58S02T0 air brake systems operation and diagnosis 2004

• Set the parking brake when working on the vehicle.. Parking Brake Control Valve .... Curriculum GoalsThe goals of this curriculum are to provide: First Time On Time” repairs Air Brake

Ford Customer Service Division

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.

• Use safety stands whenever a procedure requires you to

be under the vehicle.

• Be sure that the ignition switch is always in the OFF

position, unless otherwise required by the procedure.

• 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

RE-VERSE (engine OFF) or NEUTRAL (engine ON) unless

instructed otherwise for a specific service operation.

• 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 prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on the vehicle.

• 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.

• 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.

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 do 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.

Technical Support Operations Ford Customer Service Division

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.

first visit.

5. Service status provided within one minute of inquiry.

6. Vehicle ready at agreed upon time.

7. Thorough explanation of work done, coverages and changes.

1. Appointment available within one day of the

customer’s requested service day.

2. Write-up begins within four minutes of

arrival.

3. Service needs courteously identified,

accurately recorded on Repair Order, and

verified with customer.

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 4

“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

— Ford Multimedia Training (FMT) — Instructor-Led

— Instructor-Led

The Benefits

The successful implementation of standards means

— Satisfied customers

— Repeat vehicle sales

— Repeat service sales

Dealer-to-Customer Service Standards:

IMPORTANT SAFETY NOTICE 1 INTRODUCTION AND PREREQUISITE REVIEW Intro - 1 Course Objectives Intro - 2 Lesson Objectives Intro - 2 Course Prerequisites Intro - 2 Evaluation Intro - 3 WORKSHEET A Intro - 5 AIR BRAKE COMPONENT LOCATION AND FUNCTION INTRO - 5 INTRODUCTION 1 - 1 INTRODUCTION TO AIR BRAKE SYSTEMS 1 - 2 Air Brake Components 1 - 3 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

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 1 5-7 System Test 2 5-8 System Test 3 5-9 System Test 4 5-10 System Test 5 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 - 1

CONTENTS

INTRODUCTION AND PREREQUISITE REVIEW

Curriculum Goals

The goals of this curriculum are to provide:

First Time On Time” 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 nities for technicians to learn and improve their skills using tools and equipment; and to apply knowledge learned

opportu-in previous curriculum courses

Course Objectives

Given the information presented in the Ford Air Brake System Diagnosis and Service Course, the necessaryservice information and tools, technicians will be able to perform accurate, timely, cost-effective diagnosis andrepair of the air brake system, the ABS, and the traction control braking systems on Ford Motor Company ve-hicles

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

z Air Brake Theory and Operation Web Based Training - Course Code 58S01W0

z Air Brake Diagnosis Web Based Training - Course Code 58S02W0

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 third day The hands-on evaluation is a pass/fail type

In order to pass the course, you must demonstrate acceptable skills at the evaluated hands-on exercises AND youmust answer at least 80% of the written post test questions correctly

Course Layout

z Introduction and Prerequisite Review

z Lesson 1: Air Supply System

z Lesson 2: Air Delivery System

z Lesson 3: Service Brake System

z Lesson 4: Parking Brake System

z Lesson 5: Air Brake Diagnosis

z Lesson 6: ABS and Traction Control

SERVICE STANDARDS

Mission Statement

All dealership personnel will treat every customer as a potential lifetime purchaser, communicating a professionalimage that embraces honesty and concern for customer wants and needs

Dealer-to-Customer Service Standards

Standard 4

Vehicles serviced right on the first visit:

The technician is the most important person when it comes to Standard 4.

“Fix it Right the First Time, on Time”

Why:

Customers tell us “Fixing It Right the First Time, On Time” is one of the top reasons they would decide to return

to a dealer to buy a vehicle and get their vehicles serviced

WORKSHEET A AIR BRAKE COMPONENT LOCATION AND FUNCTION

Collects and removes solid, liquid and vapor contaminantsprior to entering the system

Protects the air brake system from excessive air pressurebuild-up

Controls the application of air pressure from the primaryand secondary reservoirs

Converts air pressure into mechanical force needed toapply the brakes

This component is pressure sensitive and will cally apply if system pressure gets too low

automati-Limits hold-off pressure to the spring brake actuators

Adjusts the brakes as necessary for brake wear

Controls Operation of the Anti-lock Brake System

TAG # COMPONENT NAME/FUNCTION COMPONENT FUNCTION

Directions: Go to the classroom vehicle Locate the Air Brake components that perform the functions listed in the

right hand column List the name of the components, the function letter and the letter on the tag attached to eachcomponent in the left column Answers will vary based on component tags numbers/letters used

END OF WORKSHEET

1 What is the most likely cause if there is a concern with cut-in pressure?

A The compressor

B The relay valve

C The governor

D The quick release valve

2 How often should reservoirs be drained?

6 Which of the following is measured when checking applied stroke?

A The amount of movement that brings the brake shoes into contact with the drum

B The delivery pressure that comes from the foot control valve

C The amount of slack adjuster movement that occurs during a full brake application

D The rotational torque that applies the service brakes

7 When testing the governor it should be checked

A at cut-in pressure

B at cutout pressure

C pressure with the vehicle off

D both cut-in and cutout pressures

8 If there is excessive moisture in the system, which of the following is the likely cause?

A The vehicle’s air filter is dirty

B The quick release valve is not operating correctly

C The air dryer is malfunctioning

D The reservoir is filled past capacity

9 What is indicated if the VLT LED is green?

A System is working properly

B There is a fault code stored

C Voltage is out of range

D The ECU is inoperative

10 At what pressure must the stoplights illuminate?

D Less than 10 psi.

NOTES

CONTENTS OBJECTIVES

INTRODUCTION

be able to:

equipped vehicle

equipped with the same components, but all

work in a similar manner

INTRODUCTION TO AIR BRAKE SYSTEMS

As you have learned while taking the web-based training in this curriculum, the purpose of the air brake system is

to provide a safe method of stopping for a heavier vehicle

The components of an air brake system can differ, however, all systems operate in a similar manner The airbrake system must provide balanced braking at all wheels

Note: For a more detailed explanation of the theory and operation of an air brake system refer to the web-based

training course

2004 F-650/750

WARNING: BEFORE ATTEMPTING TO WORK ON THE AIR BRAKE SYSTEM, CERTAIN PRECAUTIONS MUST BE OBSERVED SINCE THE COMPRESSION AND STORAGE OF AIR CAN BE COMPARED TO THE ENERGY IN A COILED SPRING, WHEN RELEASED, IT CAN PRESENT A HAZARD IF NOT CORRECTLY RECOGNIZED THE WHEELS OF THE

VEHICLE MUST ALWAYS BE CHOCKED SO THAT DEPLETION OF AIR WILL NOT

PERMIT THE VEHICLE TO ROLL.

AIR-001

Air Brake Components

Using an air brake system to stop a medium-duty truck requires the proper operation of each of the subsystems.For this to happen, each of the subsystems’ components must function correctly Every component of eachsubsystem has a task to perform that will allow the brake system to continue braking smoothly

In this course we will look at each component, how the components operate, and the basic service procedures thatare important to insuring a correctly operating brake system

AIR-002

NOTES

techni-cians will be able to:

various components of the air supply system

proce-dures

CONTENTS

z The compressor converts atmospheric air into compressed air.

the air reservoirs

cutout pressure the governor will prevent the compressor inlet valve from closing, thus preventing further airfrom being compressed

to reaching the air reservoirs

air reservoir

SYSTEM OPERATION - AIR SUPPLY SYSTEM

Air Supply System

5 Dual Air Gauge

10

10 One-way Check Valve

Air Compressor

COMPONENT FUNCTION:

reservoirs of the supply system

COMPONENT LOCATION:

DESCRIPTION AND OPERATION:

crank-case

Air Compressor

1 Belt Driven Compressor 2 Gear Driven Compressor

AIR-004

1

2

Cutaway of an Air Compressor

Air Compressor (continued)

DESCRIPTION AND OPERATION:

compressor unloader mechanism

valve to open and move from its seat

reverse its travel

cylinder through the inlet valve and the air is compressed

air into the discharge line and to the reservoir

the inlet valve, and the cycle begins again

SERVICE:

In order to maintain a properly operating air brake system it is important that the compressor receives a cleansupply of air

factor for brake system efficiency

1

2

3

4 5 6

Inlet Valves

Discharge Valves

Rear End Cover

Rear Main Bearing Journal Crankshaft

Piston

1

2 6

5

3

AIR-005

4

Air Compressor Governor

the air dryer

DESCRIPTION AND OPERATION:

The governor controls the actual compression of air by actuating the compressor unloading mechanism

unloader piston and stops the compression cycle of the compressor

unloader piston and starts the compression cycle of the compressor

controls the unloader to prevent the compressor inlet valve from closing

back through the inlet valve to the other cylinder (alternating the air back and forth between the cylinders)

the governor will control the unloader valve, which allows the inlet valve to close

Governor (continued)

SERVICE:

If during the diagnostic process you need to check the governor’s operation you should:

(105-130 psi), allowing for gauge accuracy

brakes

adjustable

NOTE: Before installing a new governor, check the accuracy of the instrument panel air gauge with a test gauge.

With the governor in its unloaded position and approximately 621-793 kPa (90-115 psi) reservoir pressure, checkfor leaks at the base of the governor where it mounts to the compressor and repair as required

Air Dryer Charge Cycle

AIR-008

Air Dryer (continued)

DESCRIPTION AND OPERATION:

Charge Cycle

the sump

shell of the cartridge

6 7 8 9

4 5

6 7

8 9

Air Dryer Purge Cycle

AIR-009

Air Dryer (continued)

DESCRIPTION AND OPERATION:

Purge Cycle

stopped)

reactivat-ing the desiccant dryreactivat-ing bed

1

3

2

4 5

1

2

3

4 5

Desiccant Cartridge Replacement

AIR-010

Air Dryer Service

Air dryers are very important to the delivery of clean, dry, oil-free air throughout the air brake system

demands or some unusual air requirement that does not allow the compressor to load and unload in theusual way Check for excessive air system leaks

of system will be saturated with moisture and it can take several weeks of operation for the system to dryout

metal tubing between the compressor discharge port and air dryer supply port

have small amounts of water accumulating in the air brake system Under these conditions, small amounts

of water should not be considered an indication that the air dryer is not working

WARNING: REMOVE ALL PRESSURE FROM THE AIR SYSTEM BEFORE DISCONNECTING

1

2

3

4 5

Desiccant Cartridge Assembly

Desiccant Cartridge Sealing Rings

Cartridge Bolt O-Rings

Desiccant Cartridge Bolt End Cover

1

2

3 4

5

To disassemble the air dryer:

Cleaning and Inspection

the end cover and the sealing surfaces for the large and small diameter desiccant cartridge sealing rings

the bolt threads are damaged sufficiently to cause it to be difficult to hand thread it into the new desiccantcartridge, replace the bolt

Assembly

When reassembling the air dryer:

desiccant bolt

cartridge bolt in the end cover

the end cover

Air Dryer Testing

The following test should be performed prior to placing the vehicle back into service

purges with an audible escape of air Apply the service brakes several times until air pressure is reduced togovernor cut-in Ensure that the system builds to full pressure and is followed by an air dryer purge

the desiccant cartridge where it is in contact with the end cover

bubble in 1 second

persists replace the air dryer assembly

Single Check Valves

AIR-012

Single Check Valve

COMPONENT FUNCTION:

compres-sor or the supply reservoir The single check valve allow the air brake system to continue to operate in anemergency situation to bring the vehicle to a safe stop

COMPONENT LOCATION:

DESCRIPTION AND OPERATION:

direction

air pressure and assisted by the spring

SERVICE:

should check this by performing a leak test as follows:

open end of the check valve with soapsuds

NOTE: In order to properly inspect the single check valve you may have to remove it.

Air Reservoir

Air Tanks

COMPONENT FUNCTION:

COMPONENT LOCATION:

DESCRIPTION AND OPERATION:

AIR-013

Air Reservoir (continued)

Dual Compartment Reservoir

DESCRIPTION AND OPERATION:

they share the same shell, they actually perform two separate functions

secondary reservoir So if damage was to occur to the supply reservoir the secondary reservoir is tected against the loss of air

spring, this moves the check valve off its seat and air pressure enters the secondary reservoir

flow from the secondary reservoir

Outlet Port

Integral Check Valve

Inlet Port

Supply Tank Tank Divider Secondary Reservoir

1

2

3

z Drain cocks are installed at the bottom or end of each reservoir.

z Automatic moisture ejectors are usually mounted in the bottom or end of the reservoir

DESCRIPTION AND OPERATION:

z Drain cocks must be opened by hand

CAUTION: Never strike the handle with a hammer or any other instrument, as the drain cock will be damaged and leakage will develop.

z Automatic ejector valves operate as follows:

– When there is no pressure in the system the inlet and exhaust valves are closed

– When the system is charged, a slight pressure opens the inlet valve, this permits air and contaminants tocollect in the sump cavity This occurs until the governor cutout pressure is reached, then the inlet valvecloses

– When reservoir pressure drops, pressure in the sump cavity opens the exhaust valve and allows moistureand contaminants to be exhausted until the sump cavity empties enough to close the exhaust valve

Air Reservoir Drainage System (continued)

SERVICE:

Drain Cocks

z To check a manual drain cock for leakage:

– Charge the air brake system, then test with a soap solution for leakage past the key and through the body

by coating the outside of the drain cock with a soap solution

– Leakage should not exceed 77mm (3 inch) soap bubbles in three seconds

Automatic Moisture Ejector Valve

z If the automatic moisture ejector valve is functioning properly the following should occur:

– With the system charged, apply the brake several times

– Check each time an application is made if an exhaust of air occurs at the exhaust port of the drain valve.– If no air comes out, push the wire stem If air still doesn’t come out, the filter or drain passage may beplugged

z To check the automatic moisture ejector valve for leakage:

– With the system charged and pressure stabilized in the system, there should not be any leaks at the drainvalve exhaust

– A constant slight exhaust of air at the drain valve exhaust could be caused by excessive leakage in the airbrake system

AIR-016

Automatic Moisture Ejector (Cutaway View)

Reservoir Draining

Moisture in the reservoirs can prevent the system from actuating smoothly and should be drained daily

(0 psi)

to press the stem on the bottom of the valve

Drain Valves

WARNING: WHEN DRAINING THE SYSTEM, DO NOT LOOK INTO THE AIR JETS OR RECT THEM TOWARD A PERSON THIS MAY CAUSE INJURY BECAUSE DIRT OR SLUDGE PARTICLES CAN BE CARRIED IN THE AIR STREAM.

DI-Air Reservoir Drainage System (continued)

DESCRIPTION AND OPERATION:

SERVICE:

DESCRIPTION AND OPERATION:

allowing pressure to escape

SERVICE:

constant “popping off” or exhausting of the safety valve

loaded