Safety regulations for airbag and seat belt tensioner General, Despatch, Storage, Assembly and disassembly, Scrapping, Disposal of control units with mercury, Important information - ra91001400610x(0610)

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Model 140

The information on safety regulations is divided up into the following sections:

General
The transport of airbag and seat belt tensioner units
The storage of airbag and seat belt tensioner units
The installation and removal of airbag and seat belt tensioner units
The scrap disposal of airbag and seat belt tensioner units
Waste disposal of control devices containing mercury
Important notes on repair and what is to be done after accidents

General
All the provisions mentioned in this information are based on the laws of the Federal Republic of Germany.

In all other countries the regulations in force should be observed.

The driver's and/or front passenger's airbag unit and the seat belt tensioners are pyrotechnical objects belonging to the T1 class. The handling, transport and storage of such objects are subject to the provisions of the "Law relating to Explosive Substances" (Explosives Law of 17 04 86) and must therefore be reported to the local trade board.

Purchase, transport, storage, installation and removal as well as disposal may only be effected by trained personnel and in accordance with the safety regulations.
Transport of Airbag and Seat Belt Tensioner Units
These may only be transported in the vehicle trunk or luggage compartment of the vehicle using the spare part packing.

It is forbidden to transport airbag and seat belt tensioner units in the passenger compartment!
Storage of Airbag and Seat Belt Tensioner Units
Storage of the airbag and seat belt tensioner units should comply with the second amendment to the Explosives Law of 17 04 86.

This amendment stipulates that small quantities of substances and objects may be stored in lockable rooms without a special storage permit as defined in the Explosives Law. Pyrotechnical objects belonging to class T1 may be stored in a commercially used building in a limited number only.

According to Appendix 6 to the supplement to the 2nd Explosives Amendment, the following maximum quantities may be stored in a commercially used building, if certain conditions are fulfilled (e.g. steel cupboard), without special permission by the appropriate authorities:

General store-room: 20 kg gross

Locked room (separate store-room): 200 kg gross

The gross mass of the component for which permission is granted in accordance with laws on explosive substances is to be taken as the basis for calculating the actual mass stored:

per driver's airbag: 0.6 kg

per front passenger's airbag: 1.2 kg

per seat belt tensioner 0.2 kg
Installation and Removal of Airbag and Seat Belt Tensioner Units
1. Testing and installation may only be carried out or supervised by specially trained personnel.
2. Before the airbag and seat belt tensioner units are installed, it is essential that the battery be unclipped, that the negative terminal and its clamp be masked and that the test coupling/plug connector (12-pin X11/7, X11/13) be disconnected. Installation should take place immediately after the units have been taken out of storage and without delay.
3. If for any reason work should be interrupted, the airbag and seat belt tensioner units should be locked up once again. On no account may they be left lying around unsupervised.
The essential points to note are:
- Airbag and seat belt tensioner units should not be treated with grease, cleaning or similar agents.
- Airbag and seat belt tensioner units should not be exposed, even temporarily, to temperatures in excess of 100°C.
- Airbag and seat belt tensioner units which have been dropped from a height in excess of than 0.5 m may no longer be installed in a vehicle.
- Airbag and seat belt tensioner units should only be electrically tested by means of stipulated testing devices in installed condition.
As for installation, it is essential, before removing the airbag and seat belt tensioner units, to unclip the battery, mask the negative terminal and separate the 10-pin test coupling/plug connector.

When removed, airbag units must always be stored with the cushioned side uppermost!

If the gas generator is accidentally ignited with the airbag underneath, the airbag unit is propelled forcibly upwards, giving rise to the possibility of injury.

Fig 1: Identifying Airbag Units
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

The Scrap Disposal of Airbag and Seat Belt Tensioner Units

In the Federal Republic of Germany the accident prevention regulations stipulate that airbag and seat belt tensioner units must be made unusable before scrap disposal. These safety measures are necessary because the pyrotechnical objects could cause injury if activated incorrectly. It is dangerous, for example, to use cutting torches; smelting carries the same risk; and the same applies when component parts which are still loaded find their way into normal or smouldering fires on rubbish tips.

In order to avoid these safety measures creating more work, we recommend that the scrap disposal of the pyrotechnical objects be entrusted to a scrap dealer, who should carry out the safety measures. On receipt of these items, the dealer should sign a declaration, undertaking to comply with the accident prevention regulations when he scraps the pyrotechnical objects.

With agreements of this kind, it is essential to ensure that the pyrotechnical objects cannot be removed from the rest of the scrap and passed on for repair. They must first be made unusable for reconditioning by triggering them. In order to do this, it is necessary to use an ignition device developed by Daimler-Benz and which renders the pyrotechnical objects completely unusable in perfect safety.

Checking whether Vehicle is Equipped with Seat Belt Tensioner or Airbag and Seat Belt Tensioner Unit

The seat belt tensioners can be identified by the "RS" Airbag symbol on the lock tongue.
The driver's airbag unit can be identified on the steering wheel cushion by the "SRS" Airbag marking.
The front passenger's airbag unit can be identified by the "SRS" AIRBAG marking.

A further identification feature is the warning lamp in the instrument cluster with the marking "SRS".

Fig 2: Identifying Airbag And Seat Belt Tensioner Units Location
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Check and, if necessary, activate seat belt tensioners and airbag units which have been removed or supplied separately.

Fig 3: Locating Observation Window On Housing Of Seat Belt Tensioners
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

There is an observation window (20) on the housing of the seat belt tensioners, through which a notch can be seen.

If no notch can be seen, the seat belt tensioner has been activated and must be replaced.
Place seat belt tensioners which have not been activated in the foot space of a scrap vehicle and directly connect the 2-pin plug connector. Ignite seat belt tensioner as described under Section b.
Airbag Unit

If the cushion plate of the airbag unit has not been destroyed, the airbag unit must be ignited using the 2-pin plug connector (see Section b).

Ignition Device

Fig 4: Identifying Battery Capacity Warning Light, Battery Check Pushbutton, Ignition Pushbutton And Ignition Warning Light

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

In order to ignite the seat belt tensioner units via the seat belt tensioner test connection (X11/7), or in the case of vehicles with an airbag via test coupling/plug connector (X11/13), a separate adapter cable must be made which is not included in the ignition device (Component No. 126 589 00 90 00).

The adapter cable must be attached to plug connector 6 of the ignition device.

Fig 5: Identifying Seat Belt Tensioner Units

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Connection Diagram Seat Belt Tensioner

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

SELF-MADE ADAPTER CABLES

Qty	Spare Parts	Component No.
1	12-pin plug connector (X11/13)	020 545 35 28
1	4-pin plug connector (X11/7)	020 545 39 28
12	Contact socket	003 545 06 26 - 9
1	10-pin plug	012 545 54 28
5	Pin	012 545 58 28
1	2 m Cable FLK 0.75 mm²	standard

Using the Ignition Device

For installed airbag and seat belt tensioner units

Check whether steering wheel and steering column are securely mounted and whether the airbag unit is firmly attached to the steering wheel (after ignition of an airbag unit the steering wheel is damaged and must also be replaced).
Turn ignition key to position 0, disconnect negative terminal of battery and mask.
For airbags with seat belt tensioners disconnect red 12-pin plug connectors X11/7 and X11/13.
Arrangement of the 12-pin test coupling/plug connector and/or of the 4-pin seat belt tensioner test coupling in the vehicle under the front passenger's foot rest.

Fig 7: Identifying 12-Pin Plug Connectors
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Connection Diagram of Scrapping Cable

Fig 8: Connection Diagram Of Scrapping Cable
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Make contact between self-made adapter cable and plug connector 6. Connect the plug connector of the adapter cable to the 12-pin plug of the airbag cable harness.

IGNITION

Driver's airbag 1	Rotary switch (4) position
Seat belt 2 tensioner (driver/front passenger)	Rotary switch (4) position
Front passenger's airbag 3	Rotary switch (4) position

Fig 9: Connecting Plug Connector Of Adapter Cable To 12-Pin Plug Of Airbag Cable Harness

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

From the prescribed safe distance of 10 m (the length of the ignition cable) press pushbutton (2) and pushbutton (3) simultaneously. After ignition the warning light (5) lights up.
For seat belt tensioners (without airbag) connect self-made adapter cable to the 4-pin test connection (X11/7) of the seat belt tensioner.

Igniting the Seat Belt Tensioner

Rotary switch (4) position 2.

Using the Ignition Device
For Unattached Airbag and Seat Belt Tensioner Units

Unattached airbag or seat belt tensioner units should, if possible, be ignited in a scrap vehicle (with closed doors). Place the unattached airbag unit in the foot space in such a way that the cushioned side is facing upwards. If no suitable vehicle is available, in exceptional cases the airbag unit can instead be ignited in the transport container for replacement engines with closed lid.

Fig 10: Connecting Plug Connector Of Adapter Cable To 12-Pin Plug Of Airbag Cable Harness
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Insert plug connector (8) in the unit to be scrapped.
2. Turn rotary switch (4) to position (1).
3. From the prescribed safe distance of 10 m (the length of the ignition cable) press pushbutton (2) and pushbutton (3) simultaneously. In the case of ignition in a scrap vehicle, always stand in front of the vehicle. After ignition the warning light (5) lights up.
NOTE: When an unattached airbag is ignited, the plug connector (8) is damaged. Therefore, the adapter cable must be detached from the plug connector and replaced (Component No. 126 589 00 90 22).
When Ignition Device Component No. 124 589 00 90 00 is Not Available

Self-made ignition cable

1 Make ignition cable with pushbutton.

Fig 11: Connection Diagram Of Ignition Cable
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2 Make adapter cable for 4 and/or 12-pin plug connector of the vehicle cable harness.

Fig 12: Identifying Plug Connector And Vehicle Cable Harness
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

NOTE: When an unattached airbag is ignited, the plug connector is damaged. Therefore, the adapter cable can no longer be used after ignition and must be replaced (Component No. 126 589 00 90 22).
4 Connect ignition cable to battery. From the prescribed distance (the length of the ignition cable) press both pushbuttons at the same time.

Fig 13: Connecting Ignition Cable To Battery

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

SPARE PARTS

Qty No.	Designation	Component
1 35 28	12-pin coupler plug (X11/13)	020 545
12 06 26	Contact bush	003 545
1 39 28	4-pin coupler plug (X11/7)	020 545
2	Coaxial plug connector	standard
2	Pushbutton (non-locking)	standard
2	Battery terminal	standard
1	Two-core cable 11 m long	standard
1	Cable 0.75 mm² 2 m long	standard
1 54 28	10-pin plug	012 545
5 Pin	012 545 58 28

OPERATING THE IGNITION DEVICE

Testing arrangement Ignition device in position	Cable harness plug No.	Extent of test	Activation: Buttons	Rated value: LED	Possible causes of divergence from rated values
1		Internal battery test	Press Ignition device not connected.	ON green warning light ON	Try replacing battery set of ignition device: 2 baby cells (2 1.5 V).

When the ignition is switched off and the negative battery terminal is detached, disconnect electrical control device and connect to ignition device.

WHEN IGNITING STAND AT SAFE DISTANCE OF 10 M.

1	3+4	Ignition of driver's ignition capsule	Press both pushbuttons	1. Before ignition ON	Ignition circuit faulty
2	1+2	Ignition of seat belt tensioner ignition capsule, left-hand seat		Ignition effected with bang.
2	3+4	Seat belt tensioner ignition capsule, right-hand seat		Ignition effected with bang.
3	5+6	Ignition of front passenger's ignition capsule		2. After ignition ON green warning light ON

Waste Disposal of Control Devices Containing Mercury
Components containing mercury must not be disposed of together with industrial waste or passed on for waste disposal in the usual way. These components must either be passed on for recycling as industrial goods in accordance with the provisions of the Waste Law or disposed of as hazardous waste.

Workshops without facilities for recycling components containing mercury can send these parts to the Sindelfingen factory, KGA Dept., Disposal Site 300, within the framework of the spare parts return transport scheme.

Guarantee and accommodation parts are to be marked accordingly.

Components Containing Mercury
1. Seat belt tensioner control device Part No. 003 820 06 10
  
  Fig 14: Identifying Seat Belt Tensioner Control Device Part No. 003 820 06 10
  Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Airbag control device Part No. 003 820 73 10 003 820 74 10
Fig 15: Identifying Airbag Control Device Part No. 003 820 73 10 003 820 74 10
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Important Notes for Testing and Repair Work after Accidents
1. Before commencement of
  - repairs on bodywork
  - welding
  - work on the airbag restraint system,
  steering wheel, airbag unit, control device, seat belt tensioner, the negative battery terminal must always be unclipped and masked.
  
  Detach the 12-pin airbag test coupling/plug connector (red) at the right in the foot space after waiting 2 secs after the battery has been disconnected.
2. After accidents
  After accidents it is essential to exchange the individual components in the following cases:
  1. recognizable deformation or damage to the control device housing.
  2. deformation of the control device console (also if control device outwardly undamaged).
  3. when an electrical fault is discovered during testing.
  4. non-activated but damaged airbag and/or seat belt tensioner units.
  5. activated airbag and/or seat belt tensioner units.
  6. in the case of impulse signal 10.
  NOTE: Damaged and/or faulty individual components must not be repaired, but must always be replaced. The same exchange provisions apply for non-activated seat belt tensioner units as in Regulations for replacement of seat belts A. By mechanical damage, B. Following an accident .
  
  When the driver's airbag unit has been activated, the steering wheel must also always be replaced.
  
  When the front passenger's airbag unit has been activated, the dashboard must also always be replaced
3. Painting
  There are no special regulations to be observed if painting is followed by drying out in an oven, as the entire airbag and seat belt tensioner system is designed in such a way that no damage whatsoever can be done by heating up the vehicle.
4. After work on the airbag and seat belt tensioner restraint system
  The system is to be tested by means of impulse signal. In the case of impulse signal 1 no fault has been stored, i.e. the system is in order.
  
  NOTE: The seat belt tensioners are not recorded via impulse signal and therefore these must be additionally tested after replacement of one or both seat belt tensioners, as described in Automobile Diagnosis Manual Bodywork Volume 1, 16.02 or 17.02.
  
  NOTE: When removing one or both of the front seats (plug connector to the seat belt locks must be disconnected) and when the ignition key is in position 1 or 2, the "SRS" warning light lights up and goes out again when the seats are reinstalled. This is recorded as a fault. (Impulse signal 5 or 6).
  
  The memory must be erased as described.