Iveco Daily. Manual — part 424

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At the end of every operation on the system, it must be

checked using Modus, I.W.T. or other diagnostic tools.
During assembly, the air bag components are labelled with a

sticker with a removable part stating the date of installation

of the system and components. The removable part is

detached and the information on it is filed together with the

system check report supplied by Modus, by the workshop that

installed the components.
After 10 years from installation, unless the components are

replaced before that time, a new air bag system (cable and

components) should be installed. As mentioned previously,

the data concerning the components and the date of system

installation are to be filed.

Removing and scrapping an activated air bag

module and pretensioner from a vehicle

Always wear gloves and safety goggles for handling an

activated air bag or pretensioner. Wash the hands and

exposed skin immediately with neutral soap and water after

handling the components of an air bag module or

pretensioner. In the case of exposure to secondary products,

immediately rinse the eyes with running water. The failure to

comply with these instructions may result in injury.
To remove and scrap an already activated air bag module and

pretensioner:
1. Follow the instructions given in this manual for removing

activated air bag module and pretensioners.

2. Disconnect the air bag module and pretensioner

mechanical fastenings.

3. Disconnect the component connector from the air bag

harness.

4. Place the air bag module and pretensioner in a special

sealed polythene bag.

5. Send to the authorised collection/disposal centre.
6. Dispose of, recycle or scrap deployed air bag modules

and pretensioners in the appropriate manner.

The residues left by combustion of the propellant require

some consideration. They are mostly concentrated in the

generator body or in small quantities in the bag. These

residues may contain copper or chloride (e.g. potassium

chloride). If the propellant is based on sodium azide or

potassium nitrate, the combustion residues are highly alkaline

and corrosive. Always wear appropriate protection for the

eyes and skin. Deployed air bags should always be stored in

dry, suitably ventilated places.

Removing or scrapping an air bag module that

has not been deployed from a reparable

vehicle

If the connector is cut or removed from the air bag unit, the

safety device is disabled and this could cause unforeseen

activation with serious consequences for the physical

integrity of people.

Air bag systems have a reserve power unit in the control unit.

This must be deactivated disconnecting the two battery

terminals and waiting for at least 10 minutes before doing any

work on any components of the air bag.

When handling an air bag module, always keep the bag and

outer cover away from the body. When positioning an active

air bag on a bench or other surface, always place the bag and

its cover upwards, not on the resting surface and away from

people. Never put any object near an active air bag as it

would become a bullet in the event of deployment.

Active, damaged air bag modules and pretensioners (e.g.

breakage of the electrical connection) must be kept away

from corrosive or oxidising substances. The failure to comply

with these instructions may cause fire, and/or serious harm

to persons.

!

Do not cut cables or tamper with the connector

between the vehicle harness and the air bag module.

The connector contains a safety circuit.

!

Always keep active, undamaged, air bag modules and

pretensioners in a cool, dry, locked and safe place.

Do not expose to naked flames or temperatures

above 150 ºC. Do not cut, drill, braze weld an air bag

module or its components with electric current.

Never expose an air bag module or pretensioner to

electric currents. The failure to comply with these

instructions may damage the unit, cause fire, cause

unforeseen deployment and serious harm to

persons.

The air bag modules and pretensioners have an

energy reserve. This decive gives the electric pulse

needed to deploy the bag if the battery or cables are

damaged during the crash before the sensor activates

the gas generator.

NOTE

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Deployment of an air bag

Remote activation
General instructions
1. The deployment procedure can be carried out in a

suitably identified and enclosed open area away from

potentially inflammable materials, fluids or other

substances and from persons. Place the air bag module on

a firm surface and clamp it closely.

2. Clean the area on which the module is placed from

materials and bits (glass, instruments, pieces, etc.) which

could be thrown out during deployment.

3. Make sure that connector C2 is disconnected from the

remote deployment device (10 m).

4. Connect the electrical connector C1 specified by the

vehicle manufacturer to the air bag module

5. Connect connector C2 to the remote deployment

device.

6. Connect the remote deployment device to a 12 V circuit

or equivalent device.

7. Make sure all persons are under shelter.
8. Wear accident prevention goggles and protective

clothing.

9. Press the double deployment button
10. After deploying an air bag module, let it cool before

touching it (about 20 min.).

11. Dispose of, recycle or scrap activated air bag modules

according to the cases, as described in the corresponding

chapters.

REMOTE DEPLOYMENT OF AIR BAG MODULES

C1 = air bag module connector

C2 = Connector to remote deployment device

(connector for air bag with circuit clip; counterparts with

male pins on air bag side)

Lb = bridle length - approx. 1 m

L = general cable, safety distance 10 m
A. Enclosed area

B. Remote deployment device

A

C1

Lb

B

L

C2

C2

+12V

Figure 255

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pretensioners still on board of irreparable

vehicles

This procedure is followed when the vehicle with one or

more active air bags needs to be scrapped. This procedure

applies whether the air bag and/or pretensioner system is still

intact or not.

It is advisable to deploy the explosive charges on the vehicle

directly connecting the electric connector of the single

module to the remote deployment system.

General instructions
1. Follow all the WARNINGS, PRECAUTIONS and safety

instructions given in this manual.

2. Take the vehicle to the area foreseen.
3. Remove all materials and bits (glass, instruments, pieces,

etc.) around the air bag cover and check that there are

no inflammable fluids in the immediate vicinity.

4. Disconnect the two battery cables (firstly the negative

one) and wait at least 10 minutes before proceeding.

5. Use a connection bridle (L = approx. 1 m) with specific

terminal connector for electrical connection with the

module to be deployed.

6. Reach the electrical connection of the module in

question (air bag or pretensioner) following the

instructions given in this manual.

7. Disconnect connector C1 of the air bag module or

pretensioner.

8. Check that connector C2 is disconnected from the

remote deployment device.

9. Connect electric connector C1 of the air bag module or

pretensioner to the connection bridle of the remote

deployment device.

10. Connect connector C2 to the remote deployment

device.

11. Make people go to a safe place.
12. Connect the remote deployment device to a 12 V circuit

or equivalent device.

13. Press the double activation button to deploy all the air

bag modules and pretensioners at the same time.

14. After deploying the air bag modules and pretensioners

always let them cool before touching them (about 20

min.).

15. Once the modules and pretensioners have been

deployed the vehicle can be scrapped - by squashing

or crushing - and/or recycled depending on the cases.

ABG =

driver's air bag

ABP =

passenger's air bag

C2

=

connector to remote deployment device

C1

=

specific connector to explosive charge

L

=

general cable, safety distance 10 m

Lb

=

bridle length

PTG =

driver's pretensioner

A. Remote deployment device

LAYOUT FOR DEPLOYING EXPLOSIVE CHARGES ON

THE VEHICLE, SINGLE DEPLOYMENT

ABP

C1

Lb

ABG

PTG

C2

C1

Lb

Lb

C2

C2

C1

C2

L

+12V

!

The deployment procedure must be carried out

away from other persons in a suitably identified

area. Check that no type of object has been left

near the modules and pretensioners and make sure

that there are no inflammable liquids in the vicinity.

No-one should remain on board during

deployment and remember to close the vehicle

doors. Personnel should stay under shelter (e.g.

behind a wall, vehicle, etc.) to protect themselves

from any objects that may be thrown. Leave the

generators and modules to cool after deployment

(wait at least 20 min.). The failure to follow these

instructions may result in serious physical harm.

Figure 256

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Electronic control unit

The electronic control unit is located on the floor at the side

of the driver's seat between the gearshift lever and the parking

brake lever; it is supplied at 12 Volt by a key-operated device,

but it is still in a condition to be able to work for about 200

msec after a power cut off.
This is possible due to the presence of a buffer condenser

inside which accumulates electric energy for normal

operation of the control unit and generate the signal for

triggering the explosive capsule.
This way system operation is guaranteed if the crash causes

a power system failure (for example damage or breakage of

the battery, power cable cut-off etc.).

The electronic control unit should always be replaced after a

crash that causes deployment of the complete system (air bag

and pretensioners).
To remove the control unit:
- follow the rules of safety
- disconnect the battery cables (firstly the negative one

then the positive) and isolate them taping the terminals

- wait at least ten minutes before proceeding
- remove the cover under which the control unit is to be

found

- using a small screwdriver on the catch of the connector

that locks the connector fastening lever, turn the latter

outwards

- disconnect the connector from the control unit
- slacken the three screws fastening the control unit to the

floor.

BATTERY CABLE INSULATION

REMOVING THE CONNECTOR FROM THE

CONTROL UNIT

REMOVING THE CONTROL UNIT

!

The control unit must be directed with the arrow

printed on the sticker facing the vehicle direction of

travel. This is absolutely necessary as it determines

the direction in which the deceleration sensor reads

the values for defining the crash condition and thus

triggering the air bag.

Figure 257

Figure 258

Figure 259

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