Mercedes Benz Sensotronic Brake Control R230 Users Manual 327 HO 09 SBC (WJB) 03 05 04

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Sensotronic Brake Control
(SBC)

327 HO 09 SBC (WJB) 03-05-04

R230 and W211: Starting MY2003

1

Objectives
1.
2.
3.
4.
5.
6.
7.
8.
9.

At the end of this presentation, you should be able to:
Explain the function of and purpose for SBC
Describe the customer interface with SBC
List the hydraulic and electronic components used for SBC
Describe how the “normal” feel of the brake pedal is maintained
Explain emergency operation of the SBC braking system
Describe “temperature compensation”
Explain “Deactivation” and describe when it is necessary to do it
“Activate” the SBC system
Locate tools and the proper procedure for bleeding brakes

These technical training materials are current as of the date noted on the materials, and may be revised or updated without notice. Always check for revised or updated information.
To help avoid personal injury to you or others, and to avoid damage to the vehicle on which you are working, you must always ref er to the latest Mercedes -Benz Technical Publication and follow all
pertinent instructions when testing, diagnosing or making repair.
Illustrations and descriptions in this training reference are based on preliminary information and may not correspond to the final US version vehicles. Refer to the official introduction manual and WIS
when available.
Copyright Mercedes-Benz USA, LLC, 2004
WIS document numbers shown apply to WIS Version USA/CDN at date of writing.
Reproduction by any means or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Mercedes -Benz USA, LLC or it's
successors.
Published by Mercedes -Benz USA, LLC
Printed in U. S.A.

2

Contents
Advantages of SBC
Driving with SBC
SBC components
Brake operating unit (BOU)
Traction system hydraulic unit
Three pressure stages
Temperature Compensation
Deactivation
System activation
Bleeding the system

5
8
13
17
27
32
38
39
42
49

3

SBC Incorporates these Functions:

ABS (Anti lock Brakes 1984)
+ ASR (Automatic Slip Regulation 1991)
+ ETS (Electronic Traction System 1995)
+ ESP (Electronic Stability Program 1996)
+ BAS (Brake Assist System 1998)

4

Advantages of SBC
• Improves metering of required brake pressure
– each wheel can be precisely controlled
• Improved BAS function
– monitors release of accelerator pedal and application of
brake
– maximum pressure available immediately
– pre-filling of system (overcoming play)
– when the BAS function is anticipated, slight pressure is
applied

5

Advantages of SBC
• Electronic Brake Proportioning: EBP
– allows brake proportioning front to back and side to side
• No pedal vibration during ABS operation
– eliminates “distraction” to the driver during critical moments
– indicator light in instrument cluster signals traction loss
• Improved driving dynamics: ABS, ASR, and ESP
– faster response to brake request inputs

6

Advantages of SBC
• Pressure reduction at standstill
– reduces stress on components
• Dry braking function
– wiper input via CAN
– ~every 7 to 14 minutes
– brake actuation changes
time interval

7

Driving with SBC - Wake-Up
SBC is functional as soon as it is “wakened” by:
• opening a door (via CAN)
• operating the central locking system (via CAN)
• depressing the brake pedal
• turning key to position 1
• operating parking brake
•The Wake-Up may be followed by a Pre-Drive self
Check performed by SBC

8

Driving with SBC – Pre-Drive Check (PDC)
When SBC performs a PDC after a "wake-up", the following are
checked:
Warning! Pressure is applied to brake calipers (~60 bar)
• reservoir pressure (if low, it will be corrected by running the
high pressure charge pump in the hydraulic unit)
• pressure sensors
• control valves
• leak tests
• operational checks
Note: self-tests are constantly conducted during driving (~ once every 16
brake applications)
9

Driving with SBC – Delayed Off Function

Time that SBC remains operational after use:
• with vehicle stationary and was locked = 20 seconds
• with vehicle stationary and ignition in “0”,
brake pedal not operated = 2 minutes
• with vehicle stationary, ignition in “0”,
brake pedal operated in delayed off phase and
released again = 4 minutes
10

Warning Display

Complete ESP control module failure Instrument cluster will scroll through failure displays

11

Warning Display
SBC control module failure

Certain faults will trigger audible signal

12

SBC Components

• Brake Operating Unit (BOU)
• Wheel speed sensors
• Traction System Hydraulic
Unit (A7/3)
13

W211 System Overview
Circuit 30

Brake lights

Rear SAM
(N10/2)

Circuit 87
SBC

Circuit 31
Wheel speed sensors
L6/1, L6/2, L6/3, L6/4

SBC
control
module
(A7/3n1)

CAN
Wheel
speeds

Wake up
Brake lights

Stop lamp switch
(S9/1)
SBC pedal travel
sensor (B37/1)

Speed status
Diagnostics

ESP control
module (N47/5)

Front
SAM
(N10/1)

Diagnostic connector
(X11/4)
14

R230 System Overview
Circuit 30

Brake lights

Circuit 87
Circuit 31
Wheel speed sensors
L6/1, L6/2, L6/3, L6/4
Stop lamp switch
(S9/1)
SBC pedal travel
sensor (B37/1)

SBC
control
module
(A7/3n1)

Rear SAM
(N10/8)

Diagnostic connector
(X11/4)
SBC
CAN
Wheel
speeds

Wake up
Brake lights
Speed status

ESP control
module (N47/5)

Passenger side
SAM (N10/11)
15

X11/4 Diagnosis Connection
R230

W211
A7/3n1
SBC

A7/3n1
SBC

X11/4

N47/5
ESP
X11/4

N10/1
L.F.SAM
Z70/4

N15/5
ESM

Pin 9
Z6/33
Pin 9

N51/2
ABC

N47/5
ESP

16

Brake Operating Unit - (BOU)

17

Brake Operating Unit
The Brake Operating Unit (BOU)
consists of the following:
• Brake fluid reservoir
(Do not overfill!)
• SBC pedal value sensor

• Tandem master cylinder

• Brake pressure simulator
(Note: no vacuum booster)

18

Master Cylinder
• Fluid level sensor
• Fluid return line
• Do not overfill
• Hydraulic lines to SBC
• Supply hose to SBC
19

Fluid Reservoir Cover

• Ultraviolet protection
(211 only)

20

Pedal Value Sensor - (B37/1)
• Contains two hall effect sensors
• Converts pedal travel value to
an electrical signal
• Provides input to SBC
control module A7/3

21

BOU Tandem Master Cylinder
Fluid reservoir
Fill valves

Primary piston

Floating piston

y2

y1

A7/3 - Traction system hydraulic
unit with separation valves y1 and
y2

A7/3
Brake pressure simulator

22
GF42.46-P-4200-03SL

Normal Braking - Light Pressure
• Driver applies
pressure to the
brake pedal
• Fill valves close
• Pedal travel sensor
sends a signal to A7/3
• y1 and y2 energized,
preventing fluid
movement externally

y2

y1
A7/3

• Floating piston allows
fluid to enter simulator,
compressing the light
spring, providing pedal
feel to the driver
23
GF42.46-P-4200-03SL

Normal Braking - Increased Pressure

y2

y1
A7/3

• Increasing pedal
travel causes the
larger spring to
compress, providing
harder pedal feel
24

Normal Braking - Strongest Feedback

• Further pedal travel

y2

y1
A7/3

causes piston to
compress rubber
bumper, providing
greatly increased
pedal pressure
25

Emergency Operation
• All electrical functions
canceled

• Hydraulic pressure
created with NO
power assist
• Pressure directed
through A7/3 y1 and
y2 to ....
Left Front and
Right Front calipers
only!

y2

y1
Left front

A7/3

Right front
26
GF42.46-P-4200-03SL
GF42.46-P-3000SL

Traction System Hydraulic Unit (A7/3)

Consists of:
• SBC control module (A7/3n1)

• High pressure charge pump
(A7/3m1)

• Pressure reservoir

27

Traction System Hydraulic Unit
A7/3

28
GF42.50-P-4000-03S

Legend
1
2
3
7
8
A7/3
A7/3b1
A7/3b2
A7/3b3
A7/3b4
A7/3b5
A7/3b6
A7/3m1

Brake Operating Unit
Brake pressure simulator
Pressure reservoir
Left front media separator
(dividing piston)
Right front media separators
(dividing piston)
Traction system hydraulic unit
Front axle pre-pressure sensor
Reservoir pressure sensor
Left front pressure sensor
Right front pressure sensor
Left rear pressure sensor
Right rear pressure sensor
High-pressure charge pump

A7/3y1
A7/3y2
A7/3y3
A7/3y4
A7/3y6
A7/3y7
A7/3y8
A7/3y9
A7/3y10
A7/3y11
A7/3y12
A7/3y13
B37/1
S9/1

Left front separation valve
Right front separation valve
Front axle balance valve
Rear axle balance valve
Left front intake control valve
Left front outlet control valve
Right front intake control valve
Right front outlet control valve
Left rear intake control valve
Left rear outlet control valve
Right rear intake control valve
Right rear outlet control valve
SBC pedal value sensor
Stop lamp switch (4-pin)

29

Emergency Operation Circuit

• Pressure applied directly
to front calipers
• y1 and y2 not energized
• b1, b3, and b4 pressure
sensors may provide
information to SBC control
module
• Media separator/Dividing
piston 7 and 8 isolate
emergency circuit from
normal circuit

30
GF42.46-P3000SL

Brake Pressure Supply

• pressure reservoir charged to
160 bar
• the high pressure charge pump
runs as needed
• pressure blocked by y6, y8,
y10, y12

31
GF 42.50-P-4000-04S
GF42.46-P-0001SL

Three Pressure Stages

Same pressure stages as used with ABS functions:
• Pressure apply
• Pressure hold
• Pressure release

32

Pressure Apply - Rear Wheels

Brake pedal pressure
Reservoir pressure

• Brake pedal depressed
• B37/1 and b1 report brake
application to control module
• y1 and y2 energized
• y10 and y12 intake control valves
energized
• Pressure at each rear wheel
monitored by b5 and b6
• Balance valve y4 not energized

GF42.50-P-4000-04S33
GF42.46-P-1000SL
GF42.46-P-4500-02SL

Pressure Apply - Front Wheels

Brake pedal pressure
Reservoir pressure

• y6 and y8 energized
• pressure applied to left and
right dividing pistons 7 and 8
• 7 and 8 apply pressure to caliper
• pressure at each wheel monitored
by b3 and b4
• Balance valve y3 not energized
34
GF42.50-P-4000-04S
GF42.46-P-1000SL

Pressure Apply - All Wheels

• Outlet control valves y7, y9, y11, y13 energized

35
GF42.50-P-4000-04S
GF42.46-P-1000SL

Pressure Hold - All Wheels
• y6, y8, y10, y12 de-energized

36
GF42.50-P-4000-04S
GF42.46-P-1000SL

Pressure Reduction - All Wheels
• y7, y9, y11, y13 de-energized

37
GF42.50-P-4000-04S
GF42.46-P-1000SL

Temperature Compensation

During continuous brake use the
fluid in the calipers expand, this:
• creates high pressure
• prevents valves 7 & 8 from moving
To reduce this pressure, y1 and
y2 are pulsed
38

Deactivation
SBC must be deactivated with SDS before any work is performed
on the system. This will prevent the pre-drive check from being
automatically performed which could cause injury.

Deactivating the system will:
• empty the pressure reservoir
(a lower pressure with no volume may be retained)
• prevent the charge pump from operating
•Note: the warning buzzer is deactivated when accessing
SBC with the SDS.
39

Deactivation
SBC must be deactivated PRIOR to:
• working on the hydraulic system
• removing or installing brake pads
• replacing rotors
• replacing the pressure reservoir
• replacing the BOU
• replacing the SBC hydraulic unit (A7/3)
40

Deactivation
Charge pump disabled and accumulator fluid returned to the reservoir!

41

Pressure at A7/3b2

System Activation
Activation must be performed anytime the system has been
deactivated, BEFORE the engine is started!
Failure to activate will prevent proper operation and create fault
codes!
Activating SBC with SDS will:
• charge the accumulator
• perform a Predrive Check
• move the pads towards the rotors with ~60 bar pressure
• erase the fault memory
(Note: may have to activate several times to position the brake pads)

42

System Activation

43

Activation - Left Front

Caliper held with ~60 bar

44

Activation - Right Front

Caliper held with ~60 bar

45

Activation - Right Rear

Caliper held with ~60 bar

46

Activation - Left Rear

Caliper held with ~60 bar

47

Activation - Recharge

48

Bleeding the Brake System

Proper system bleeding is critical!
Follow directions in SDS
• Bleeding must be performed using the SDS

• Pressure at bleeder valves will exceed 100 bar
(Hold the bleeder hose securely)
• Bleeding may require ~1.5 hours
• Bleeding may use ~ 1.5 liters of brake fluid
49
AR42.10-P-0012R

Equipment Required
• Pressure bleeder
• Adapters
• Fluid receptacle
• SDS - follow instructions carefully
211 589 01 91 00

CAUTION:
Extremely high pressure at bleeder!
AR42.10-P-0010-02R
AR42.10-P-0012R
WS42.00-P-0048B

50

Bleeding the Brake System
Connect equipment and follow steps in SDS

51
AR42.10-P-0012R

Acronym List
(Used in This Handout.)

ABS - Anti-lock Brake System
ASR - Anti Slip Regulation
BAS - Brake Assist System
BOU - Brake Operating Unit
CAN - Controller Area Network
EBP - Electronic Brake Proportioning
EBR - Electronic Brake Regulation
E-Gas - Electronic Accelerator
ESP - Electronic Stability Program
ETS - Electronic Traction System
PDC - Predrive Check
SAM - Signal Acquisition Module
SBC - Sensotronic Brake Control

52

Appendix

AR42.10-P-0010I
AR42.10-P-0012R
GF42.45-P-0001-04SL
GF42.45-P-0001SL
GF42.45-P-2000SL
GF42.45-P-3500SL
GF42.46-P-0001SL
GF42.46-P-1000SL
GF42.46-P-2000SL
GF42.46-P-3000SL
GF42.46-P-4200-03SL
GF42.46-P-4210SL
GF42.46-P-4500-02SL
GF42.50-P-4000-03S
GF42.50-P-4000-04S
GF42.50-P-4000S
WS42.00-P-0048B

Carrying out bleeding operation
Bleeding system with Star Diagnosis
ESP driver information
ESP function
ESP brake moment control
ASR control mode function
SBC function
SBC Normal braking function
SBC additional braking functions
SBC braking with malfunction
BOU function
SBC pedal value sensor
SBC control module – task
Hydraulic unit design
Hydraulic unit function
Hydraulic unit task/location/function
EHB adaptor

53



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