Connect/disconnect test valve block at hydraulic unit

AR77.37-P-4205W

Connect/disconnect test valve block at hydraulic unit

17.2.11

Connect/disconnect

Danger!

Risk of injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

1

Remove crossmember cover (5) from Vario roof crossmember (8) until the Vario roof control hydraulic cylinder (A7/5) is accessible

AR77.37-P-3500W

2

Fold up insulating mat (20) and secure against falling down

3

Unclip hydraulic wiring harness (7) form Vario roof crossmember (8)

4

Open cable tie (17) and disconnect electrical connector on Vario roof control hydraulic unit (A7/5x1)

 Installation: Replace cable ties (17).

5

Unhook Vario roof control hydraulic unit (A7/5) from rubber mounts (21) and lay down in vehicle interior on suitable base such as foam rubber mat covered with cloth.

 Lay down Vario roof control hydraulic unit (A7/5) as shown. Otherwise, the vehicle interior can be soiled with hydraulic fluid running out. Escaping hydraulic oil causes an unpleasant odor and is hard to remove.

6

Open emergency operation valve (11) one turn

 Emergency operation valve (11) remains open.

7

Prepare valve block (1)

AR77.37-P-4205-01V

 Testing unit

*126589142100

 Set of stop plugs

*129589009100

 Valve block

*172589009100

8

Remove connection plates (13, 14) on hydraulic unit valve block (16)

 If only the system pressure in the hydraulic system is tested, remove only connection plate (13). Test system pressure using the connection no. 53 on hydraulic unit valve block (16).



*BA77.37-P-1002-01A

9

Remove stop plugs (15) from
valve block (1), pull hydraulic lines (12, 22, 33, 42, 53) out of hydraulic unit valve block (16) and connect to valve block (1)

 Reconnect hydraulic lines (12, 22, 33, 42, 53) individually. Pull stop plugs (15) out of  valve block (1) immediately before connecting. Immediately close connections on hydraulic unit valve block (16). Otherwise, the vehicle interior can be soiled with hydraulic fluid running out.
Do not pull hydraulic lines (12, 22, 33, 42, 53) too forcefully. Otherwise, the installation position can change and the hydraulic lines (12, 22, 33, 42, 53) can be damaged when moving the Vario roof.

 Set of stop plugs

*129589009100

 The shutoff valves (9) on the
 valve block (1) must be open. Observe connection schematic for hydraulic lines (12, 22, 33, 42, 53) on valve block (1): 

Connection scheme for pressure test

AR77.37-P-4205-02V

 Valve block

*172589009100

10

Tighten connection plate (18) on valve block (1)

 Ensure that connection plate (
18) is seated correctly. Otherwise the hydraulic lines (12, 22, 33, 42, 53) can detach during the pressure test and hydraulic oil can spray out of the connections.

 Valve block

*172589009100

11

Connect adapter line (6) on valve block (6) to connection no. 53 on hydraulic unit valve block (16)

 Valve block

*172589009100

12

Connect test lines (19) to corresponding connections on hydraulic unit valve block (16) and install connection plates (13, 14)

 Connect  test lines (19) one at a time. Remove  stop plugs on test lines (19) and hydraulic unit valve block (16) immediately before disconnecting. Otherwise, the vehicle interior can be soiled with hydraulic fluid running out.
Ensure that connection plates (13, 14) are seated correctly. Otherwise the test lines (19) and the adapter line (6) can detach during the pressure test and can spray out of the connections.

 Observe line coding on hydraulic unit valve block (16).



*BA77.37-P-1002-01A

 Valve block

*172589009100

13

Turn Vario roof control hydraulic unit (A7/5) to installation position and install with rubber mounts (21) to Vario roof crossmember (8)

 The Vario roof control hydraulic unit (A7/5) must be in the installation position to perform the pressure test.

14

Close emergency operation valve (11).



*BA77.37-P-1001-01A

15

Connect electrical connector to Vario roof control hydraulic unit (A7/5x1)

 The pressure test can now be started.

16

Disconnect in reverse order

 Disconnect hydraulic lines (12, 22, 33, 42, 53),  test lines (19) and
 adapter line (6) separately or reconnect and plug immediately. Also plug connections on  valve block (1) immediately after pulling out hydraulic lines (12, 22, 33, 42, 53) Otherwise, the vehicle interior can be soiled with hydraulic fluid running out.

 Set of stop plugs

*129589009100

 Valve block

*172589009100

17

After disconnecting the test tools and before installing the Vario roof control hydraulic unit (A7/5), bleed hydraulic system by opening and closing the Vario roof several times with the Vario roof actuation switch.

Number

Designation

Model
172

BA77.37-P-1001-01A

Emergency operation valve at hydraulic unit

Nm

2.5

See picture

-

BA77.37-P-1002-01A

Bolt, connection plate to hydraulic unit

Nm

4