MEDIUM DUTY TRUCK HYDRAULIC BRAKES OPERATION AND DIAGNOSIS Student Guide FCS-13989-REFref ORDER NUMBER:FCS-13989-REF COURSE CODE:58S01T0 February, 2004 Ford Customer Service Division Technical Training IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle • • Always wear safety glasses for eye protection • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure • • Do not smoke while working on the vehicle Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation • Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood Use safety stands whenever a procedure requires you to be under the vehicle • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide • Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: Many brake linings contain asbestos fibers When working on brake components, avoid breathing the dust Breathing the asbestos dust can cause asbestosis and cancer Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2004 Ford Motor Company Produced and Coordinated by Technical Support Operations Ford Customer Service Division February, 2004 SERVICE STANDARDS Mission Statement: All dealership personnel will treat every customer as a potential lifetime purchaser, communicating a professional image which embraces honesty and concern for customer wants and needs Dealer-to-Customer Service Standards: Appointment available within one day of the customer’s requested service day Write-up begins within four minutes of arrival Service needs courteously identified, accurately recorded on Repair Order, and verified with customer Vehicles serviced right on the first visit Service status provided within one minute of inquiry Vehicle ready at agreed upon time Thorough explanation of work done, coverages and changes These seven service standards provide a process and product value that are compelling reasons for owners to purchase and repurchase Ford or Lincoln-Mercury products These standards also help to attract new owners through favorable testimonials and improved owner satisfaction Standard “Fix It Right the First Time, on Time.” The technician is the most important player when it comes to Standard #4 Why Customers tell us “Fixing It Right the First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix it Right the First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via STST New Model — Web-Based Training — FORDSTAR — Ford Multimedia Training (FMT) — Instructor-Led — Instructor-Led The Benefits The successful implementation of standards means — Satisfied customers — Repeat vehicle sales — Repeat service sales — Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” Contents INTRODUCTION AND PREREQUISITE REVIEW FORD BRAKES SERVICE TECHNICIAN SPECIALITY TRAINING (STST) CURRICULUM Intro - Curriculum Goals Intro - Air Brake System Operation and Diagnosis Instructor-Led Course Description Intro - Course Objective Intro - Lesson Objectives Intro - Audience Intro - Course Prerequisites Intro - Evaluation Intro - Student Guide Intro - Service Standards Intro - PREREQUISITE REVIEW Intro - LESSON 1: HYDRAULIC BRAKES THEORY AND OPERATION Introduction To Hydraulic Brake Systems - Hydraulic Description - Hydraulic Operation - Brake System Overview - Master Cylinder - Hydro-Max Description - Hydro-Max Operation - ABS Description - 16 ABS Operation - 17 Parking Brake System - 18 Auxiliary Brake System Description and Operation - 19 LESSON 2: COMPONENTS Hydraulic Brake System Components - Disc Brake System Components - Hydro-Max System Components - 13 ABS System Components - 19 Parking Brake System Components - 26 LESSON 3: DIAGNOSIS Diagnosis and Testing - Preliminary Brake System Checks - Diagnostic Test - Common Customer Concerns - 12 Brake Pedal Conditions - 15 Hydro-Max Booster Diagnostics - 24 ABS Diagnostics - 28 Meritor-WABCO Toolbox Software Functions - 29 Standard ABS Testing - 31 Standard ABS Component Testing - 31 i APPENDIX Appendix - GLOSSARY Glossary - TOOL LIST Tool - ROTUNDA ORDER FORM Rotunda - ii INTRODUCTION AND PREREQUISITE REVIEW INTRODUCTION AND PREREQUISITE REVIEW OBJECTIVES CONTENTS Review the Ford Medium Duty Truck Brakes Service Technician Speciality Training (STST) Curriculum Introduction to the Ford Medium Duty Truck Brakes Service Technician Speciality Training (STST) Curriculum Administer the prerequisite review Prerequisite Review Hydraulic Brakes Operation and Diagnosis February, 2004 Intro - INTRODUCTION AND PREREQUISITE REVIEW FORD MEDIUM DUTY (MD) TRUCK BRAKES SERVICE TECHNICIAN SPECIALITY TRAINING (STST) CURRICULUM MD TRUCK BRAKES CURRICULUM MAP Electrical/Electronic Curriculum MD Truck Hydraulic Brakes Theory and Operation Web Based Training - Course Code 58S03W0 MD Truck Air Brakes Theory and Operation Web Based Training - Course Code 58S01W0 MD Truck Air Brakes Service and Diagnosis Web Based Training - Course Code 58S02W0 MD Truck Hydraulic Brakes Operation and Diagnosis Instructor-Led Training - Course Code 58S01T0 MD Truck Air Brakes Service and Diagnosis Instructor-Led Training Course Code 58S02T0 Courses of The Ford Medium Duty Truck Brakes Service Technician Speciality Training (STST) Curriculum The Ford Medium Duty Truck Brakes Service Technician Speciality Training (STST) Curriculum consists of five courses related to brake system operation and diagnosis Each course in the curriculum is a “building block” for the next course in the curriculum This curriculum is designed for technicians who want to learn the methods and techniques to properly diagnose and service brake systems and components Intro - February, 2004 Hydraulic Brakes Operation and Diagnosis INTRODUCTION AND PREREQUISITE REVIEW Curriculum Goals The goals of this curriculum are to provide: The necessary training to enable the technician to identify, diagnose and perform timely “Fix It Right The First Time On Time” repairs Increased customer satisfaction Increased technician productivity Fewer repeat repairs Medium Duty Truck Hydraulic Brakes Operation and Diagnosis Instructor-Led Course Description This is the first instructor-led course in the Medium Duty Truck Brakes Curriculum It is a two-day course facilitated by an instructor This course is designed to provide hands-on opportunities for technicians to learn and improve their skills using tools and equipment; and to apply knowledge learned in previous curriculum courses Course Objective Given the information presented in the Ford Medium Duty Hydraulic Brake System Operation and Diagnosis Course, the necessary service information and tools, technicians will be able to perform accurate, timely, costeffective diagnosis and repair of ABS, Hydro-Max, and basic hydraulic brake systems on Ford Motor Company Medium Duty Trucks Lesson Objectives Each lesson of this course starts with a list of objectives for the participants The lesson objectives are designed to support the course objective Audience This course is designed for any Ford and Lincoln and Mercury service technicians who are enrolled in the Ford Medium Duty Truck Brakes Service Technician Speciality Training (STST) Curriculum Additionally, this course is also designed for training service technicians of Ford Designated Fleets Course Prerequisites All students must have completed the first course in the curriculum prior to enrolling in this course If you have not completed all of the prerequisite courses please notify your instructor Automotive Electrical 34S14T0 Automotive Electronics 34S19T0 Medium Duty Truck Hydraulic Brakes Theory and Operation Web Based Training - Course Code 58S03W0 Hydraulic Brakes Operation and Diagnosis February, 2004 Intro - INTRODUCTION AND PREREQUISITE REVIEW Evaluation Each technician attending this course will be required to pass a combination hands-on/written evaluation This will be administered on the afternoon of the second day The hands-on evaluation is a pass/fail type Hands-on evaluations will be conducted with exercises in: – ABS diagnosis – Written evaluation – Special tool usage In order to pass the course, you must demonstrate acceptable skills at the evaluated hands-on exercises and you must answer at least 80% of the written post test questions correctly Student Guide The Student Guide contains the worksheets used at the workstations for each of the two days You must complete each worksheet IMPORTANT: Actively participate in exercise reviews This is your opportunity to ask questions and clear up any areas that you may not fully understand Intro - February, 2004 Hydraulic Brakes Operation and Diagnosis APPENDIX SID FMI Fault Frame Pin/Plug Fault ID System Reaction WL ABS: selective Inlet (IV) or switch OFF outlet (OV) or common wire More than failures: valve relay is shorted to OFF, ABS disabled 12V WL Single failure: ABS selective switch OFF Multiple failures: Front/Front: ABS both selective Front/Rear Diagonal: ABS selective Front/Rear Same Side: ABS disabled Rear/Rear: ABS disabled Inlet (IV) or outlet (OV) or common wire Check modulator wires is permanently or temporarely broken WL Single failure: ABS selective switch OFF Multiple failures: Front/Front: ABS both selective Front/Rear Diagonal: ABS selective Front/Rear Same Side: ABS disabled Rear/Rear: ABS disabled Inlet (IV) or outlet (OV) or common wire is shorted to ground C au se Action Solenoid Inlet Valve, Right Rear 45 45 45 - 10 Short to UVENT or UBATT Open circuit short to ground 11/x3 6/ grey 11/x3 6/ grey 11/x3 6/ grey February, 2004 Check modulator wires Check modulator wires Hydraulic Brakes Operation and Diagnosis APPENDIX SID FMI Fault Frame Pin/Plug Fault ID System Reaction WL ABS: selective Inlet (IV) or switch OFF outlet (OV) or More than common wire failures: valve relay is shorted to OFF, ABS disabled 12V WL Single failure: ABS selective switch OFF Multiple failures: Front/Front: ABS both selective Front/Rear Diagonal: ABS selective Front/Rear Same Side: ABS disabled Rear/Rear: ABS disabled Inlet (IV) or outlet (OV) or common wire Check modulator wires is permanently or temporarely broken WL Single failure: ABS selective switch OFF Multiple failures: Front/Front: ABS both selective Front/Rear Diagonal: ABS selective Front/Rear Same Side: ABS disabled Rear/Rear: ABS disabled Inlet (IV) or outlet (OV) or common wire is shorted to ground C au se Action Solenoid Inlet Valve, Left Front 48 48 48 Short to UVENT or UBATT Open circuit short to ground 1/x3 10/ grey 1/x3 10/ grey 1/x3 10/ grey Hydraulic Brakes Operation and Diagnosis February, 2004 Check modulator wires Check modulator wires - 11 APPENDIX SID FMI Fault Frame Pin/Plug Fault ID System Reaction WL ABS: selective Inlet (IV) or switch OFF outlet (OV) or common wire More than failures: valve relay is shorted to OFF, ABS disabled 12V WL Single failure: ABS selective switch OFF Multiple failures: Front/Front: ABS both selective Front/Rear Diagonal: ABS selective Front/Rear Same Side: ABS disabled Rear/Rear: ABS disabled Inlet (IV) or outlet (OV) or common wire Check modulator wires is permanently or temporarely broken WL Single failure: ABS selective switch OFF Multiple failures: Front/Front: ABS both selective Front/Rear Diagonal: ABS selective Front/Rear Same Side: ABS disabled Rear/Rear: ABS disabled Inlet (IV) or outlet (OV) or common wire is shorted to ground C au se Action Solenoid Outlet Valve, Right Front 49 49 49 - 12 Short to UVENT or UBATT Open circuit short to ground 4/x3 9/ grey 4/x3 9/ grey 4/x3 9/ grey February, 2004 Check modulator wires Check modulator wires Hydraulic Brakes Operation and Diagnosis APPENDIX SID FMI Fault Frame Pin/Plug Fault ID System Reaction WL ABS: selective Inlet (IV) or switch OFF outlet (OV) or common wire More than failures: valve relay is shorted to OFF, ABS disabled 12V WL Single failure: ABS selective switch OFF Multiple failures: Front/Front: ABS both selective Front/Rear Diagonal: ABS selective Front/Rear Same Side: ABS disabled Rear/Rear: ABS disabled Inlet (IV) or outlet (OV) or common wire Check modulator wires is permanently or temporarely broken WL Single failure: ABS selective switch OFF Multiple failures: Front/Front: ABS both selective Front/Rear Diagonal: ABS selective Front/Rear Same Side: ABS disabled Rear/Rear: ABS disabled Inlet (IV) or outlet (OV) or common wire is shorted to ground C au se Action Solenoid Outlet Valve, Left Rear 50 50 50 Short to UVENT or UBATT Open circuit short to ground 7/x3 8/ grey 7/x3 8/ grey 7/x3 8/ grey Hydraulic Brakes Operation and Diagnosis February, 2004 Check modulator wires Check modulator wires - 13 APPENDIX SID FMI Fault Frame Fault Pin/Plug ID System Reaction C au se Action Solenoid Outlet Valve, Right Rear 51 51 51 - 14 Short to UVENT or UBATT Open circuit short to ground 10/x3 7/ grey 10/x3 7/ grey 10/x3 7/ grey WL ABS: selective Inlet (IV) or switch OFF outlet (OV) or More than common wire failures: valve relay is shorted to OFF, ABS disabled 12V WL Single failure: ABS selective switch OFF Multiple failures: Front/Front: ABS both selective Front/Rear Diagonal: ABS selective Front/Rear Same Side: ABS disabled Rear/Rear: ABS disabled Inlet (IV) or outlet (OV) or common wire Check modulator wires is permanently or temporarely broken WL Single failure: ABS selective switch OFF Multiple failures: Front/Front: ABS both selective Front/Rear Diagonal: ABS selective Front/Rear Same Side: ABS disabled Rear/Rear: ABS disabled Inlet (IV) or outlet (OV) or common wire is shorted to ground February, 2004 Check modulator wires Check modulator wires Hydraulic Brakes Operation and Diagnosis APPENDIX SID Frame Pin/Plug Fault ID System Reaction C au se Action High level at monitor without pump motor activation 15/x3 8/2 6/ black 10/ black WL ABS: Disabled Monitor interrupted Check RCP monitor wiring Low level at monitor with pump motor activation 15/x3 6/ black ABS: Disabled Low level with act Pump relay does not switch ON Check RCP relay, fuse and wiring Check the pump, the pump wiring and pump connector Check pump monitor Pump motor sticks, motor locked Check the pump and pump wiring If it is a current failure exchange the modulator If not disconnect the ECU from harness, fit FL diagnostic connector to the ECU vehicle connector, turn the ignition ON, link PIN 2/x2 (2/black) to PIN 15/x3 (6/black) If the pump is not running audible then exchange the modulator FMI Fault Recirculation Pump 54 54 WL 54 Dynamical pump failure 15/x3 6/ black WL 30 Short to UVENT or UBATT 15/x3 6/ black WL ABS: Disabled, valve relay OFF Short to UVENT/UBATT Check the pump motor relay and wiring 30 Open circuit 15/x3 6/ black WL ABS: Disabled Open circuit Check the pump motor relay and wiring 30 Short to ground 15/x3 6/ black WL ABS: Disabled Short to ground Check the pump motor relay and wiring Pump 15/x3 motor 6/ permanentlblack y running ABS: Disabled Motor relay sticks, relay permanently powered Check the pump motor relay and wiring 30 WL Hydraulic Brakes Operation and Diagnosis ABS: Disabled February, 2004 - 15 APPENDIX SID FMI Fault Frame Pin/Plug Fault ID System Reaction C au se Action Check ground connections Ground Connection 55 Reference ground interrupted 3/x3 2/ grey WL ABS: Disabled, valve relay OFF Reference ground interrupted (PIN 3/x3 (2/grey) connector) Supply Voltage 251 251 Supply voltage too high 2/x2 2/ black WL ABS: Disabled High supply voltage Check alternator and battery Supply 2/x2 voltage is 2/ temporarely black too low WL ABS: Disabled Low supply voltage Check supply voltage Tire parameter in the EEPROM is not correct Correct tire parameter in the EEPROM Multiple possibilities Replace ABS electronic if fault detection repeats Tire Parameter 253 Tire parameter incorrect % WL ABS: Disabled, valve relay OFF EC U internal failure % WL ABS: Disabled, valve relay OFF Internal 254 - 16 12 February, 2004 Hydraulic Brakes Operation and Diagnosis APPENDIX NOTES Hydraulic Brakes Operation and Diagnosis February, 2004 - 17 APPENDIX NOTES - 18 February, 2004 Hydraulic Brakes Operation and Diagnosis GLOSSARY ABS Anti-lock Brake System BOO Brake ON/OFF BPP Switch Brake Pedal Position Brake Pedal Reserve The distance between the bottom of the brake pedal and the floor Brake Pedal Free Play The distance that the brake pedal is applied before braking begins to occur CAN Controller Area Network DOT Department of Transportation DTC Diagnostic Trouble Code DTV Disc Thickness Variation ECU Electronic Control Unit EHCU Electronic Hydraulic Control Unit (ABS module that is co-located with HCU) GEM Generic Electronic Module HCU Hydraulic Control Unit Hydro-Max Hydraulic brake boosting system KOEO Key On Engine Off KOER Key On Engine Running LED Light Emitting Diode LPA Low Pressure Accumulator MIL Malfunction Indicator Lamp Multiplexing A computer strategy that allows module-to-module communication during normal vehicle operation NGS New Generation STAR Tester OBD On-board Diagnostics PC/ED Powertrain Control/Emission Diagnosis PCM Powertrain Control Module PID Parameter Identification Protocol A computer language that allows communication between control modules PSI Pounds per Square Inch PWM Pulse Width Modulated RPM Revolutions Per Minute Hydraulic Brakes Operation and Diagnosis February, 2004 Glossary - GLOSSARY SIG RTN Signal Return SSCC Symptom-to-System-to-Component-to-Cause SW B+ Switched Battery Voltage TPS Throttle Position Sensor TSB Technical Service Bulletin VIN Vehicle Identification Number VSS Vehicle Speed Sensor WSS Wheel Speed Sensor WDS World Diagnostic System Glossary - February, 2004 Hydraulic Brakes Operation and Diagnosis TOOL LIST TOOL LIST Rotunda ABS and Brake Pressure Test Kit 107-02353 Disc Brake Caliper Lubricant D7AZ-19590-A Silicone Brake Caliper Grease and Dielectric Compound WA-10 (D7AZ-19A331-A) or equivalent meeting Ford specifications ESE-M1C171-A Ford Premium Long Life Grease (XG-1-C) Worldwide Diagnostic System (WDS) 418-F224 Parking Brake Cable Adjustment Gauge 206-086 88 Digital Multimeter 105-R0053 Flex Probe Kit 105-R025B Meritor-WABCO Truck Software and Cable Kit 418-D553 Hydraulic Brakes Operation and Diagnosis February, 2004 Tool - TOOL LIST Tool - February, 2004 Hydraulic Brakes Operation and Diagnosis QTY PART I BAL OF NO ITEM NUMBER PREFIX Dealer Parts Code #: Dealer Name: Address: City, State, Zip: Phone #: Fax #: Attention: Order Date: Ship to arrive by (Date or ASAP): Address: City, State, Zip: COL ADDITIONAL SPECIFICATIONS (if required) COL ORDER FORM OPTIONAL: CATALOG PAGE NO PART II DESCRIPTION Prices subject to change without notice EXTENDED TOTAL AUTHORIZED DEALERSHIP SIGNATURE (BUYER) PRINT NAME FCSD CREDIT MANAGER APPROVAL (ORDERS OVER $4,000) PART III TOTAL UNIT PRICE FAX NUMBER 1-800-762-6181 ❏ 36 Mo (Minimum $5,000) Buyer, having been quoted both an installment Price and a lesser Cash Price, hereby purchases from Seller on installment price basis, upon the terms and conditions set forth on the face hereof, the equipment to be delivered and installed at Buyer’s premises, as described above and agrees to pay Seller the Installment Price therefore as so set forth until paid in full ❏ 30 Day Open Account Installment Plan (Fixed Rate) ❏ 12 Mo (Minimum $1,000) ❏ 24 Mo (Minimum $3,000) ❏ 48 Mo (Minimum $10,000) ❏ 60 Mo (Minimum $15,000) (Reverse side must be completed) ❏ 90 Days Same as Cash (Minimum $1,000) Notice To Buyer: 315-195 Do not sign this contract before you read it or if it contains any blank spaces You are entitled to an exact copy of the contract you sign Under the law you have the right to pay off in advance the full amount due and under certain circumstances to obtain partial refund of the time charge BUYER ACKNOWLEDGES RECEIPT OF A TRUE AND COMPLETELY FILLED IN COPY OF THIS CONTRACT AT THE TIME OF SIGNING September 1999 FOR TELEPHONE ORDERS USE THE ROTUNDA TOLL-FREE NUMBER 1-800-ROTUNDA (768-8632) DEALER: Be sure you have completed Parts I and II for all orders, Part III for Installment Plan Orders 315-195 (Previous editions may not be used) Payment and Terms of Payment a If Buyer has requested the Dealer Open Account payment plan via the Ford Dealer Statement in Part II of the order form, and Seller agrees to sell pursuant to such plan, then Buyer shall pay the total purchase price shown on the invoice b If Buyer has requested the Installment Plan (Fixed Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Down Payment (if any), and the Time Balance in equal monthly installments in accordance with the terms set forth below c If Buyer has requested the Installment Plan (Variable Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Total Cash Price and any interest thereon in accordance with the Loan and Security Agreement to be executed by Buyer and Seller Title Title to Equipment purchased by Buyer from Seller shall pass to Buyer upon Seller’s receipt of all amounts owing by Buyer to Seller hereunder Risk of Loss Seller shall be responsible for risk of loss until Equipment is delivered to the location set forth herein, at which time risk of loss shall be the responsibility of Buyer Acceptance and Inspection Buyer shall be deemed to have accepted Equipment upon Seller’s delivery Equipment shall be deemed to have been delivered in good condition unless Buyer gives Seller notice to the contrary within 10 days after Seller’s delivery Delays Seller shall not be liable for any failure or delay in delivering Equipment, or for any failure to perform any provision hereof, resulting from fire, flood or other casualty, riot, strike or other labor difficulty, governmental regulation or other restriction, or any other cause beyond Seller’s control Unconditional Obligation Buyer’s obligation to make payments to Seller or its assignee shall be absolute and unconditional and shall continue unmodified despite any loss, damage or other interruption in the use of Equipment The obligation of Buyer to pay in full any amounts due under this contract shall not be subject to dispute, claim, counterclaim, defense or other right which Buyer may have to assert against Seller or the manufacturer of Equipment Buyer acknowledges that: (a) Buyer has selected Equipment and Manufacturer, and Buyer has determined Equipment’s suitability and fitness for the Buyer’s purpose, (b) Seller is not the manufacturer of Equipment, and (c) Manufacturer issues its own warranty and performs the obligations under such warranty Warranty THE MANUFACTURER’S WARRANTY SHALL BE BUYER’S EXCLUSIVE REMEDY, RECOURSE OR DAMAGE FOR ANY DEFECT IN WORKMANSHIP OR MATERIAL OR ANY FAILURE OF THE EQUIPMENT SELLER MAKES NO WARRANTIES, REPRESENTATIONS, INDEMNITIES OR GUARANTEES WHATSOEVER WITH RESPECT TO EQUIPMENT EITHER EXPRESS OR IMPLIED, ARISING BY LAW OR CUSTOM, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THE LIABILITY OF THE SELLER SHALL BE LIMITED TO EXPRESS OBLIGATION TO DELIVER THE EQUIPMENT UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE OR RESPONSIBLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, WHETHER FORESEEABLE OR UNFORESEEABLE, WHICH BUYER MAY INCUR, EXPERIENCE OR CLAIM, INCLUDING, BUT NOT LIMITED TO, CLAIMS FOR LOSS OF PROFITS, INTERRUPTION IN BUSINESS, LOST OPPORTUNITY, WORK STOPPAGE OR OTHER IMPAIRMENT OF ASSETS, ARISING OUT OF MISREPRESENTATION, NEGLIGENCE, STRICT LIABILITY, IN TORT OR OTHERWISE, ON ACCOUNT OF ENTERING INTO OR RELYING ON THIS AGREEMENT, EVEN IF SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES Freight and Taxes Freight costs and applicable taxes will be added to the final invoice and will be borne by Buyer Security Interest Buyer hereby grants to Seller a continuing security interest in the Equipment, including all products and proceeds thereof, until all amounts due hereunder are paid Buyer agrees to execute, and pay filing fees for, any financing statement or other documents deemed necessary by Seller to maintain a valid security interest in the Equipment TERMS & CONDITIONS 10 Maintenance Buyer shall use the Equipment carefully and properly Buyer, at Buyer’s own expense, shall maintain and repair all items of the Equipment in order to keep them in good order and condition and, in particular, shall comply fully with the maintenance, operating, usage or other instructions provided by the manufacturer Buyer authorizes Seller, or any third party appointed by Seller, to inspect the Equipment when necessary Buyer shall at all times keep the Equipment free and clear of all liens, charges or encumbrances 11 Personal Property Ford proprietary diagnostic equipment (including the software, if applicable) shall be kept at Buyer’s premises as listed on the reverse side and shall remain personal property regardless of how and to what degree it may be affixed or attached to any building or structure or what may be the consequence of its removal from such building or structure Buyer shall not encumber the Equipment (including software, if applicable) until all amounts owing to Seller hereunder are paid In addition, Seller grants to Buyer, and Buyer accepts, a non-exclusive license to use the Equipment (including the software, if applicable) in accordance with the terms and conditions set forth herein The license (and Equipment) shall not be leased, sold, assigned or otherwise transferred, in whole or in part In the event, Buyer proposes to lease, sell assign or otherwise transfer the Equipment (and/or its software, if applicable), in whole or in part, to any person or entity, Ford Motor Company shall have a Right of First Refusal to purchase the Equipment (including all software, if applicable) for Ten and 00/100 Dollars ($10.00) in U.S currency 12 Insurance and Indemnification Buyer shall defend, indemnify and hold harmless Seller from and against, and at Buyer’s own expense provide insurance satisfactory to Seller covering any and all losses, damages, claims, expenses and other liabilities (including attorney’s fees,) relating to or arising out of: (I) damage, loss, theft, or destruction of the Equipment, or (ii) death, injury or property damage connected with the use, operation or condition (including without limitation, defects whether or not discoverable by any party) of the Equipment Buyer shall promptly notify Seller of any such claim Seller shall have the right to participate, at its own expense, in any proceeding for which Buyer has undertaken the defense of Seller, and in no event shall Buyer settle any claim against Seller without Seller’s prior written consent, Buyer shall provide evidence of such insurance to Seller upon demand Seller is under no obligation to examine any insurance certificate or advise Buyer that its insurance does not comply with the requirements set forth herein The losses covered by insurance shall in all cases be payable to Seller and Buyer as their interests may appear If Buyer fails to insure the Equipment as herein provided, Seller may, but is not obligated to, place such insurance upon the Equipment and the Buyer agrees to pay to Seller on demand the premiums for such insurance placed by Seller In no event shall any insurance coverage be deemed to limit or replace Buyer’s obligation to indemnify Seller as provided herein 13 Default In the event that Buyer: (a) fails to pay any amount due hereunder within ten (10) days of the due date, (b) fails to comply with any other provision hereof, (c) files, or if there is filed against Buyer, any petition under any bankruptcy or insolvency laws or suffers the appointment of any trustee or receiver for all or any part of Buyer’s business or assets, or (d) has any assignment (voluntarily or involuntarily), lien, attachment or levy issued against the Equipment (unless such petition, assignment or appointment, lien, attachment or levy is withdrawn or nullified within twenty (20) days) then Buyer shall be in default hereunder and all of Buyer’s indebtedness and obligations to Seller shall, at Seller’s option, become immediately due and payable, and Seller may, at its option, terminate this contract and repossess any and all items of Equipment with or without legal process and sell the same at private or public sale without prior notice to Buyer to the extent permitted by law Upon request, Buyer shall deliver the Equipment to Seller at a place designated by Seller Repossession and/or sales of the Equipment upon such default shall not affect the Seller’s right to retain all payments made prior to repossession or to recover the balance due hereunder for any deficiency Buyer shall reimburse Seller all costs of collection, repossession and resale (including reasonable attorneys’ fees, court costs and other expenses incurred by Seller.) Buyer hereby releases Seller from any liability for damages resulting from repossession hereunder The rights and remedies of Seller, in the event of default herein mentioned shall not be deemed exclusive but shall be cumulative and in addition to all other rights and remedies existing under law, and may be enforced successively or concurrently Waiver by Seller of any default shall not be deemed a waiver of any other default 14 General The waiver by either party of, or failure to claim, a breach of any provision of this contract shall not be deemed to be a waiver of any provision of this contract, shall not be deemed to be a waiver of any subsequent breach or to affect in any way the effectiveness of such provision This contract constitutes the entire agreement between the parties and may not be changed except by an instrument in writing signed by the party to be charged This contract may not be assigned by Buyer without the Seller’s prior written consent Seller may assign this contract at any time but shall not thereby be relieved from any liability hereunder In the event that one or more clauses of this contract are found to be unenforceable, illegal or contrary to public policy by court of competent jurisdiction, the remainder of this contract shall remain in full force and effect except for the unenforceable, illegal or other provisions This agreement is a Michigan agreement and shall be interpreted, construed and enforced in accordance with the laws of the State of Michigan, United States of America Each of the parties here to agrees that any legal or equitable action or proceeding with respect to this agreement shall be brought only in any court of the State of Michigan, or in any court of the United States of America sitting in Michigan, and each of the parties hereto submits to and accepts generally and unconditionally the jurisdiction of those courts with respect to such party’s person and property Each party hereby irrevocably waives any objection to the laying of venue of any such action or proceeding in the above described courts 15 Finance Charge Monthly portion of Finance Charge (Part III, Item 3) due is calculated each month by multiplying 1/12 of the annual finance charge rate times the remaining portion of the Unpaid Balance of Cash Price, and is added to the portion of the Unpaid Balance of Cash Price due each month PART III Cash Price $ $ $ Installment Plan Agreement Down Payment (if any) $ Unpaid Balance of Cash Price (Difference between and 2) Finance Charge (Finance charge will reduce each month) Call 1-800-768-8632 for the current finance charge rate $ $ Time Balance (3 + 4) Number of Installments ❏ 12 ❏ 24 ❏ 36 ❏ 48 ❏ 60 equal monthly installments Taxes and transportation (if any) will be billed separately Installment Payment Price (1 + 4) 315-195 Date: Prices subject to change without notice MAIL COMPLETED ORDER FORM TO: ROTUNDA EQUIPMENT PROGRAM P.O Box 1450 Kenosha, WI 53141 I agree to pay the time Balance set forth in accordance with the above schedule and the terms and conditions of this order form Dealer Signature: February 2004 ... bleed Hydraulic Brakes Operation and Diagnosis February, 2004 Intro - INTRODUCTION AND PREREQUISITE REVIEW NOTES Intro - February, 2004 Hydraulic Brakes Operation and Diagnosis LESSON 1: HYDRAULIC. .. theory and operation of a hydraulic system refer to the web-based training course 1-2 February, 2004 Hydraulic Brakes Operation and Diagnosis LESSON 1: HYDRAULIC BRAKES THEORY AND OPERATION HYDRAULIC. .. A hydraulic system can be used to increase or decrease force or motion Hydraulic Brakes Operation and Diagnosis February, 2004 1-3 LESSON 1: HYDRAULIC BRAKES THEORY AND OPERATION HYDRAULIC OPERATION