model 206 Note for all kits:
7035-1-011-XXXX – Inflatable Restraint System Assembly *7035- part number in parenthesis indicates Brazilian
(Co-Pilot Seats) STC alternate for these assemblies.
*(7035-1-031-XXXX)
7035-1-021-XXXX – Inflatable Restraint System Assembly
(Pilot Seats)
*(7035-1-041-XXXX)
7035-3-011-XXXX – Inflatable Restraint System Assembly
(Left Middle Seat- Pilot Side)
*(7035-3-031-XXXX)
7035-3-021-XXXX – Inflatable Restraint System Assembly
(Right Side Middle Seat – Co-Pilot Side)
*(7035-3-041-XXXX)
508794-401 – Inflator Assy, 90 deg. Fitting

508792-401 – Inflator Assy, 0 deg. Fitting

508358-421 (508358-409) – EMA Assy
508976-203 – Cable Harness
509121-1 – Airbag Equipped Label

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Qty per System

Pilot-Co-Pilot
172 Aircraft

182 Aircraft

206 Aircraft

206 Aircraft

206 Aircraft
Middle Seat
Only

Only
Item Part Number Part Description
Fig. No. Used On
No. (XXXX – Color Code) (For Installation Kits Parts Breakdown, refer to Chart on Page 5)

7035-1-011-XXXX
1 1A INFLATABLE RESTRAINT SYSTEM ASSEMBLY (Co-Pilot Seats) RF 1 1 1 1
*(7035-1-031-XXXX)
7035-1-021-XXXX
1 1B INFLATABLE RESTRAINT SYSTEM ASSEMBLY (Pilot Seats) RF 1 1 1 1
*(7035-1-041-XXXX)
7035-2-011-XXXX
1 1C INFLATABLE RESTRAINT SYSTEM ASSEMBLY (Rear Seats) - LH RF 1 1 1
*(7035-2-031-XXXX)
7035-2-021-XXXX
1 1D INFLATABLE RESTRAINT SYSTEM ASSEMBLY (Rear Seats) - RH RF 1 1 1
*(7035-2-041-XXXX)
7035-3-011-XXXX
1 1E INFLATABLE RESTRAINT SYSTEM ASSEMBLY (Middle Seats – Pilot Side) RF 1 1
*(7035-3-031-XXXX)
7035-3-021-XXXX INFLATABLE RESTRAINT SYSTEM ASSEMBLY (Middle Seats – Co-Pilot
1 1F RF 1 1
*(7035-3-041-XXXX) Side)
7035-203011XXXX
1 10A THREE-POINT AIRBAG BELT (Co-Pilot Seat) A 1 1 1 1
(7035-211031XXXX)
7035-204021XXXX
1 10B THREE-POINT AIRBAG BELT (Pilot Seat) B 1 1 1 1
(7035-212041XXXX)
7035-205011XXXX
1 10C THREE-POINT AIRBAG BELT (Rear Seat - LH) C 1 1 1
(7035-213031XXXX)
7035-206021XXXX
1 10D THREE-POINT AIRBAG BELT (Rear Seat - RH) D 1 1 1
(7035-214041XXXX)
7035-207011XXXX
1 10E THREE-POINT AIRBAG BELT (Middle Seat – Pilot Side) E 1 1
(7035-215031XXXX)
7035-208021XXXX
1 10F THREE-POINT AIRBAG BELT (Middle Seat – Co-Pilot Side) F 1 1
(7035-216041XXXX)
- -11 508298-1 SAFETY CABLE TIE A/B/C/D/E/F 4 4 6 4 4

- -12 511006-1 CAUTION TAG A/B/C/D/E/F 2 2 3 2 2

7035-201011XXXX
1 20A END-RELEASE BUCKLE ASSY (All Seat Positions) LH A/B/C/D/E/F 2 2 3 1
(7035-201031XXXX)
7035-201021XXXX
1 20B END-RELEASE BUCKLE ASSY (All Seat Positions) RH A/B/C/D/E/F 2 2 3 1
(7035-201041XXXX)
7035-2090112396 END-RELEASE BUCKLE ASSY (AUX CHILD SEAT BUCKLE – REAR
- -20C C/D 1 1 1
(7035-2170312396) SEAT) (LH)
7035-2100212396 END-RELEASE BUCKLE ASSY (AUX CHILD SEAT BUCKLE – REAR
- -20D C/D 1 1 1
(7035-2180412396) SEAT) (RH)
7035-2190112396 END-RELEASE BUCKLE ASSY (AUX CHILD SEAT BUCKLE – MIDDLE
- -20E E/F 1 1
(7035-2200312396) SEAT) (LH)
7035-2190212396 END-RELEASE BUCKLE ASSY (AUX CHILD SEAT BUCKLE – MIDDLE
- -20F E/F 1 1
(7035-2200412396) SEAT) (RH)

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Qty per System

Pilot-Co-Pilot
172 Aircraft

182 Aircraft

206 Aircraft

206 Aircraft

206 Aircraft
Middle Seat
Part Number

Only

Only
Item Part Description
Fig. No. (XXXX – Color Used On
No. (For Installation Kits Parts Breakdown, refer to Chart on Page 5)
Code)

1 30A 508792-401 INFLATOR ASSEMBLY, (Co-Pilot and Middle Seats, 0) A/B/E/F 1 1 3 1 2

1 30B 508794-401 INFLATOR ASSEMBLY (Pilot and Rear Seats, 90) C/D 3 3 3 1

2 31 508531-1 SHIPPING CAP, ROI-V2 A/B/C/D/E/F 4 4 6 2

1 40A 508976-201 CABLE INTERFACE ASSEMBLY – Pilot and Co-Pilot Seat A/B 1 1
CABLE INTERFACE ASSEMBLY – Pilot to Middle Seat LH and Co-Pilot to
1 40B 508976-203 A/B/E/F 2 1 1
Middle Seat RH
1 40C 508976-205 CABLE INTERFACE ASSEMBLY – Rear Seat, LH and RH C/D 1 1 1

- -41 508346-1 TRACK, CONNECTOR A/B/C/D/E/F 1 1 1 1 1

1 50A 508358-409 ELECTRONICS MODULE ASSEMBLY (For Reference Only) RF

1 50B 508358-421 ELECTRONICS MODULE ASSEMBLY A/B/C/D/E/F 2 2 3 1 1

3 60 508668-201 V23 SYSTEM DIAGNOSTIC TOOL A/B/C/D/E/F A/R A/R A/R A/R A/R

- 70 509121-1 AIRBAG EQUIPPED LABEL A/B/C/D/E/F 2 2 2 2 2

- Item not shown

*7035- part number in parenthesis indicates Brazilian STC alternate for these assemblies.
RF – indicates reference only

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SUPPLEMENTAL INSTRUCTIONS FOR CONTINUED AIRWORTHINESS E508804

MAINTENANCE AND INSPECTION

Maintenance

No other maintenance is required other than an annual inspection and functional testing of the system.

System Functional Testing

WARNING: IF THE AMSAFE SEATBELT AIRBAG SYSTEM IS NOT ELECTRICALLY

FUNCTIONAL, ENHANCED OCCUPANT PROTECTION PROVIDED BY THE AMSAFE
SEATBELT AIRBAG SYSTEM WILL NOT OCCUR.

Other than annually, a system functional test is to be performed when components are
disconnected/reconnected, removed and replaced and when aircraft receives a post-incident inspection
as defined in 14CFR Part 830.2 (see Appendix A). This is the only means by which system functionality
can be checked. If, upon disconnecting and reconnecting the system (such as when removing a seat), a
system functional test cannot be performed immediately, perform a system functional test at the earliest
opportunity.

To perform a functional test for the AmSafe Seatbelt Airbag V23 System, use the V23 System Diagnostic
Tool. For complete instructions on the use of the V23 System Diagnostic Tool, please refer to the V23
SDT Operation and Maintenance Manual, E508750.

NOTE: IT IS REQUIRED, AFTER COMPLETION OF FUNCTIONAL TESTING, TO DOCUMENT THIS

TASK AS AN ENTRY IN THE AIRCRAFT’S LOGBOOK.

Post-Incident Aircraft Documentation Process

The documentation process for the repair facility is as follows (see Appendix A for Inspection Checklist):

1. The repair facility will do a complete inspection of the aircraft as defined by AmSafe maintenance
documentation
2. Any discrepancies will be noted and the work order line items will be defined for completion of the
aircraft repair.
3. All maintenance/repairs must be accomplished per FAA AC 43.13b.
4. Once maintenance/repair is completed and the work order is closed, manufacturer
checklist/maintenance documentation is filed with the closed Work Order and must be kept on file
for a period of three (3) years.
5. An entry is required to be made in the aircraft logbook stating that the maintenance action for
specific items/systems was performed “per AmSafe Supplemental Instructions for Continued
Airworthiness, Document No. E508804, Section - Maintenance and Inspection.”

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SUPPLEMENTAL INSTRUCTIONS FOR CONTINUED AIRWORTHINESS E508804

Inspection

A detailed visual inspection should be performed at a minimum of once annually.

Check Inflatable Restraint System Replace belt assembly if any of the following are observed:
Assembly for:  Frayed webbing is defined as broken filaments either the
 Cut or worn edges warp (longitudinal) yarns or the filler (transverse) yarns.
 Damaged stitching The number of broken filaments should not be sufficient to
 Broken fabric threads obscure the identity of any yarn when viewed from a
 Holes or tears distance of about 8 inches.
 Excessive chafe marks  Any fabric is cut or torn from the edge.
 Excessive wear  The amount of fray exceeds 10% of the width of the
 Excessive fraying webbing and exceeds 8 inches in length.
 Holes in airbag cover or tear-away seam  Webbing with more than 15 broken yarns in locations
other than the edge.
Note: Slight wear of the webbing or airbag Webbing that is frayed or distorted sufficiently to cause
cover is permitted. Excessive web wear that improper operation of any portion of the restraint system.
has progressed to cut or worn edges of .25
inches or more should be replaced.
Excessive airbag cover wear that has
progressed to cut or worn edges of .25 inches
or more should be replaced.
Check seat belt hardware (end fittings, buckle, If any cracks are visible on the seat hardware, the assembly
connector) for: should be replaced. Dents or corrosion on the metal
 Cracks components must not affect the functional operation of any
 Dents parts. Replace assembly if operation is affected.
 Corrosion
Check exposed hoses and cables for: Hose wear is acceptable as long as no holes are present. If
 Fraying any exposed hoses or cables show significant signs of
 Excessive wear of hose and cable fraying or excessive wear such as holes, the assembly
protective sleeving should be replaced. Excessive wear of outer hose sleeve is
 Tears acceptable as long as no holes are present.
Check Cable Interface Assembly for:
 Secure connections and connectors
Check Inflator Assembly for:
 Loose mounting hardware
 Cracks or deformation of mounting brackets
 Loose Hose connection
 Unsecured electrical connections
Check EMA for:
 Loose connections
 Loose mounting hardware and cracks or deformation
 EMA housing cracks

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Cleaning

It is recommended that AmSafe Seatbelt Airbag system components be cleaned on a regular (annual)
basis. Build-up of dirt and debris could interfere with system operation, shorten the life of the system, and
cause corrosion of metal parts. Surface clean the belt assembly, hoses, cables, inflator assembly, and
EMA.

NOTE: EQUIVALENT ALTERNATIVES ARE PERMITTED FOR THE EQUIPMENT AND

MATERIALS IN THIS LIST.

Qty Description Part Number

AR Warm water in a spill-resistant container Standard Issue
AR Soft lint-free washing cloth Standard Issue
AR Sponge or soft brush Standard Issue
AR Mild soap Standard Issue (household dishwater
liquid soap, household laundry detergent)
AR Leather Cleaner and Conditioner Townsend Leather
(refer to Cessna maintenance manual for 4549 Townsend Ave.
same product used on aircraft seats) Johnstown, NY 12095
AR Isopropyl Alcohol Standard Issue

WARNING: DO NOT SOAK PARTS TO BE CLEANED WITH EITHER WATER SOLUTION OR

ISOPROPYL ALCOHOL. DOING SO MAY DAMAGE THE AMSAFE SEATBELT
AIRBAG SYSTEM.

CAUTION: THE BELT ASSEMBLY MUST NOT BE DRY CLEANED OR IMMERSED IN WATER.

CAUTION: AVOID EXCESSIVE USE OF WATER WHEN CLEANING. MOISTURE MAY DAMAGE
INTERNAL COMPONENTS AND CAUSE COMPONENT FAILURE.

CAUTION: WHEN CLEANING THE AMSAFE SEATBELT AIRBAG SYSTEM, CARE MUST BE
TAKEN TO KEEP FOREIGN MATTER AND CLEANING MEDIA AWAY FROM THE
HARDWARE ASSEMBLIES.

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

CAUTION: WHEN USING ISOPROPYL ALCOHOL, AVOID ANY CONTACT WITH THE WEBBING,
AIRBAG COVER, OR GAS HOSE MATERIAL.

When cleaning non-metallic parts (except airbag cover), use warm water and household soap/laundry
detergent. Care should be taken to use only enough cleaning agent to produce minimal suds. Apply
cleaning solution with a damp (wrung-out) washing cloth. Do not leave residue on cleaned areas. Rinse,
if necessary, with clear water on a damp (wrung-out) washing cloth. Hand-wash the webbing and gas
hose. Gentle scrubbing with a soft brush and cold soapy solution is permissible. Air dry the belt
assembly. Do not dry the belt assembly in sunlight or near any source of heat.

Hand wash airbag cover with mild solution of leather cleaning soap and clear, lukewarm water. Apply by
dipping a clean white cloth or sponge into soapy water, wring excess water and wipe. Always check for
colorfastness in an inconspicuous part before applying soapy cleaning solution. DO NOT SOAK leather
cover with soapy solution. It is recommended that conditioner be used – following manufacturer’s
directions. Condition leather airbag cover after clean and dry. If leather cover is not conditioned, it will
crack and dry. Follow manufacturer’s instructions for leather conditioner.

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If necessary, clean the airbag hardware with a lint-free cloth moistened with isopropyl alcohol.

If cleaning of the EMA is required, cover cable opening into the EMA with pieces of cloth.

Hand-wash the Inflator and cables with a lint-free cloth moistened with a cold water/mild soap solution.

STORAGE OF SPARES

Inflator Assembly

NOTE: THE AMSAFE SEATBELT AIRBAG SYSTEM INFLATOR MUST BE HANDLED AND STORED
BY A PERSON TRAINED IN THE REQUIREMENTS ASSOCIATED WITH DANGEROUS
GOODS.

Store the Inflator in a cool and dry environment. Acceptable temperature range is -22 to +131°F (-30° to
+55°C). The Inflator should be protected from sunlight, dust, moisture, and other contamination. The
Inflator must be protected from excessive EMI/RFI/ESD environments. Observe all local storage
regulations.

The maximum continuous storage time for the Inflator is 10 years from date of manufacture, after which
the Inflator should be returned to AmSafe for disposal. The inflator must be renewed after a continuous
storage period of ten (10) years from date of manufacture. The actual maximum storage time of the gas
storage container and the internal squib of the Inflator Assembly is in excess of 10 years, allowing a factor
of safety for excess storage time and shipment.

Electronics Module Assembly (EMA)

Store the EMA in a cool and dry environment. Acceptable temperature range is -22 to +131°F (-30° to
+55°C). The EMA should be protected from sunlight, dust, moisture, and other contamination. The EMA
must be protected from excessive EMI/RFI/ESD environments.

The maximum continuous storage time for the EMA is 14 years from date of manufacture, after which the
EMA should be discarded. An EMA must be renewed after a period of seven (7) years from date of
manufacture and must be returned to AmSafe for refurbishment.

Inflatable Restraint System Assembly

Store the Inflatable Restraint System Assembly in a cool and dry environment. Acceptable temperature
range is -22 to +131°F (-30° to +55°C). The Inflatable Restraint System Assembly should be protected
from sunlight, dust, moisture, and other contamination.

REMOVAL AND REPLACEMENT

These maintenance instructions provide the necessary detail to remove and replace the AmSafe Seatbelt
Airbag V23 System.

WARNING: WHEN REMOVING A SEAT FROM THE AIRCRAFT, VERIFY THAT THE SEATBELT
AIRBAG SYSTEM RESTRAINT IS NOT BUCKLED AND DISCONNECT CABLE
INTERFACE ASSY FROM THE END-RELEASE BUCKLE ASSEMBLY INFLATABLE
RESTRAINT SYSTEM ASSEMBLY CONNECTOR BEFORE REMOVAL OF THE SEAT.
AN ELECTRICALLY CONNECTED AMSAFE SEATBELT AIRBAG RESTRAINT
SYSTEM AND BUCKLED SEAT BELT MAY RESULT IN DAMAGE TO THE
EQUIPMENT OR DEPLOYMENT OF THE SYSTEM.

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WARNING: THE INFLATOR ASSEMBLY IS A STORED, GAS/ENERGETIC MATERIAL DEVICE.

SEVERE PERSONAL INJURY OR BODILY HARM MAY BE CAUSED BY MISUSE
AND/OR TAMPERING. DO NOT TAMPER WITH OR MISHANDLE THE PRODUCT IN
ANY WAY. NEVER ATTEMPT TO OPEN THE INFLATOR TO SERVICE THE
INFLATOR SYSTEM. NEVER APPLY ELECTRICAL CURRENT TO THE
ELECTRONICS CONNECTION.

CAUTION: DO NOT DROP OR MISHANDLE THE ELECTRONICS MODULE ASSEMBLY (EMA).

DAMAGE TO THE ELECTRONICS, BATTERY, OR SENSOR MAY OCCUR. IF THE
EMA IS DROPPED OR DAMAGED THERE IS POTENTIAL FOR AN ANOMALY, SUCH
AS NOT FUNCTIONING AS INTENDED OR DESIGNED. A DAMAGED OR
MISHANDLED EMA COULD BE INJURIOUS TO MAINTENANCE PERSONNEL OR
PASSENGERS IF INSTALLED ON THE SEAT. IF DAMAGE OR MISHANDLING IS
SUSPECTED, DO NOT INSTALL THE EMA, RETURN TO AMSAFE FOR
REPLACEMENT. REFER TO RMA PROCEDURES IN SECTION 15000 FOR EMA
SHIPPING INFORMATION.

CAUTION: IF SEATBELT AIRBAG REPLACEMENT IS NOT IMMEDIATELY POSSIBLE, COVER

INFLATOR NOZZLE TO PROTECT FROM DEBRIS.

Equipment and Materials Required

The following items are required to remove the AmSafe Seatbelt Airbag System.

Description Part Number

Repairman Tool Kit Standard Issue
Safety Glasses Standard Issue
Screwdriver Bit Set, Hex Drive Standard Issue
Torque Wrenches, In. Lb. Type to Standard Issue
accommodate 5 to 130 In. Lbs of torque
Thread Locking Compound, Loctite 242 Loctite Corporation
1-800-LOCTITE (562-8483)

The following table identifies the appropriate torque value, tool, and tool size to use for attaching
hardware.
Table 1 - Torque Values and Tool Sizes

Associated Torque - In.

Callout/Figure Part Description Tool and Size
Subassembly Lbs.
Torque Wrench,
31 Inflator Shipping Cap Inflator Assembly 5 +/- 10
In. Lb type
Inflatable Restraint
System Torque Wrench,
Figure 4 Hose Connection to Inflator 110 +/-130
Assembly/Inflator In. Lb type
Assembly

Refer to Figures 1, 2, and 3 in the INTRODUCTION Section or refer to parts list for referenced callouts
unless noted.

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In Removal and Replacement section text when prompted, refer to the latest revision of the following
Cessna AmSafe Seatbelt Airbag System Installation Drawings for details regarding seat attachment
details, EMA Installation Brackets detail, or Inflator Assembly Installation Brackets details:

0519092 Inflatable Restraint Instl – AMSAFE (Model 172)

0719092 Inflatable Restraint Instl – AMSAFE (Model 182)
1219115 Inflatable Restraint Instl – AMSAFE (Model 206)

Removal

CAUTION: VERIFY AMSAFE SEATBELT AIRBAG SYSTEM IS UNBUCKLED BEFORE ANY

REMOVAL/REPLACEMENT OF SYSTEM COMPONENTS.

1. Access Inflatable Restraint System Assembly connector(s) (yellow) to Cable Interface Assy and
disconnect by sliding the Red Locking Tab (
2.
Figure 7) backwards to the unlocked position, depressing the Yellow Tab, and then pulling apart both
connector halves.
3. Remove squib connector from the Inflator (40) by squeezing both sides of the connector and gently
pulling away from the Inflator (Figure 5).

Squib Connector

Inflator Hose Connector

Figure 5 – Electrical and Hose Connectors of Inflator Assembly

CAUTION: IF REPLACEMENT OF THREE-POINT AIRBAG BELT IS NOT IMMEDIATELY

POSSIBLE, COVER INFLATOR HOSE CONNECTOR TO PROTECT FROM DEBRIS.

4. Disconnect the gas hose(s) from the Inflator Assy(s). The gas hose barb is Loctite coated which
makes it a very secure fit. Use a second back-off wrench for loosening fitting. DO NOT damage
crimp end of gas hose if using vise grips.

5. Loosen the Inflator Assembly (40) from its mounting hardware (refer to model-specific Cessna
AmSafe Seatbelt Airbag System installation drawing for specifics on attaching hardware for Inflator
Assembly).

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6. Remove the Inflator Assy(s) from mounting brackets.

7. After removal of Inflator(s), replace Shipping Cap(s) in the hose connector fitting. See Table 1 for
torque value.

8. Remove inertia reel(s) (Three-Point Airbag Belt) from aircraft structure mounting point and seatbelt
from seat mounting point (refer to model-specific Cessna AmSafe Seatbelt Airbag System installation
drawing).

9. Remove End-Release Buckle Assy(s) housing from seat or aircraft structure mounting point (refer to
model-specific Cessna AmSafe Seatbelt Airbag System installation drawing).

10. Disconnect the Cable Interface Assembly from the EMA (Figure 6) by depressing locking
mechanism releasing connector halves.

Inflatable
Restraint System
Assembly
Connectors

EMA
Connector

Diagnostics
Cable Interface Assembly Connector

Figure 6 – Cable Interface Assembly

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Red Locking Tab – Yellow Red Locking Tab – Yellow

Unlocked Position Tab Locked Position Tab

Figure 7 – Inflatable Restraint System Assembly Connector

11. Remove Cable Interface Assembly.

12. Remove EMA from mounting hardware (refer to Cessna’s Installation drawings).

Replacement
Replace all AmSafe Seatbelt Airbag System components with same part number as that of removed
assembly (refer to model-specific Cessna AmSafe Seatbelt Airbag System installation drawing or SICA
Parts List).

1. Before replacing new Inflator(s) Assy(s), unscrew the Shipping Cap (31) from the Inflator hose
fitting (Figure 2). Do not discard Shipping Cap. It is used for shipping the Inflator Assy.

2. Insert prepared Inflator Assy(s) into mounting brackets. Do not secure in mounting bracket at this
time.

3. Remove the end cap plug (if new Inflatable Restraint System Assembly) from Three-Point Airbag
Belt(s) gas hose and discard. DO NOT REMOVE Safety Cable Tie (11) for airbag connector tongue
at this time.

CAUTION: CHECK ORIENTATION OF THREE-POINT SEATBELT

AIRBAG BELT(S) BEFORE I NSERTING
GAS HOSE INTO INFLATOR. GAS HOSE SHOULD BE
PROTRUDING ON TOP OF SEATBELT
ATTACHMENT HARDWARE. AIRBAG COVER MUST
PRESENT AWAY FROM OCCUPANT (LABEL
ORIENTATION IS ON INSIDE TOWARDS
OCCUPANT).
NOTE: APPLY A THIN, EVEN COAT OF LOCTITE 242 THREAD LOCKING COMPOUND ON THE
HOSE BARB THREADS BEFORE ATTACHING TO INFLATOR ASSY.

4. Connect gas hose from Three-Point Airbag Belt(s) to Inflator(s) using required in/lbs torque. See
Table 1 for torque value. The Inflator(s) hose connector fitting (Figure 5) is a pressure fitting which
must be fully seated (fitting fully extended) onto the gas hose barb for an air-tight fit.

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5. Attach Squib Connector(s) (Figure 5) to Inflator(s). Orient connector as shown in Figure 5 and seat
into inflator until it locks in place.

6. Secure the Inflator Assy(s) within its original position on the mounting hardware. NOTE: Do not
damage any portion of TRW serial number on Inflator when mounting.

7. Insert EMA into mounting hardware and secure. EMA (50B) requires different mounting bracket from
EMA (50A). Consult model-specific Cessna AmSafe Seatbelt Airbag System installation drawing and
Service Center regarding installation of new EMA mounting bracket. The arrow on the EMA label
should face aircraft forward (see Figure 8). Connect EMA to Cable Interface Assy’s EMA
connector. The connectors are keyed. Align connector halves and seat fully until they lock.

Aircraft
Forward

EMA Pigtail toward rear of

aircraft

Directional Label on Side of EMA

Figure 8 – Typical EMA Aircraft Forward Installation

8. Connect End-Release Buckle Assembly to aircraft structure or seat mounting point (refer to model-
specific Cessna AmSafe Seatbelt Airbag System installation drawing).

9. Connect Cable Interface Assy’s connector(s) to Inflatable Restraint System Assembly connector(s).
Connect mated halves together in proper orientation and slide Red Locking Tab forward to locking
position.

10. Secure Three-Point Airbag Belt(s) inertia reel to aircraft structure. Secure lapbelt to seat mounting
point (refer to model-specific Cessna AmSafe Seatbelt Airbag System installation drawing).

11. Remove Safety Cable Tie from airbag buckle tongue before performing functional testing.

12. Perform functional test on system (refer to V23 System Diagnostic Tool - Operation and Maintenance
Manual for testing procedures).

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NOTE: IT IS REQUIRED, AFTER COMPLETION OF FUNCTIONAL TESTING, TO DOCUMENT THIS

TASK AS AN ENTRY IN THE AIRCRAFT’S LOGBOOK.

AIRWORTHINESS LIMITATIONS

The Airworthiness Limitations section is FAA approved and specifies maintenance required under
§§43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA
approved.
Continued or renewed airworthiness of the AmSafe Seatbelt Airbag System is to be determined by means
of an inspection and may only be performed by the manufacturer or by agencies specially approved by
the aviation authorities.

Inspection Intervals
Concurrently with the airworthiness inspection of the aircraft.
Concurrently with any unscheduled inspection of aircraft involved in an accident/incident, as defined by
14CFR Part 830.2, under the deployment threshold of the AmSafe Seatbelt Airbag System (also see
Appendix A).
When the equipment has sustained damage.
When the equipment has been over-stressed or if over-stress is suspected.
Upon expiration of the storage/service life as defined in the following sections.

Inoperable AmSafe Seatbelt Airbag System

System inoperable status is determined by;
 cable or component out of place while aircraft is in service.
 system diagnostic check determines operable or inoperable seat position(s).
 seatbelt airbag has a large tear in airbag cover or buckle/belt is non-functioning.

Condemnation
The EMA is to be removed for disposal after:
 a maximum storage period of fourteen (14) years calculated from the month of manufacture,
or;
 upon expiration of the service life defined as the total sum of storage life and installation life,
which must not exceed fourteen (14) years calculated from the month of manufacture.

Upon expiration of the service life (total life), the EMA cannot be renewed.

The Inflator Assembly is to be removed and returned to AmSafe for disposal after:
 a maximum storage period of ten (10) years calculated from the month of manufacture as
indicated in the expiration date stamped on the gas cylinder, or;
 upon expiration of the service life defined as the total sum of storage life and installation life,
which must not exceed ten (10) years calculated from the month of manufacture as indicated
in the expiration date stamped on the gas cylinder,.

Upon expiration of the service life (total life), the Inflator Assembly cannot be renewed.

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Renewal
The EMA is to be removed and returned to AmSafe for refurbishment after:
 a maximum storage period of seven (7) years calculated from the month of manufacture.
 a maximum service period of seven (7) years calculated from the month of manufacture.
The EMA can only be renewed by the manufacturer.
Upon expiration of the service life (total life), the Inflator Assembly cannot be renewed.

WARRANTY AND RETURN INFORMATION

Warranty

Seller warrants to Buyer AmSafe Seatbelt Airbags subject to this Agreement shall be free from defects in
workmanship or material and shall conform to Seller’s specifications as set forth in its Declaration of
Design and Performance or in the Seat Qualification Statement, or equivalent document, which are
acknowledged by buyer and incorporated herein by this reference as if fully set forth below.

All claims for defective AmSafe Seatbelt Airbag system units must be presented to Seller, in writing,
within three (3) years after date of manufacture of a defective part; provided, however, in the event of
defective webbing, claims must be presented to Seller, in writing, within one (1) year of installation of
webbing on AmSafe Seatbelt Airbag system. Disassembly of any part of the Inflatable Restraint System
Assembly, EMA, Inflator Assy, Cable Interface Assy/Inflator Interface Cable, or the System Diagnostic
Tool, unless specified by AmSafe maintenance manual, Service Letter, or Service Bulletin, voids the
warranty on that component.

Returning AmSafe Seatbelt Airbag System Components and RMA Procedures

AmSafe Seatbelt Airbag system components must be routed to AmSafe to ensure they are tested and
repaired by qualified repair technicians and returned to service by a licensed repairperson. The RMA
process described in the following paragraphs must be followed.

RMA Procedures

For Return Material Authorization (RMA) number, contact a Customer Service Sales Analyst at:
(602) 850-2850 or by email at customerservice@amsafe.com.

Identify customer’s name, location, contact person, and phone number. Request a Return Material
Authorization number (RMA) for either an AmSafe Seatbelt Airbag system repair/replacement component,
calibration check, or for re-calibration of the AmSafe Seatbelt Airbag System Diagnostic Tool.

Mark and identify RMA number on the package label. Mailing address will be provided by customer
service at time of contact for either AmSafe Seatbelt Airbag system component and/or System Diagnostic
Tool.

Packaging and Shipping Requirements – Inflator Assembly

WARNING: FAILURE TO COMPLY WITH ALL RELEVANT DANGEROUS GOODS REGULATIONS

REGARDING THE INFLATION DEVICE MAY RESULT IN CIVIL OR CRIMINAL
PENALTIES.
Use the original packaging material in which the inflation device was received, when it is in a serviceable
condition. The inflation device must be shipped in an AmSafe container which is DOT approved having
been UN tested and marked under UN Performance Oriented Packing (POP). A new AmSafe UN POP
container may be requested in the RMA process.

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The Shipping Cap to the Inflator Hose Connector fitting must be attached for shipping. See Removal and
Replacement section for complete information.

Use only AmSafe UN POP shipping container.

The exterior container shall be labeled durably and legibly to show at least:

 All appropriate hazmat labels per Title 49 CFR Section 172.400.

 All appropriate labels required by country of shipping origin.
 When shipping by air, use cargo plane only label

The exterior container shall be marked durably and legibly to show at least:

 All appropriate hazmat markings per Title 49 CFR Section 172.300.

 All appropriate markings required by country of shipping origin.

Markings such as RMA number and ship-to/from addresses shall be placed to avoid loss or obstruction
during opening and closing of the container.

Any person performing shipping functions for the inflation device must be trained in accordance with the
requirements contained in Title 49 CFR Section 172.700.

All local and relevant international handling, shipping, transporting regulations must be followed.

For shipment by air, the inflation device is to be shipped by cargo plane only. AmSafe’s preferred carriers
for shipment of the inflation device are FedEx and Emery Air Freight.

Ship the component to AmSafe address as stated in previous RMA Procedures section.

Packaging and Shipping Requirements – AmSafe Seatbelt Airbag System Components except the
Inflator Assembly

Use the packaging material in which the AmSafe Seatbelt Airbag System was received, when it is in a
serviceable condition. If not serviceable, new materials of the same quality and size shall be used.

“Peanut” type foam materials should not be used for dunnage as it tends to migrate in the container,
causing the item to shift which can cause shipping damage. Use a minimum of three inches of
cushioning material to prevent movement of the item within the container.

Place the RMA number and ship-to/from addresses to prevent loss or obstruction during opening and
closing of the container.

REFERENCE PUBLICATIONS

V23 System Diagnostic Tool - Operation and Maintenance Manual, AmSafe Document No. E508750.

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APPENDIX A – AMSAFE SEATBELT AIRBAG SYSTEM POST-INCIDENT INSPECTION

CHECKLIST

Background: AmSafe has defined the following procedure for managing the AmSafe Seatbelt Airbag
system evaluation for aircraft involved in accidents/incidents under the deployment threshold of the
AmSafe Seatbelt Airbag System.

Procedure Defined: When an aircraft is involved in an accident or incident as defined in 14CFR Part
830.2, the following evaluation is necessary to validate the integrity of the AmSafe Seatbelt Airbag system
installation. These items may be done while the aircraft damage is evaluated for the necessary repair(s).
A confirmation of the successfully completed evaluation and diagnostic check must be performed prior to
the aircraft re-entering service.

1. Inspect EMA Bracket for cracks or deformation

2. Inspect EMA for cracks
3. Inspect EMA attachment location for damage
4. Inspect Inflator installation and confirm attach brackets are still secure
5. Run System Diagnostic
6. Sign & Date Validation Checklist items when ALL criteria are determined to be acceptable and
return to AmSafe for record keeping.

If the EMA mounting, EMA housing or system diagnostic do not meet ALL the criteria for acceptability
noted above, it will be necessary for the EMA to be replaced as part of the aircraft repair. For Return
Material Authorization (RMA) procedure, see section RMA procedures section of this document.

AmSafe Seatbelt Airbag System Validation Checklist

AmSafe Seatbelt Airbag Installation Validation Status Technician Date

Requirements (OK or NG)
1) Inspect EMA Bracket
2) Inspect EMA
3) Inspect EMA attachment location
4) Inspect Inflator attachment bracket
5) Run AmSafe Seatbelt Airbag System
Diagnostic

NOTE: IT IS REQUIRED, AFTER COMPLETION OF FUNCTIONAL TESTING, TO DOCUMENT THIS

TASK AS AN ENTRY IN THE AIRCRAFT’S LOGBOOK.

Aircraft ‘N’ Number: ___________________________

AmSafe EMA S/N: ___________________________

Repair Facility Address and Contact Information:

____________________________________________
____________________________________________
____________________________________________
____________________________________________
____________________________________________

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