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Iveco Daily. Manual - part 423

218

ELECTRIC/ELECTRONIC SYSTEM

AILY

Base - May 2004

fitted with the air bag system supplied to us by the supplier.

Preliminary rules

Before starting any body repair work, welding, work requiring

the removal of air bags or of the control unit, it is necessary

to:
- move the ignition key to STOP" and remove it
- always disconnect the battery, i.e.: disconnect the two

terminals from their post and isolate them taping

appropriately

- wait for at least 10 minutes before proceeding
- disconnect the control unit connector.
Store the modules with the cover upwards in a key-lockable

metal cabinet. The cabinet, to be used for this purpose only,

must not be used for storing other types of material, especially

if inflammable.
All the connectors used and wired on air bag modules contain

a short circuit clip. Up to the moment in which the air bag

modules are connected to an appropriate source of energy,

there is no possibility of undue activation of the units.
A system component not activated during an accident is to

be considered still active".
Therefore, undeployed components to be removed from

vehicles (due to faults, guarantee expiry or other causes) must

be returned to the special centre through the procedure

described below.

All the system components have been specifically designed

to work on vehicles of a specific brand and type. Therefore,

air bags cannot be adapted, re-used or installed on other

vehicles than the one for which they have been designed and

manufactured.

The following rules must absolutely be followed

when doing any work concerning vehicles fitted with

safety system with air bag.

Remember that air bag modules are devices to be

handled with care. Their use, transport and storage

are ruled by the following procedures.

The assembly or disassembly of components may

ONLY be carried out by competent and authorised

personnel.

The failure to follow the instructions given below may

involve unwanted activation of the system, personal

injury or unnecessary system repair. IT IS STRICTLY

PROHIBITED TO DISASSEMBLE AIR BAG

MODULES STRIPPING THEIR COMPONENTS.

NOTE

Any attempt to re-use, adapt or install them on a

different type of vehicle may cause serious or lethal

harm to the occupants of the vehicle in the event of

a crash.

NOTE

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Operations after an accident

Accidents with or without deployment of the air bag device
Some system components should be inspected whether the

system has been activated or not. These components are:
- steering column;
- steering column support;
- electronic control unit and modules retaining area;
- clock spring;
- dashboard (in the passenger's air bag area).
The component must be replaced in the presence of

distortion, breakage and flexure.
Accidents with the deployment of the air bag device
If the vehicle has undergone a head-on crash involving the

total deployment of the system, the following components

must be replaced:
- air bag modules;
- pretensioners;
- electronic control unit;
- clock spring.
The harness and connectors should be inspected for signs of

burns, melting of the outer insulation or damage due to

excessive heat.
Any signs of damage on the clock spring in the control unit

retaining area and on the air bag modules call for the

replacement of the damaged components.

Painting work

No particular rules of safety are to be followed for painting

work followed by oven drying, as the modules and

pretensioners have been designed in such a way that they will

not be damaged heating the outer surfaces of the vehicle

with normal paint drying systems.
It is prohibited to use naked flames near the modules.
All electronic control units (including the air bag system)

should always be removed if their temperature in certain

environments may reach or exceed 85 °C.

Health hazards

The precautions to be taken when handling deployed air

bags are the following:
- use protective polyethylene gloves and safety goggles;
- after touching triggered air bags, wash your hands and

the parts of the body exposed with soap and water.

Effects of over-exposure

There is no potential hazard of exposure to the propellants

as the system is completely sealed.
The propellant mixture is in the solid state, therefore

inhalation is impossible even in the event of breakage of the

gas generator cartridge.
Should any gas come out there is not health hazard.
Avoid any contact with the skin and do not swallow the

propellant.
In the event of:
- contact with the skin wash immediately with soap and

water;

- contact with the eyes: wash immediately with running

water for at least 15 minutes;

- inhalation: take the person outdoors immediately;
- swallowing: induce vomit if the person is conscious.

If any component of the safety system is damaged

following an accident, it should be replaced.

Do not attempt to repair the control unit, clock

spring or air bag modules.

NOTE

Always call a doctor for all the above conditions.

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Base - May 2004

Under normal conditions the driver's and passenger's air bag

are activated by the electronic triggering device during the

crash. The gas developed (mainly nitrogen) under these

conditions is not harmful.
Personnel carrying out operations on the device fitted on

vehicles must absolutely adhere to the rules of safety given

below.
Personnel operating on these devices must be suitably trained

and follow the precautions given below:
- In open (exploded) air bag removal and replacement

operations handle only one air bag at a time and for

removal use polyethylene gloves and protective goggles.

- Always rest the air bag module with the opening lid and

pre-split groove facing upwards. Do not put anything on

top of this lid.

- Afterwards wash your hands carefully with neutral soap

and in the event of contact with the eyes of residual

powder, rinse immediately with running water.

- Before starting work on the system, disconnect the two

battery cables (firstly the negative one) isolate the

terminals with insulating tape and wait at least 10 minutes

before proceeding.

- The metal components of an air bag that has just been

deployed are very hot. Avoid touching these

components for 20 minutes from the time of air bag

deployment.

- Do not carry out repairs on air bag modules. Send all

faulty modules to the supplier. Do not heat the air bag

module for example by welding, hammering, drilling,

mechanical machining etc.

- Never install on the vehicle air bags that have been

dropped or show signs of any type of damage.

- It is prohibited to keep air bags together with inflammable

material or fuel.

- The gas generators must not come into contact with

acids, greases and heavy metals. Contact with these

substances may cause the formation of poisonous,

harmful gas or explosive compounds.

- Never use naked flames near air bag devices and system

components.

Any spare parts should be stored in their original packing and

temporary storage should follow the same procedure as for

an undeployed air bag removed from the vehicle, i.e. a

key-lockable metal cabinet must be used, especially for this

purpose (metal, shock resistant cabinet with grilles to allow

natural ventilation inside). The cabinet must have special

warning notices (DANGER EXPLOSIVES - NO NAKED

FLAMES - NOT TO BE OPENED BY UNAUTHORISED

PERSONS).

Air bag module scrapping

The air bag modules fitted on the vehicle must not be

scrapped with the vehicle itself, but removed beforehand and

then deployed as described in the following pages.
Air bag units must not be scrapped without firstly deploying

them.
If the air bag module has not been activated during a crash,

the device is to be considered as still charged.
All unexploded material MUST NOT BE ACTIVATED and

should be sent to a specialised centre with the following

wording on the delivery note:
- AIR BAG DEVICE CONTAINING EXPLOSIVE

CHARGE TO BE DEACTIVATED

The devices must absolutely be shipped in the same package

in which the spares are received and if this is not available it

is possible to ask the SPARES division for the package only.
Clearly in the case of replacing air bag devices the original

packing should be kept intact for sending the undeployed

device.
For FOREIGN MARKETS follow local regulations.

The failure to follow the procedures listed here may

cause undue activation of the air bag units and

personal injury. Undeployed air bag units must NOT

be disposed of through the usual refuse disposal

channels. Undeployed air bag units contain harmful

substances for the health and may cause personal

injury if the sealed container which contains them is

damaged during disposal.

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Rules of safety in handling pretensioners

In the event of a head-on crash, the driver's and passenger's

pretensioners are activated an instant before the air bag

modules.
The personnel that intervenes on the devices must be suitably

trained and observe the following precautions:
- When handling activated pretensioners, i.e. when the

propellant has already been triggered, use protective

gloves and goggles.

- At the end of operations wash your hands carefully with

neutral soap and in the event of contact of residual

powder with the eyes, rinse immediately with running

water.

- Disconnect the two battery cables (firstly the negative

one) isolate the terminals with insulating tape and wait at

least 10 minutes before proceeding.

- During activation the pretensioner develops heat; it is

therefore necessary to wait at least 10 minutes after

deployment, before touching them.

- During transport or handling, pretensioners should be

protected from shocks or falling; pretensioners that have

been knocked or dropped must not be used and must be

returned to the supplier stating the reason.

- Pretensioners should not be carried by the belt.
- Pretensioners must be protected from sparks and naked

flames; they should not contact surfaces for over 6 hours

with temperatures above 100 ºC .

- The gas generator propellant that is not burnt is

inflammable, therefore, the parts of the generator should

never be taken to pieces, damaged or tampered with.

- It is prohibited to store pretensioners with inflammable

materials or fuel.

- The gas generators must not come into contact with

acids, greases and heavy metals. Contact with these

substances may cause the formation of poisonous,

harmful gas or explosive compounds.

- Belts with pretensioners may only be stored in

key-lockable places or cabinets, ventilated and away from

naked flames and sources of heat.

Scrapping pretensioners

Undeployed pretensioners (not fitted on the vehicle) to be

scrapped must firstly be deployed; those not activated but

fitted on the vehicle must be removed and not scrapped

with the vehicle.
If the pretensioner was not activated during a crash, the

device is to be considered as still active; proceed as

described i this manual.

After every crash in which the pretensioner has been

activated, the belt is unserviceable and must be

replaced.

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