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Mercedes Benz Sensotronic
Mercedes Benz Sensotronic
Mercedes Benz Sensotronic
cBrake Control
(SBC)
Obj
ectives
1.
2.
3.
4.
5.
6.
7.
8.
9.
These technical training materials are current as ofthe date noted on the materials,and maybe revised or updated without notice. Always check for revised or updated information.
To help avoid personal inj
uryto you or others,and to avoid damage to the vehicle on which you are working,you must always refer to the latest Mercedes -BenzTechnical Publication and follow all
pertinent instructions when testing,diagnosing or making repair.
Illustrations and descriptions in this training reference are based on preliminaryinformation and maynot correspond to the final US version vehicles. Refer to the official introduction manual and WIS
when available.
Copyright Mercedes-BenzUSA,LLC,2004
W IS document numbers shown appl
y to W IS Version USA/CDN at date ofwriting.
Reproduction by any means or by any information storage and retrievalsystem or transl
ation in whol
e or part is not permitted without written authorization from Mercedes -BenzUSA,LLC or it'
s
successors.
Publ
ished by Mercedes -BenzUSA,LLC
Printed in U.S.A.
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
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
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
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
Warning Display
Complete ESP control module failure Instrument cluster will scroll through failure displays
11
Warning Display
SBC control module failure
12
SBC Components
Brake Operati
ng Uni
t(BOU)
W heelspeed sensors
Tracti
on System Hydraul
i
c
Uni
t(A7/3)
13
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
Speed status
Diagnostics
ESP control
module (N47/5)
Front
SAM
(N10/1)
Diagnostic connector
(X11/4)
14
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
W211
A7/3n1
SBC
A7/3n1
SBC
X11/4
N47/5
ESP
X11/4
N10/1
L.F.SAM
N15/5
ESM
Z70/4
Pin 9
Z6/33
Pin 9
N51/2
ABC
N47/5
ESP
16
17
18
Master Cylinder
Fluid level sensor
Fluid return line
Do not overfill
Hydraulic lines to SBC
Supply hose to SBC
19
Ultraviolet protection
(211 only)
20
21
Pri
marypi
ston
Fl
oati
ng pi
ston
y2
y1
A7/3- Tracti
on system hydraul
i
c
uni
twi
th separati
on val
ves y1 and
y2
A7/3
Brake pressure si
mul
ator
22
GF42.46-P-4200-03SL
y2
y1
A7/3
y2
y1
A7/3
Increasing pedal
travel causes the
larger spring to
compress, providing
harder pedal feel
24
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
Consists of:
SBC control module (A7/3n1)
Pressure reservoir
27
Tracti
on System Hydraul
i
cUni
t
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
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
29
30
GF42.46-P3000SL
31
GF 42.50-P-4000-04S
GF42.46-P-0001SL
32
GF42.50-P-4000-04S33
GF42.46-P-1000SL
GF42.46-P-4500-02SL
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
35
GF42.50-P-4000-04S
GF42.46-P-1000SL
36
GF42.50-P-4000-04S
GF42.46-P-1000SL
37
GF42.50-P-4000-04S
GF42.46-P-1000SL
Temperature Compensation
Deacti
vati
on
SBC mustbe deacti
vated wi
th SDS before anyworki
sperformed
on the system. Thi
swi
l
lpreventthe pre-dri
ve checkfrom bei
ng
automati
cal
l
y performed whi
ch coul
d cause i
nj
ury.
Deacti
vati
ng the system wi
l
l
:
emptythe pressure reservoi
r
(a l
owerpressure wi
th no vol
ume maybe retai
ned)
preventthe charge pump from operati
ng
Note:the warni
ng buzzeri
sdeacti
vated when accessi
ng
SBC wi
th 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
44
45
46
47
Activation - Recharge
48
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
W S42.00-P-0048B
50
51
AR42.10-P-0012R
Acronym List
(Used in This Handout.)
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
53