Iveco Daily. Manual — part 311
Pretensioners scrapping
Non-activated pretensioners (not installed on vehicle) must
always
be
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.
20
STEERING GEAR
D
AILY
Base - May 2004
AIR-BAG MODULE REMOTE ACTIVATION DIAGRAM
8663
A
C1
Lb
B
L
C2
C2
+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
on
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
A
fenced area
B
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
21
D
AILY
Base - May 2004
8664
ABP
C1
Lb
ABG
PTG
Lb
Lb
C2
C2
C1
C2
L
+12V
A
General instructions:
- follow all WARNINGS, PRECAUTIONS and safety
instructions reported in this manual;
- bring the vehicle outside in the provided area;
- remove from the area around the Air-Bag covering all
materials and slugs (glasses, tools, components etc.) and
make sure that no inflammable liquids are nearby;
- disconnect the two battery cables (first the negative
cable) and wait for at least 10 minutes before proceeding;
- use a connecting braid (L= about 1 m) with specific
terminal connector for the electric connection with the
module to activate;
- reach the electric module connection (Air-Bag or
electronic pretensioner), following the instructions of this
manual;
- disconnect connector C1 of the pretensioner or Air-Bag
module;
- check whether connector C2 is disconnected from
remote activation device;
- connect the electric connector C1 of the pretensioner or
Air-Bag module to the connecting braid of the remote
activation device;
- connect connector C2 to remote activation device;
- place people in a safe place;
- connect the remote control device to a 12 Volts circuit
or equivalent device;
- press the double activation push-button to activate all
pretensioners and Air-Bag modules at the same time;
- after activating the Air-Bag modules and pretensioners,
leave them cooling before touching them (about 20
minutes);
- after activating the Air-Bag modules and pretensioners,
the vehicle can be scrapped - by squashing or crushing -
and/or recycled, depending on the cases.
ABG= driver Air-Bag
ABP = passenger Air-Bag
C2 = remote activation device connector
C1 = specific pyrotechnic charge connector
L
= main cable, safety distance 10 m
Lb
= braid length
PTG = driver pretensioner
A.
Remote activation device
VEHICLE PYROTECHNIC CHARGES ACTIVATION DIAGRAM, SINGLE
ACTIVATION
C2
C1
Figure 14
22
STEERING GEAR
D
AILY
Base - May 2004
62107
62108
62108
62109
Figure 15
Figure 16
Figure 17
Disconnect the battery (2) cables (1-3) first the negative cable
(1) then the positive one (3) and insulate them taping the
terminals.
For vehicles without Air-Bag, remove the pressure-fit cover
(2) on the steering wheel.
For vehicles with Air-Bag, turn the steering wheel and position
it as shown in the figure, in order to easily reach the screws (1
and 3) and remove them.
- Lift the Air-Bag module (1) in order to disconnect
connector (2);
- Remove the Air-Bag module (1) from the steering wheel
(3).
Set front wheels in straight running and mark (
→) steering
wheel assembly position (1) on upper steering gear shaft (2)
Remove the steering wheel (1) from the shaft (2).
For vehicles with Air-Bag, make sure not to extract or damage
coil device cable (3).
!
After removal, non-activated Air-Bag modules must
be stored with plate laying on the surface in a suitable
key-locked cabinet.
For all vehicles
Remove fixing nut (4).
For vehicles equipped with Air-Bag
Follow the safety standards given in the relevant chapter and
wait for 10 minutes before proceeding.
Figure 18
STEERING GEAR
23
D
AILY
541415
Upper steering gear shaft removal
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