7200... Safety regulations for handling components with gas generators (Countryman 2017-2023, except PHEV)

When working on airbag units or seat belt tensioners, the regulations must be observed in accordance with the law relating to the use of explosives. 

Airbags, seat belt tensioners etc. are pyrotechnical objects. Pyrotechnical objects are assigned to different danger classes on the basis of the quantity of propellant gas that they contain. The assignment can be recognized using the identification on the product:

Attention! 

Failure to comply with the warning notices and repair notes for gas generator components can cause accidental deployment and result in injury and vehicle damage!

This applies in particular to the following components:

• Airbag modules (driver's/front passenger airbags, side airbags)
• Seat belt tensioner
• Head airbag
• Active knee protection
• Active head restraint
• Safety battery terminal
• Actuators for the active pedestrian protection

1. Regulations 

   The regulations cited below apply to the Federal Republic of Germany.

   In all other countries, the applicable laws and regulations must be observed. Country-specific legal regulations that go beyond this information or case law derived therefrom must always be observed and take precedence over these regulations.

   • Pyrotechnical restraint systems are subject to danger class PT1
   • Gas generators are pyrotechnical objects belonging to danger class T1

   The handling, transport and storage of unignited gas generators are subject to the law relating to the use of explosives (of September 13, 1976).

   The first handling of pyrotechnic objects must be reported to the responsible trade inspector's office at least 2 weeks in advance. In this process, notify the person responsible at the relevant authority (e.g. dealership owner, holder of general power of attorney, shop foreman) in writing. A certificate of competency, namely a special training, is not required for the person responsible.

2. Dismantling and installation 
   • Checking and installation work must be carried out by professionally trained personnel only.
   • Work on airbag system components must only ever be carried out with a disconnected vehicle battery, covered negative terminal and disconnected plug connection of the cable leading to the gas generator. If only the vehicle battery is disconnected, the following prescribed waiting time must be observed:
     • 30 min for vehicles up to 9/93
     • 1 min for vehicles from 9/93
   • In the event of breaks in work, a component with a gas generator that has been removed must be secured against access by other persons.
   • Individual components must never be repaired. Instead, always replace them.
   • Do not treat airbag system components with cleaning agents or grease.
   • Components of the airbag system must not be exposed to temperatures in excess of 75 °C.
   • Components of the airbag system, including diagnostic electronics, that have fallen from a height of more than 0.5 m may no longer be installed in the vehicles.
   • Do not remove components of the airbag system from the original packaging until immediately before they are to be installed in the vehicle.
   • Before installing, subject components such as housing, connector pins, etc. of the airbag system (including diagnostic electronics) to a visual inspection for damage and replace if necessary.
   • Airbag system components may only be electrically tested while they are installed and only with the diagnostic system.
   • Injury hazard:  The airbag module may only be set down with the airbag itself facing upwards.  Otherwise, if the gas generator is ignited, the gas generator will be launched upwards.
   • The ignition squib of a gas generator must not be pointed at people.
   • Components with gas generators must not be fired while they are removed. It must be disposed of by special disposal companies or returned in the packaging of the new parts.
   • When carrying out straightening and welding work with an electric welder:
     • Disconnect the vehicle battery
     • Cover negative terminal (post)
   • Avoid all contact with the skin when removing a fired airbag module - wear gloves. Wash with water after contact with the skin.
3. Transport 
   • Components with gas generators must be shipped in the packaging of the new parts.
4. Storage 

• Observe the regulations of the responsible trade inspector's office or valid national regulations!