Sensotronic Brake Control
(SBC)
1
R230 and W211: Starting MY2003
327 HO 09 SBC (WJB) 03-05-04
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Contents
Advantages of SBC
Driving with SBC
5
8
SBC components
13
17
27
32
38
39
42
49
Brake operating unit (BOU)
Traction system hydraulic unit
Three pressure stages
Temperature Compensation
Deactivation
System activation
Bleeding the system
3
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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
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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
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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
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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
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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
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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
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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
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Warning Display
Complete ESP control module failure -
Instrument cluster will scroll through failure displays
11
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Warning Display
SBC control module failure
Certain faults will trigger audible signal
12
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SBC Components
• Brake Operating Unit (BOU)
• Wheel speed sensors
• Traction System Hydraulic
Unit (A7/3)
13
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W211 System Overview
Rear SAM
(N10/2)
Circuit 30
Circuit 87
Circuit 31
Brake lights
SBC
CAN
SBC
ESP control
control
module
(A7/3n1)
module (N47/5)
Wheel
speeds
Wheel speed sensors
L6/1, L6/2, L6/3, L6/4
Wake up
Front
SAM
(N10/1)
Brake lights
Stop lamp switch
(S9/1)
Speed status
Diagnostics
SBC pedal travel
sensor (B37/1)
Diagnostic connector
(X11/4)
14
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R230 System Overview
Circuit 30
Circuit 87
Circuit 31
Rear SAM
(N10/8)
Brake lights
Diagnostic connector
(X11/4)
SBC
control
module
(A7/3n1)
Wheel speed sensors
L6/1, L6/2, L6/3, L6/4
SBC
CAN
ESP control
module (N47/5)
Wheel
speeds
Stop lamp switch
(S9/1)
Wake up
Passenger side
SBC pedal travel
sensor (B37/1)
Brake lights
SAM (N10/11)
Speed status
15
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X11/4 Diagnosis Connection
R230
W211
A7/3n1
SBC
A7/3n1
SBC
X11/4
Pin 9
N47/5
ESP
N10/1
L.F.SAM
X11/4
Pin 9
Z70/4
N15/5
ESM
Z6/33
N47/5
ESP
N51/2
ABC
16
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Brake Operating Unit - (BOU)
17
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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
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Master Cylinder
• Fluid level sensor
• Fluid return line
• Do not overfill
• Hydraulic lines to SBC
• Supply hose to SBC
19
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Fluid Reservoir Cover
• Ultraviolet protection
(211 only)
20
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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
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BOU Tandem Master Cylinder
Fluid reservoir
Fill valves
Primary piston
Floating piston
A7/3 - Traction system hydraulic
unit with separation valves y1 and
y2
y2
y1
A7/3
Brake pressure simulator
22
GF42.46-P-4200-03SL
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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
• Floating piston allows
fluid to enter simulator,
compressing the light
spring, providing pedal
feel to the driver
y2
y1
A7/3
23
GF42.46-P-4200-03SL
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Normal Braking - Increased Pressure
• Increasing pedal
travel causes the
larger spring to
compress, providing
harder pedal feel
24
y2
y1
A7/3
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Normal Braking - Strongest Feedback
• Further pedal travel
causes piston to
compress rubber
bumper, providing
greatly increased
pedal pressure
y2
y1
A7/3
25
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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
Right front
A7/3
26
GF42.46-P-4200-03SL
GF42.46-P-3000SL
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Traction System Hydraulic Unit (A7/3)
Consists of:
• SBC control module (A7/3n1)
• High pressure charge pump
(A7/3m1)
• Pressure reservoir
27
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Traction System Hydraulic Unit
A7/3
28
GF42.50-P-4000-03S
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Legend
1
2
3
7
Brake Operating Unit
Brake pressure simulator
Pressure reservoir
Left front media separator
(dividing piston)
Right front media separators
(dividing piston)
Traction system hydraulic unit
A7/3y1
Left front separation valve
Right front separation valve
Front axle balance valve
A7/3y2
A7/3y3
A7/3y4
A7/3y6
A7/3y7
A7/3y8
A7/3y9
Rear axle balance valve
Left front intake control valve
Left front outlet control valve
Right front intake control valve
Right front outlet control valve
8
A7/3
A7/3b1 Front axle pre-pressure sensor
A7/3b2 Reservoir pressure sensor
A7/3b3 Left front pressure sensor
A7/3b4 Right front pressure sensor
A7/3b5 Left rear pressure sensor
A7/3b6 Right rear pressure sensor
A7/3m1 High-pressure charge pump
A7/3y10 Left rear intake control valve
A7/3y11 Left rear outlet control valve
A7/3y12 Right rear intake control valve
A7/3y13 Right rear outlet control valve
B37/1
S9/1
SBC pedal value sensor
Stop lamp switch (4-pin)
29
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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
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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
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Three Pressure Stages
Same pressure stages as used with ABS functions:
• Pressure apply
• Pressure hold
• Pressure release
32
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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
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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
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Pressure Apply - All Wheels
35
GF42.50-P-4000-04S
GF42.46-P-1000SL
• Outlet control valves y7, y9, y11, y13 energized
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Pressure Hold - All Wheels
• y6, y8, y10, y12 de-energized
36
GF42.50-P-4000-04S
GF42.46-P-1000SL
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Pressure Reduction - All Wheels
• y7, y9, y11, y13 de-energized
37
GF42.50-P-4000-04S
GF42.46-P-1000SL
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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
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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
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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
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Deactivation
Charge pump disabled and accumulator fluid returned to the reservoir!
41
Pressure at A7/3b2
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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
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System Activation
43
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Activation - Left Front
44
Caliper held with ~60 bar
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Activation - Right Front
Caliper held with ~60 bar
45
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Activation - Right Rear
46
Caliper held with ~60 bar
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Activation - Left Rear
47
Caliper held with ~60 bar
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Activation - Recharge
48
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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
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Equipment Required
• Pressure bleeder
• Adapters
• Fluid receptacle
• SDS - follow instructions carefully
211 589 01 91 00
CAUTION:
Extremely high pressure at bleeder!
50
AR42.10-P-0010-02R
AR42.10-P-0012R
WS42.00-P-0048B
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Bleeding the Brake System
Connect equipment and follow steps in SDS
51
AR42.10-P-0012R
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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
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Appendix
AR42.10-P-0010I
Carrying out bleeding operation
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
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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