Part 1. CAUTION : Release established test pressure before beginning the next test step.

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Vincent Blankenship
5 years ago
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1 1 of 16 4/29/2008 4:35 PM Home Account Contact ALLDATA Log Out Help Select Vehicle New TSBs Technician's Reference Component Search: METRO TOYOTA OK 1998 Mercedes Benz SL 500 ( ) V8-5.0L ( ) Conversion Calculator Vehicle Level Body and Frame Body Control Systems Testing and Inspection Testing and Inspection Procedures Soft Top, Roll Bar (ST/RB) (Manual Deployment) TP - Test Program HTP - Hydraulic Test Program Notes For Hydraulic Test Part 1 Part 1 Notes PART 1 OF 2 NOTES FOR HYDRAULIC TEST: The following jobs are the same for all test steps: A. B. C. D. Connection of test equipment to hydraulic unit (Figure 4). Torque check valve to 5 Nm. Build up and release test pressure (example), Test hydraulic cylinder only at end position of piston (Observe soft top positions). If hydraulic lines need to be disconnected from the valve blocks during pressure tests, the appropriate soft top position (end position of the hydraulic cylinder) must first be ensured. Example: Building Up And Releasing Test Pressure. Soft Top : => 1.0 to 16.0 Ignition ON : Activate power soft top switch (toward lower if the soft top is down, toward raise if the soft top is up) for 5 seconds. Have a second technician disconnect relay (A7/5k1, Figure 4). Hold power soft top switch for 5 additional seconds. Read and record test pressure. Release Test Pressure : Briefly activate power soft top switch several more times. CAUTION : Release established test pressure before beginning the next test step. WARNING : Disconnected hydraulic lines should be held in a container (connect a transparent hose such as windshield washer hose). Hydraulic components that leak should be replaced. During pressure tests, the valve block connections must be plugged with threaded plug If hydraulic components need to be replaced, the disconnected hydraulic lines must be

2 2 of 16 4/29/2008 4:35 PM plugged with plug , while the connections of valve blocks, hydraulic cylinders and hydraulic manifolds must be plugged immediately using plug to prevent the possible entry of dirt. Roll Bar : => 17.0 to 18.0 Ignition ON : Activate RB switch (toward lower if the roll bar is lowered, toward raise if it is raised) for 5 seconds. Have a second technician disconnect relay (A7/5k1, Figure 4). Hold roll bar switch for 5 additional seconds. Read and record test pressure. Release Test Pressure : Briefly activate power soft top switch several more times. Y55/1 Left Power Soft Top Valve Block (4 connections) Figure 2 y1 y2 y3 y4 Soft top "closed"/fabric bow lock "open" valve Fabric bow "closed" valve Fabric bow "open" soft top compartment cover "closed" valve Soft top compartment cover "open"/soft top compartment cover lock "open" valve Y56/1 Right Power Soft Top Valve Block (3 connections)

3 3 of 16 4/29/2008 4:35 PM Figure 3 y1 Soft top "open"/front lock "open" valve y2 y3 Roll bar "lower" valve Roll bar "raise" valve Connection Diagram - Check Valve And Pressure Gauge To Hydraulic Unit Figure 4

4 4 of 16 4/29/2008 4:35 PM 1 Check valve Adaptor kit Test pressure line 3 Connector piece 4 Pressure gauge 11 Test connection 12 Soft top/roll bar operation hydraulic line 13 Return line A7/5 RST/RB hydraulic unit A7/5k1 Relay Soft Top/Roll Bar Figure 5

5 of 16 4/29/2008 4:35 PM 1/2 Left/right soft top compartment cover hydraulic cylinder 3 Right roll bar support element 3a/3b Left/right locking paw hydraulic cylinder 4/5 Left right fabric bow

5 5 of 16 4/29/2008 4:35 PM 1/2 Left/right soft top compartment cover hydraulic cylinder 3 Right roll bar support element 3a/3b Left/right locking paw hydraulic cylinder 4/5 Left right fabric bow hydraulic cylinder 6/7 Left right power soft top hydraulic cylinder A7/5 RST/RB hydraulic unit A B C a VV/1 Soft top roll bar operation hydraulic circuit Pressure control lines Return flow lines Hydraulic manifold at A-pillar cross member Left front lock

6 6 of 16 4/29/2008 4:35 PM VV/2 Right front lock VM/1 Left center lock VM/2 Right center lock VH/1 VH/2 Left rear lock Right rear lock Y55/1 Left power soft top valve block (4 connections) Y56/1 Right power soft top valve block (3 connections) Hydraulic Circuit Schematic (Soft Top Closed, Roll Bar Lowered) Soft Top/Roll Bar Figure 6

7 7 of 16 4/29/2008 4:35 PM 1/2 Left/right soft top compartment cover hydraulic cylinder 3 Right roll bar support element

8 8 of 16 4/29/2008 4:35 PM 3a/3b Left/right locking pawl hydraulic cylinder 4/5 Left/right fabric bow hydraulic cylinder 6/7 Left/right power soft top hydraulic cylinder A7/5 RST/RB hydraulic unit A B C D a VV/1 VV/2 VM/2 VM/2 VH/1 VH/2 Y55 1 Y56 1 Soft top roll bar operation hydraulic circuit Pressure control lines Return flow lines Suction line Hydraulic manifold at A-pillar cross member Left front lock Right front lock Left center lock Right center lock Left rear lock Right rear lock Left power soft top valve block (4 connections) Right power soft top valve block (3 connections) Figure 7

9 9 of 16 4/29/2008 4:35 PM Test Step 1.0 Figure 8

10 10 of 16 4/29/2008 4:35 PM Test Step 2.0 Figure 9

11 11 of 16 4/29/2008 4:35 PM Test Step 3.0 Figure 10

12 12 of 16 4/29/2008 4:35 PM Test Step 4.0 Figure 11

13 13 of 16 4/29/2008 4:35 PM Test Step 4.1 Figure 12

14 14 of 16 4/29/2008 4:35 PM Test Step 4.2 Figure 13

15 15 of 16 4/29/2008 4:35 PM Test Step 4.3 Figure 14

1 of 9 4/29/2008 4:36 PM Home Account Contact ALLDATA Log Out Help Select Vehicle New TSBs Technician's Reference Component Search: METRO TOYOTA OK 1998 Mercedes Benz SL 500 (129.067) V8-5.0L (119.

17 1 of 9 4/29/2008 4:36 PM Home Account Contact ALLDATA Log Out Help Select Vehicle New TSBs Technician's Reference Component Search: METRO TOYOTA OK 1998 Mercedes Benz SL 500 ( ) V8-5.0L ( ) Conversion Calculator Vehicle Level Body and Frame Body Control Systems Testing and Inspection Testing and Inspection Procedures Soft Top, Roll Bar (ST/RB) (Manual Deployment) TP - Test Program HTP - Hydraulic Test Program Notes For Hydraulic Test Part 2 Part 2 Notes PART 2 OF 2 CONTINUED FROM PART 1 Figure 7 Test Step 1.0

18 2 of 9 4/29/2008 4:36 PM Figure 8 Test Step 2.0

19 3 of 9 4/29/2008 4:36 PM Figure 9 Test Step 3.0

20 4 of 9 4/29/2008 4:36 PM Figure 10 Test Step 4.0

21 5 of 9 4/29/2008 4:36 PM Figure 11 Test Step 4.1

22 6 of 9 4/29/2008 4:36 PM Figure 12 Test Step 4.2

23 7 of 9 4/29/2008 4:36 PM Figure 13 Test Step 4.3

24 8 of 9 4/29/2008 4:36 PM Figure 14 Test Step 4.4

A22s1 Bow "closed" switch (8) A22s2 Bow "locked" switch (8) A23s1 Bow "closed" switch (8) A23s2 Bow "locked" switch (8) Sized for Print

A22s1 Bow closed switch (8) A22s2 Bow locked switch (8) A23s1 Bow closed switch (8) A23s2 Bow locked switch (8) Sized for Print 4 of 10 4/17/2008 8:23 AM A22s1 Bow "closed" switch (8) A22s2 Bow "locked" switch (8) A23s1 Bow "closed" switch (8) A23s2 Bow "locked" switch (8) 5 of 10 4/17/2008 8:23 AM A24s1 Cover "closed" switch (3)