Iveco Daily Euro 4. Manual

Inspect cables and connectors to find any burning, external
insulation melting or damages due to excessive heat.

If any faulty condition is found on coil cable, electronic control
unit anchoring area and modules, replace the faulty
component.

Painting

Since modules and pretensioners are designed to withstand
the temperatures developed during standard baking operation
on bodywork, no special safety requirement shall be observed
during painting or baking.
Do not use open flames when working near the modules.
Electronic control units (including the Air-Bag one) shall always
be removed when temperature in certain rooms is equal to or
exceeds 85

°C.

Risks for health

Precautions to be observed when handling live Air-Bag are the
following:

- wear protective polyethylene gloves and goggles;

- wash hands and any exposed body part with water and

soap after handling live modules.

Overexposure effects

Since system is completely sealed there is no potential danger
of exposure to propelling gas.
Propelling gas mixture is at solid state, it is therefore impossible
to inhale gas even in case of gas generator cartridge breakage.
There is no risk for health in case of gas leakage.
Avoid in any case contact with the skin and do not swallow the
propelling gas.
In case of:

- contact with the skin: rinse immediately with water and

soap;

- contact with eyes: rinse immediately with fresh water for

15 minutes at least;

- inhalation: bring immediately the injured person to open

air;

- swallow: make the injured person vomit if conscious.

Always call the doctor in any of the above cases.

Safety Standards to observe when handling
Air-Bag modules

Driver and passenger Air-Bags usually activate in case of
collision through the action of the electronic activation
control. Gas (mainly nitrogen) produced under these
conditions are not toxic.
Personnel operating on safety system shall strictly observe the
following safety standards.
Personnel operating on these devices shall be suitably trained
and must observe the following precautions:

- when removing or replacing activated Air-Bags, wear

protective polyethylene gloves and goggles and handle
just one module at a time;

- always place the Air-Bag module with the cover and

exhaust hole upwards. Never put something on Air-Bag
cover;

- once servicing is over rinse hands with water and neutral

soap, in case of eyes contact with residual powders rinse
immediately with fresh water;

- before starting servicing, disconnect both battery cables

(first the negative one), insulate terminals by tape and wait
at least 10 minutes before proceeding;

- metal components of the Air-Bag are hot after explosion,

avoid to touch these components for at least 20 minutes
from module activation;

- do not repair Air-Bags but send faulty modules to

supplier. Do not heat the Air-Bag module by welding,
percussion, drilling, mechanical machining, etc.;

- never install on vehicle a damaged or fall Air-Bag module;

- it is prohibited to store Air-Bag modules together with

flammable material or fuels;

- gas generators must not come into contact with acids,

greases or heavy metals since contact can result in
formation of poisonous, noxious gas or explosive
compounds;

- never use open flames when working near Air-Bag

modules or system components.

STEERING GEAR

AILY

URO

Spare parts shall be stored in their original package and
temporary storing shall follow the same procedure as for live
modules disconnected from vehicle, i.e. storage into dedicated
metallic key-locked cabinet (resistant to shocks and provided
with grids to enable natural ventilation). Cabinet shall be
provided with proper warning plates (RISK OF EXPLOSION
-

OPEN

FLAMES

OPENING

UNAUTHORISED PEOPLE).

Air-Bag module scrapping

Air-Bag modules must not be scrapped together with the
vehicle, but must be previously removed and activated as
described in the following pages.
Air-Bag units must always be activated before scrapping.
An Air-Bag module not exploded during an accident is to be
considered still ”live”.
Live materials MUST NOT BE ACTIVATED but must be sent
to a specialised centre (in Italy to GECMA in Chivasso)
specifying on the freight note:

- Air-Bag DEVICE CONTAINING PYROTECHNIC

CHARGE TO BE DEACTIVATED.

Devices must be sent using their original packages only. Should
the original package be not available, a new one shall be
requested to SPARE PARTS.
In case of Air-Bag device replacement, the original package
shall obviously be kept in good conditions to send the
non-activated device.

FOREIGN MARKETS shall observe local current laws and
regulations.

Failure to observe these procedures can result in
unintentional Air-Bag module activation and severe
injury. Live Air-Bag units must NOT be disposed of
using the common disposal procedure. Live Air-Bag
units contain substances dangerous for health that can
cause severe injury if the sealed container is damaged
during disposal.

Safety Standards to observe when handling
pretensioners

In case of front impact, driver and passenger pretensioners
usually activate just a minute before Air-Bag modules
Personnel operating on these devices shall be suitably trained
and must observe the following precautions:

- when handling activated pretensioners, i.e. with activated

propelling gas, wear protective gloves and goggles;

- once servicing is over rinse hands with water and neutral

soap, in case of eyes contact with residual powders rinse
immediately with fresh water;

- disconnect both battery cables (first the negative one),

insulate terminals by tape and wait at least 10 minutes
before proceeding;

- pretensioner produce heat during activation, it is

therefore necessary to wait at least 10 minutes before
operating;

- protect pretensioners against fall or shock during handling

or transport; damaged or fallen pretensioners must not
be used and must be returned to supplier communicating
the reason for;

- never carry pretensioners by the seat belt;

- pretensioners must be protected against sparks and open

flames and must not stay in contact with surfaces with
temperatures exceeding 100

°C for more than 6 hours;

- propelling gas not burnt is flammable, therefore

generator components must never be disassembled,
damaged or tampered;

- it is prohibited to store pretensioners together with

flammable material or fuels;

- gas generators must not come into contact with acids,

greases or heavy metals since contact can result in
formation of poisonous, noxious gas or explosive
compounds;

- seat belts with pretensioners shall be stored in proper

key-locked compartments or cabinets, suitably aerated
and away from open flames and heat sources.

STEERING GEAR

AILY

URO

Pretensioners scrapping

Non-activated pretensioners (not installed on vehicle) must
always

activated

before

scrapping.

Non-activated

pretensioners installed on vehicle must not be scrapped
together with the vehicle, but must be previously removed.
Pretensioner not activated during an accident is to be
considered still ”live” and therefore it is necessary to follow the
procedure described in this manual.

Operations on system components

Once servicing operations are completed, the system shall be
tested by Modus, I.W.T. or equivalent diagnostic equipment.
Air-Bag components are provided at installation with a label
with a removable part showing system and components date
of installation.
The removable part is detached and data are stored together
with the test report provided by Modus, by the workshop that
has installed the components.
After 10 years from installation, unless prior replacement, a new
Air-Bag system (cable and components) shall be installed. As
said above components technical data and the date of
installation will be filed.

Removing and scrapping activated Air-Bag
module and pretensioner from vehicle

Always wear gloves and goggles when handling activated
Air-Bag or pretensioner. Wash hands and exposed skin with
water and neutral soap after handling activated Air-Bag or
pretensioner. In case of exposure to secondary products, rinse
eyes immediately with fresh water. Failure to observe these
indications can result in severe injury.
To remove and scrap activated Air-Bag module and
pretensioner proceed as follows:

- follow instructions contained in this manual to remove

activated Air-Bag module and pretensioner;

- disconnect Air-Bag module and pretensioner mechanical

fixings;

- disconnect component connector form Air-Bag wiring;

- put Air-Bag module and pretensioner in the proper sealed

nylon bag;

- send to authorised collection/disposal centre;

- dispose of, recycle or scrap deployed Air-Bag module and

pretensioner using the suitable procedure.

After any impact involving pretensioner activation,
the seat belt is unserviceable and must be replaced.

Propelling gas residues shall be considered with attention.
These residues that are mostly concentrated on the generator
body or in small amount in the bag can contain copper or
chlorides (e.g. potassium chloride). Combustion residues are
very alkaline and corrosive.
Always wear skin protections and goggles. Activated Air-Bags
must always be stored in dry and well ventilated places.

Never cut the cables or tamper the connector
between vehicle wiring and Air-Bag module.
Connector contains a safety clip.

Removing

and

scrapping

non-activated

Air-Bag module from a repairable vehicle

If connector is cut or removed from Air-Bag unit, the safety clip
is disabled and this can result in unintentional activation and
severe injury.
Air-Bag systems have a backup power supply located in the
control unit. This power supply shall be deactivated by
disconnecting the two battery terminals and waiting for at least
10 minutes before starting any operation on whatever Air-Bag
component.
Keep the bag and the external bag cover in opposite direction
to body when handling a live Air-Bag module. When placing
a live Air-Bag on the bench or some surface like that, set the
bag and the cover facing upwards and far from people. Never
place objects near a live Air-Bag, since in case of module
deployment objects will be thrown away like shells.

Always store live Air-Bag modules an pretensioners
in fresh, dry, close and safe place. Do not expose to
open flames or temperatures exceeding 150

°C.

Never cut, drill, solder or weld an Air-Bag module or
its components. Failure to observe these indications
can result in unit damages, fire, unintentional
deployment and severe injury.

STEERING GEAR

AILY

URO

AIR-BAG MODULE REMOTE ACTIVATION DIAGRAM

8663

+12V

Damaged live Air-Bag modules and pretensioners (e.g. electric
connection breakage), shall be store far from corrosive or
oxidising substances. Failure to observe these indications can
result in fire and/or severe injury.

Air-Bag module deployment
Remote activation

General instructions:
- activation procedure can be performed in open area,

suitably defined and fenced, far from flammable materials,
liquids or other substances and far from people. Set the
Air-Bag module on a firm surface and lock it;

- clean this area from any material (glass, instruments, parts,

etc.) which could become like shells during deployment;

- check whether connector C2 is disconnected from

remote activation device (10 m).

- connect electric connector C1, specified by vehicle

manufacturer, to remote activation Air-Bag module;

- connect connector C2 to remote activation device;

- connect remote activation device to 12V circuit or

equivalent device;

- stand protected;

- wear goggles and protective clothes;

- depress double activation push-button;

- wait for approx. 20 minutes before touching the activated

Air-Bag module since it is hot;

- dispose of, recycle or scrap, as required, activated Air-Bag

modules as described in the relevant chapters.

Activating Air-Bag modules and electronic
pretensioners

installed

unrecoverable

vehicles

This procedure is to be used when scrapping a vehicle with one
or more live Air-Bag modules. This procedure is valid whether
Air-Bag system and/or electronic pretensioners are sound or
not.
It is recommended to activate pyrotechnic charges on vehicles
by directly connecting the electric connector of each module
to remote activation device.

Deployment procedure shall be performed outdoor,
away from people and in a well defined area. Check
for absence of objects and flammable fluids near
modules and pretensioners. Do not remain on the
vehicle during activation and remember to close the
doors. Stand protected (e.g. behind a wall, a vehicle,
etc.) against thrown-away objects, if any. Let
generators and modules cool down after deployment
(20 min. at least before proceeding). Failure to
observe these indications can result in severe injury.

C1 = Air-Bag module connector
C2 = remote activation device connector (Air-Bag

connector with safety clip, counterparts with male
pins on Air-Bag side)

Lb = braid length = approx. 1 m
L =

main cable, safety distance 10 m

fenced area

Remote activation device

Air-Bag modules and pretensioners are provided
with backup power supply giving the electrical pulse
required to bag deployment when the accident
damages the battery or the cables before the sensor
activates the gas generator.

Figure 13

STEERING GEAR

AILY

URO

Content .. 195 196 197 198 ..

Iveco Daily Euro 4. Manual - part 197