58S02T0 air brake systems operation and diagnosis 2004

Air Brake Systems Operation and Diagnosis Student Guide FCS-13990-REFi gk ORDER NUMBER: FCS-13990-REF COURSE CODE: 58S02T0 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 Vehicles serviced right on the first visit Write-up begins within four minutes of arrival Service status provided within one minute of inquiry Service needs courteously identified, accurately recorded on Repair Order, and verified with customer Vehicle ready at agreed upon time Thorough explanation of work done, coverages andchanges 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 NewModel — 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 IMPORTANT SAFETY NOTICE INTRODUCTION AND PREREQUISITE REVIEW Intro - Course Objectives Intro - Lesson Objectives Intro - Course Prerequisites Intro - Evaluation Intro - WORKSHEET A Intro - AIR BRAKE COMPONENT LOCATION AND FUNCTION INTRO - INTRODUCTION - INTRODUCTION TO AIR BRAKE SYSTEMS - Air Brake Components - OBJECTIVES 1-1 SYSTEM OPERATION - AIR SUPPLY SYSTEM 1-2 Air Compressor 1-3 Governor 1-5 Air Dryer 1-7 Air Dryer Service 1-10 Desiccant Replacement 1-11 Air Dryer Testing 1-12 Single Check Valve 1-13 Air Reservoir 1-14 Air Reservoir Drainage System 1-16 Tank Valve 1-19 Safety Valve 1-20 Double Check Valve 1-21 Air Pressure Gauge 1-23 Low Pressure Indicator Switch 1-24 Stoplight Switch 1-25 OBJECTIVES 2-1 SYSTEM OPERATION - AIR DELIVERY SYSTEM 2-2 Foot Control Valve 2-3 Relay Valve 2-6 Quick Release Valve 2-9 Air Brake Chambers 2-10 OBJECTIVES 3-1 Cam Brakes 3-2 Automatic Slack Adjusters 3-4 Free Stroke Measurement 3-7 Applied Stroke Measurement 3-8 Brake Inspections 3-9 Brake Service 3-10 Caging Procedure 3-11 Brake Relining 3-12 Cam Brake Component Inspections 3-13 Cam Brake Reassembly 3-14 i OBJECTIVES 4-1 SYSTEM OPERATION - PARKING/EMERGENCY BRAKE SYSTEM 4-2 Parking Brake Control Valve 4-3 Inverting Relay Valve 4-5 Spring Brake Chambers 4-12 OBJECTIVES 5-1 INTRODUCTION TO AIR BRAKE SYSTEM DIAGNOSIS 5-2 SERVICE PRECAUTIONS 5-3 SYMPTOM-TO-SYSTEM-TO-COMPONENT-TO-CAUSE (SSCC) DIAGNOSTIC STRATEGY 5-4 AIR BRAKE SYSTEM TROUBLESHOOTING 5-6 System Test 5-7 System Test 5-8 System Test 5-9 System Test 5-10 System Test 5-11 Brake Shoe and Component Inspection 5-12 AIR BRAKE INSPECTION PROCEDURES 5-13 MAINTENANCE 5-15 Contaminated Air 5-16 Adjustments 5-17 Air Compressor Diagnosis 5-18 AIR BRAKE CONCERNS 5-20 BRAKE SHOE WEAR PATTERNS 5-23 Brake Noise 5-24 OBJECTIVES 6-1 ANTI-LOCK BRAKE (ABS) SYSTEM 6-2 AUTOMATIC TRACTION CONTROL (ATC) SYSTEM 6-4 Anti-lock Control (ABS) Module 6-5 Automatic Traction (ATC) Control 6-6 ABS Relay Valve 6-7 ABS and ATC Indicator Lights 6-8 ABS Modulator Valve 6-9 Wheel Speed Sensors and Wheel Speed Indicators 6-15 ABS DIAGNOSIS 6-16 Performing Diagnosis 6-17 Diagnostic LEDs 6-18 CONTROL MODULE CONFIGURATION 6-19 PARTIAL SHUTDOWN 6-20 TOOL LIST Tool - ii iii NOTES iv INTRODUCTION AND PREREQUISITE REVIEW INTRODUCTION AND PREREQUISITE REVIEW OBJECTIVES CONTENTS z Administer the prerequisite review z Prerequisite Review z Discuss the air brake system z Introduction to the air brake system Air Brake Systems Operation and Diagnosis February, 2004 Intro - INTRODUCTION AND PREREQUISITE REVIEW Curriculum Goals The goals of this curriculum are to provide: z The necessary training to enable the technician to identify, diagnose and perform timely “Fix It Right The First Time On Time” repairs z Increased customer satisfaction z Increased technician productivity z Fewer repeat repairs Air Brake System Diagnosis and Service Instructor-Led Course Description This course is a three-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 Objectives Given the information presented in the Ford Air Brake System Diagnosis and Service Course, the necessary service information and tools, technicians will be able to perform accurate, timely, cost-effective diagnosis and repair of the air brake system, the ABS, and the traction control braking systems on Ford Motor Company vehicles z Describe air brake theory and operation z Explain air brake system operation z Identify Ford medium truck air brake system components z Explain air brake system diagnostics z Describe the components and operation of the ABS and ATC air brake systems z Explain ABS and ATC diagnostic procedures 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 Medium Duty Truck service technicians Additionally, this course is also designed for training service technicians of Ford Designated Fleets Course Prerequisites All students must have completed the first three courses in the curriculum prior to enrolling in this course If you have not completed all of the prerequisite courses please notify your instructor z Automotive Electrical 34S14T0 z Automotive Electronics 34S19T0 z Air Brake Theory and Operation Web Based Training - Course Code 58S01W0 z Air Brake Diagnosis Web Based Training - Course Code 58S02W0 Intro - February, 2004 Air Brake Systems Operation and Diagnosis LESSON 6: ABS AND TRACTION CONTROL ABS Modulator Valve (continued) AIR-069 Anti-lock Hold Item Description Item Description Exhaust Port Supply Solenoid (Energized) Exhaust Diaphragm Spring Exhuast Solenoid Supply Diaphragm Foot Control Valve Service Brake Chamber Spring DESCRIPTION AND OPERATION: z z z The control module will also place the ABS modulator in the hold position prior to entering reapply, when it detects recovery from a locked wheel condition – In this mode of operation the ABS modulator in the hold position prior to entering reapply, when it detects recovery from a locked wheel condition – In this mode of operation the anti-lock modulator supply solenoid remains energized while the exhaust solenoid is de-energized De-energizing the exhaust solenoid opens its inlet and closes its exhaust – Opening the exhaust solenoid inlet allows application air to flow to the control side of the exhaust diaphragm which then seals the exhaust passage – With the exhaust diaphragm seated, further exhaust of brake chamber air pressure is prevented – Because the supply solenoid remains energized the supply diaphragm remains seated, thus preventing application air from flowing to the delivery port and out to the brake chamber The ABS modulator can enter the anti-lock exhaust or reapply mode from the anti-lock hold mode - 12 February, 2004 Air Brake Systems Operation and Diagnosis LESSON 6: ABS AND TRACTION CONTROL ABS MODULATOR VALVE (CONTINUED) AIR-070 Anti-lock Re-Apply Item Description Exhaust Port Item Description Supply Solenoid (Energized) Exhaust Diaphragm Exhuast Solenoid Supply Diaphragm Foot Control Valve Service Brake Chamber Spring Spring DESCRIPTION AND OPERATION: z If the control module senses that wheel speed has increased sufficiently to require reapplication of braking pressure, it de-energizes the supply and exhaust solenoids z With both solenoids de-energized, the anti-lock modulator reapplies air to the brakes in the same manner it did during a non-anti-lock application Air Brake Systems Operation and Diagnosis February, 2004 - 13 LESSON 6: ABS AND TRACTION CONTROL ABS Modulator Valve (continued) Operation Test z To properly test the function of the modulator will require two service technicians z Park the vehicle on a level surface and block or chock the wheels Release the parking brakes and build the air system to governor cut out z Turn the engine ignition key to the OFF position then make and hold a full brake application – With the brake application held and one service technician posted at one of the modulators, turn the vehicle ignition key to the ON position – ONE OR TWO SHORT bursts of air pressure should be noted at the modulator exhaust Repeat the test for each modulator on the vehicle – If at least a single burst of exhaust is not noted or the exhaust of air is prolonged and not short, sharp and well defined, perform the Electrical Tests Leak Test z If you suspect a modulator of leaking perform the following check: z Park the vehicle on a level surface and block or chock the wheels Release the parking brakes and build the air system to full pressure z Turn the engine OFF and make or brake applications and note that the service brakes apply and release promptly z Build system pressure to governor cutout and turn the engine OFF z After determining the pressure loss with the brakes released (2 PSI/minute allowed), make and hold a full service brake application Allow the pressure to stabilize for one minute z Begin timing pressure loss for two minutes while watching the dash gauges for a pressure drop The leakage rate for the service reservoirs should not exceed PSI/minute z If either circuit exceeds the recommended two PSI/minute, apply soap solution to the exhaust port of the modulator and any other components in the respective circuit z The leakage at the exhaust port should not exceed a one-inch bubble in three seconds If leakage at the modulator is determined to exceed the maximum limits, replace the modulator - 14 February, 2004 Air Brake Systems Operation and Diagnosis LESSON 6: ABS AND TRACTION CONTROL Wheel Speed Sensors and Wheel Speed Indicators AIR-071 Wheel Speed Indicator and Sensor Item Description Wheel Speed Indicator Item Description Wheel Speed Sensor COMPONENT FUNCTION: z Wheel speed sensors send wheel speed signals to the control module COMPONENT LOCATION: z The wheel speed sensors are located at the end of each wheel positioned near the wheel speed indicator that is attached to the wheel hub DESCRIPTION AND OPERATION: z Wheel speed sensors are magnetic pickup sensors – They are made up of a coil wrapped around a magnet z As the wheel spins, the wheel speed indicator (which is a toothed wheel) passes by the sensor z The sensor creates a voltage pulse as each tooth of the wheel speed indicator passes by the tip of the sensor z These pulses are relayed to the ABS control module and used to determine wheel speed SERVICE: Static Wheel Speed Sensor Inspection z To check the wheel speed sensors use a volt/ohm meter to measure the connector pins of the suspected faulty sensor – z The sensor should read 1500 - 2500 OHMS across sensor connector pins to ground Inspect the wheel speed sensors for corrosion or damage, also check for proper sensor lead routing and clamping Air Brake Systems Operation and Diagnosis February, 2004 - 15 LESSON 6: ABS AND TRACTION CONTROL ABS DIAGNOSIS AIR-072 ABS Control Module z The ABS/traction control module contains self-test and diagnostic circuitry that continuously checks for proper operation of the entire ABS and traction control systems, including system wiring continuity z When the vehicle is first started both the ABS and traction control indicator lamps illuminate z Also, when the vehicle is first started the control module energizes the modulators in the following sequence: – Right-Front, Left-Front, Right-Rear, Left-Rear z If the brakes aren’t applied, as the modulators are energized an audible “click” will be heard If the brake is applied a “chuff” noise will be heard z The ABS light should turn off as the self-test is performed z When the system successfully completes the self-check the TRAC light and the ABS light will turn off – If a problem is detected at start up, the ABS light will remain on – If there is a problem in the ABS system normal air braking will still operate - 16 February, 2004 Air Brake Systems Operation and Diagnosis LESSON 6: ABS AND TRACTION CONTROL Performing Diagnosis AIR-073 Control Module Display z The condition of specific components is provided by a series of labeled, light emitting diodes (LEDs) in the ABS/traction control module housing – No special tools or diagnostic equipment is needed to read or interpret the diagnostic display – The ABS/traction control module diagnostic LED display is separate from the ABS and TRAC system condition lamps on the instrument panel – The instrument panel lamps are designed to indicate a problem within the system, that can be further diagnosed using the control module LED display – The instrument panel lamps not display any codes or other specific diagnostic information – When the control module senses a problem condition, it stores the condition in memory, disables all or a portion of the anti-lock or traction control function, and illuminates the instrument panel-mounted condition lamp and the appropriate diagnostic LEDs on the ABS/traction control module – The failure condition is truly stored in the ABS/traction control module and will not be cleared by loss of power to the control module – The LEDs will relight when power is restored and will remain illuminated until the failure is corrected Air Brake Systems Operation and Diagnosis February, 2004 - 17 LESSON 6: ABS AND TRACTION CONTROL Diagnostic LEDs AIR-074 Light Emitting Diodes Diagnostic LEDs are located on the side of the ABS/traction control module The number of LEDs may vary depending on the vehicle and system, however, there are usually ten LEDs A magnetically actuated RESET switch can also be found on the side of the control module z When a fault is detected the control module identifies the faulted component with diagnostic LEDs z When a wheel speed sensor fault, or an ABS modulator fault is detected, the SEN or MOD LED will be accompanied by two location LEDs z – An example of this would be FRT-RHT-SEN – FRT means front axle, RHT means right side, SEN means wheel speed sensor – For a complete explanation of the diagnostic LEDs, consult the appropriate service publication If a fault is detected, and corrected, the control module will typically automatically reset (self-heal) the active fault code when the fault is corrected – However, if a fault is continually repeated the fault code will latch – Once the fault code latches, a manual reset (magnet, blink code switch, or scan tool) is required – When a fault self-heals or is manually reset, the fault code remains in fault history Fault history can be retrieved by using blink code diagnostics or a diagnostic tool NOTE: Latched faults can assist when troubleshooting intermittent faults z There can be more than one fault stored, they will appear in order of a preprogrammed priority list - 18 February, 2004 Air Brake Systems Operation and Diagnosis LESSON 6: ABS AND TRACTION CONTROL CONTROL MODULE CONFIGURATION z The ABS/Traction Control module has a self-configuring feature z The self-configuration feature allows wheel speed sensor and ATC configurations to be altered when activated with a magnet or diagnostic tool z The control module will then configure to determine the following: – The number of wheel speed sensors – If the traction control torque limiting feature is active – If traction control differential braking is active z If the vehicle is equipped with a traction control ON/OFF switch the switch must be set to the OFF position before performing self-configuration z All or part of the traction control system will be lost during self-configuration if: – TRAC lamp bulb is missing or burned open – The traction control on/off switch is inoperative – An ABS or traction control system wire harness is not connected Configuration Procedure z Connect all ABS and traction control wire harnesses z Place the traction control on/off switch in the OFF position – Turn the ignition switch to the ON position – Hold a magnet (at least 800 gauss) on the RESET portion of the control module for seconds – The LED display should light all LEDs simultaneously – When this self-configuration is complete, the ABS/traction control module is ready for a self-test – Turn the ignition switch OFF Air Brake Systems Operation and Diagnosis February, 2004 - 19 LESSON 6: ABS AND TRACTION CONTROL PARTIAL SHUTDOWN z When a fault is detected, the ABS and ATC may be fully or partially disabled, depending on which component is malfunctioning z Even with the ABS warning lamp on, the control module may still provide ABS on wheels that are not affected by the fault z Front ABS modulator fault: z z z z z – ABS on the affected wheel is disabled – ABS and ATC on all other wheels remains active Rear ABS modulator fault: – ATC is disabled – ABS on the affected wheel is disabled – ABS and ATC on all other wheels remains active Mid or rear wheel speed sensor fault: – ATC is disabled – ABS on the affected wheel is disabled – ABS and ATC on all other wheels remains active J1939/J1922 communication fault: – ATC is disabled – ABS remains active ABS/ATC control module fault: – ABS and ATC are disabled – The air brake system performs as normal Voltage fault: – While voltage is low ABS and ATC are disabled – The air brake system performs as normal – When the correct voltage level is restored, full ABS and ATC function is available - 20 February, 2004 Air Brake Systems Operation and Diagnosis GLOSSARY ABS Anti-lock Brake System ATC Automatic Traction Control BOO Brake ON/OFF BPP Switch Brake Pedal Position DOT Department of Transportation DTC Diagnostic Trouble Code DTV Disc Thickness Variation FRT Front KM Kilometers KOEO Key On Engine Off KOER Key On Engine Running KPA Kilopascals LB/FT Foot Pounds LED Light Emitting Diode LPA Low Pressure Accumulator LT Left MIL Malfunction Indicator Lamp MM Milimeters MOD Module NGS New Generation STAR Tester NM Newton Meters OBD On-board Diagnostics OHMS Ohm meters 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 RHT Right RPM Revolutions Per Minute Air Brake Systems Operation and Diagnosis February, 2004 Glossary - GLOSSARY SEN Sensor SSCC Symptom-to-System-to-Component-to-Cause TC Traction Control TRAC Traction Control TSB Technical Service Bulletin VIN Vehicle Identification Number VSS Vehicle Speed Sensor WSS Wheel Speed Sensor WDS World Diagnostic System Glossary - February, 2004 Air Brake Systems Operation and Diagnosis TOOL LIST TOOL LIST z New Generation Star (NGS) Tester 418-F052 z Worldwide Diagnostic System (WDS) 418-F224 z 88 Digital Multimeter 105-R0053 z Flex Probe Kit 105-R025B Brake System Diagnosis and Service May, 2003 Tool - TOOL LIST Tool - May, 2003 Advanced Brake System Diagnosis and Service 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: September 1999 ... operating brake system Air Brake Systems Operation and Diagnosis February, 2004 Overview - OVERVIEW NOTES Overview - February, 2004 Air Brake Systems Operation and Diagnosis LESSON 1: AIR SUPPLY... Less than 10 psi Air Brake Systems Operation and Diagnosis February, 2004 Intro - INTRODUCTION AND PREREQUISITE REVIEW NOTES Intro - February, 2004 Air Brake Systems Operation and Diagnosis OVERVIEW... compressor and repair as required 1-6 February, 2004 Air Brake Systems Operation and Diagnosis LESSON 1: AIR SUPPLY SYSTEM Air Dryer AIR- 007 Air Dryer COMPONENT FUNCTION: z The air dryer collects and