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APTA Bus Maintenance Webinar Series
“Remote Diagnostics”
John Carney, General Manager, CMTM
Worcester Regional Transit Authority
Worcester Regional Transit Authority
 The WRTA is responsible for the provision of public transit services to thirtyfive (35) communities within the Worcester County region, and is funded
with federal, state and local monies, as well as fare box revenue. WRTA was
created pursuant to Massachusetts General Laws, Chapter 161B, in August
1974.
 CMTM, a division of First Group, is WRTA’s current Contractor for fixedroute service and demand response paratransit service management
Services.
 The WRTA is the second largest RTA in Massachusetts serving the second
largest city in New England
WRTA Fleet Composition
 Active Fleet – 46 buses
 Qty 6 -1996 RTS
 Qty 7 - 1998 RTS
 Qty 2 - 2000 RTS
 Qty 8 - 2008 Gillig
 Qty 15 - 2010 Gillig (4 diesel/electric hybrid)
 Qty 8 - 2012 Gillig (3 diesel/electric hybrid)
 Future Fleet Additions/Replacements
 6 Additions - Spring 2013 - Proterra (fast charge electric)
 Fleet Expands to 52 Buses
 15 Replacements - Fall 2013 - Gillig (10 diesel/electric hybrid)
Intelligent Transportation System
 $3.9m ARRA Funded
 TranSystems – Procurement and Implementation Consultant
 Clever Devices – Prime Contractor
 Improve Operational Efficiency, Cost-Effectiveness, Security, Marketing and
Customer Satisfaction through System-wide Technical Enhancements
 Major Goals Included:
 Increase the availability of transit information to its customers
 Improve dispatching, operational efficiency and cost effectiveness
 Increase driver and passenger safety and security
 Improve Maintenance Efficiency Using Smart Technologies
The WRTA’s Solicitation Included
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One Vendor and Total System Integration
Giro HASTUS/Stratengen & Adept/Route Match Integration
CAD/AVL Fixed Route Integrated with Demand Response ADA VANS
Arrival Prediction System “Real Time Information”
Automated Vehicle Stop Announcements
Next Bus Wayside Arrival “Real Time”
Interactive Voice Recognition IVR
Web Based Bus Tracker System Voice/Text/QR Codes
One Point Operator Log On
Automated Passenger Counting APC
Traffic Signal Priority TSP
VoIP Voice over Internet Protocol Data and Voice Communications
AVM Automated Vehicle Monitoring System
Data archival, management and reporting system
Maintenance Features
“Improving Maintenance Efficiency Using
Smart Technologies”
 IVN Intelligent Vehicle Network
 Automated Work Orders
 AVM Automated Vehicle Monitoring
 Paperless Shop
 Location stamping of faults
 Vehicle Availability Reporting
 Intelligent Work Order Integration
 Integrated Gas Boy Fuel and Fluids
Reporting
 Integrate with Turley RTA
Maintenance System
 Bus in the Box
Complete ITS Solution
Integrated & Modular
IVN®
BusTime™
CleverCAD™
Automatic Passenger
Counting
Automatic Voice
Automatic Vehicle
Annunciation
Monitoring
AVM - Automatic Vehicle Monitoring
 AVM is a decision support system that provides simple, accurate, and
timely vehicle performance information
 AVM monitors and collects faults and operational performance data from
on-board systems
 Automated wireless transfer of information to maintenance and
operational personnel
AVM – Vehicle Health and Performance
WRTA/CMTM Lessons Learned
 J1708/J1939 Compatible
 SafetyVision 18 DVR’s $67,000
 Gateways
 I/O Controls $7,100
 ThermoKing $ 13,800
 Twin Vision Smart Series $57,960
 Software/Firmware Updates
 Ron Turley RTA
 Data Storage Memory $200,000
 Cellular Rates vs. Conventional Radio
 Hand Held Radio
 New Bus Specification Consideration
Vehicle Health Monitoring
Number of Monitored Faults & Performance Measures
Monitored Sub-Components
Gillig (J1939) RTS (J1708)
I/O Controls
150
WABCO ABS
1,601
1,518
Cummins Engine
5,242
Detroit Diesel
531
Safety Vision Cameras
75
249
Allison Transmission
105
Thermoking
184
Vanner Battery Equalizer
1,388
Hybrid Drive
37
Total Fault & Performance Measures
8,782
2,298
Of Which 54 Faults have been deemed Critical by the CMTM Maintenance Team
Vehicle Health Monitoring Year 1
The Most Critical 54 Faults as identified by the CMTM Maintenance Team
ABS 51
Transmission
105
Hybrid Drive
8
Total
Component
Faults
Monitored
3,090
Engine 1,436
Battery
Equalizer
1,388
Climate
Control 102
AVM is like having a diagnostic laptop
connected to every bus around the clock
Clever Devices Supported Systems
Engine
• Cummins
• Detroit
Diesel
• John Deere
• Caterpillar
• Navistar
Door System
• Vapor
• Volvo
Transmission/
Propulsion
• ZF
• BAE
• Allison
• Voith
Air
Conditioning
• ThermoKing
• Carrier
ABS
• Wabco
• Bendix
DPF
• ESW
Multiplex
Brake Wear
Monitoring
• IO Controls
• Vansco
• Volvo
• Actia
• Allen Bradley
• Siemens
• Geoguidance
Brake Insight
• MGM Brakes
E-Stroke
Supplemental
Heaters
Tire
Monitoring
• ProHeat
• Webasto
• Spheros
• SmarTire
TPMS
Cooling Fans
• EMP
Battery
Equalizer
• Vanner
Articulated
Joint
• Hubner
Camera
• Safety Vision
• March
Networks
• GE Mobile
View
Quattro
• Apollo
• Dedicated
Micros
The benefits of AVM are felt throughout
WRTA’s entire organization
New Vehicle Purchases
Warranty
Maintenance
Legal
New Vehicle Purchases
Empower our Bus Inspectors at Factory Acceptance Testing
Identify Issues Before Bus Delivery (New Gillig and Proterra Buses)
Make Data-Based Purchasing Decisions and Purchase the Highest “Value” Bus
Minimize Risk During Bus Acceptance
Implement More Detailed Acceptance Criteria
Opportunity to Negotiate Longer Warranties by Sharing Data
Warranty
Increase Warranty Recovery Claims
Automatically Identify Fleet Defects
Automate Warranty Service Requests
Reduce Parts and Labor Reimbursements
Reduce Overtime Due to Warranty Work
Measure and Manage with actual data
Make Informed Warranty Claim decisions
Maintenance
Helps Reduce Bus Breakdowns in Service increasing MDBF/MTBF
Gives mechanics a single source of diagnostic information – reducing task time
Helps Eliminate Preventable Failures
Integration into our MMIS – Helps Automate the Work Flow Process
Reduce Overtime/Lower Parts Inventory
Lower Cost Per Mile
Legal
Secure Encrypted Event Files for Court
Helps Identify Hard Brake Events
Records Last Stop Events for Low MPH Accidents
Precisely and Objectively Measures Events
Deal in Facts
Reduces Fictitious Injury Claims & Bogus Lawsuits
Helps Settle Legitimate Claims for our Customers
Forensic Investigations
19 Data Points Reported on Every Last Stop Event (Bus reaches 0 MPH)
Start Lifetime Odometer
Trigger Lifetime Odometer
End Lifetime Odometer
Average Acceleration
Peak Acceleration
Peak Speed
Total Distance
Date / Time
Event Duration
Vehicle Speed MPH
Engine Speed (RPM)
Engine Load (%)
Brake Applied (Yes/No)
ABS Active (Yes/No)
Throttle Position (%)
Distance
Time Zone
Daylight Savings Time
ACTM (Alternating Current Traction Motor) Torque Commanded (Hybrid Application)
Forensic Investigations
Composite Data Chart
Forensic Investigations
Vehicle Speed Chart
Forensic Investigations
Distance Traveled Chart
Forensic Investigations
Composite Data Chart
11:36:23.78 No Brake or
ABS 24 MPH
11:36:25.84 Brake & ABS
Applied 19.2 MPH
11:36:27.83 Brake & ABS
Applied .8 MPH
Forensic Investigations
Left Hand Turn Incident at WRTA
12 MPH On Impact
8 MPH After
Applying Brake
8:53:20 14 mph
8:53:21 12 mph
8:53:22 8 mph
Questions
Presentation Notes
54 Critical Events that Worcester Mechanics Chose to Be Notified Of
1 J1939 (SA Cummins CM2150 143
Engine Oil Rifle Pressure - Data Valid but Below Normal Operational Range Moderately Severe Level. Engine oil pressure signal indicates engine oil pressure
is below the engine protection warning limit.
2 J1939 (SA Cummins CM2150 146
Engine Coolant Temperature - Data Valid but Above Normal Operational Range Moderately Severe Level. Engine coolant temperature is above engine
protection warning limit.
3 J1939 (SA Cummins CM2150 155
Intake Manifold 1 Temperature - Data Valid but Above Normal Operational
Range - Most Severe Level. Intake manifold air temperature signal indicates
intake manifold air temperature above engine protection critical limit.
4 J1939 (SA Cummins CM2150 197
Coolant Level - Data Valid but Below Normal Operational Range - Moderately
Severe Level. Low engine coolant level detected.
Engine Oil Temp
Engine Crankshaft Speed/Position - Data Valid but Above Normal Operational
Range - Most Severe Level. Engine speed signal indicates engine speed above
engine protection limit.
5
214
6 J1939 (SA Cummins CM2150 234
7 J1939 (SA Cummins CM2150 322
Injector Solenoid Driver Cylinder 1 Circuit - Current Below Normal, or Open
Circuit. Current detected at injector Number 1 when the voltage is turned off.
8 J1939 (SA Cummins CM2150 323
Injector Solenoid Driver Cylinder 5 Circuit - Current Below Normal, or Open
Circuit. Current detected at injector Number 5 when the voltage is turned off.
9 J1939 (SA Cummins CM2150 324
Injector Solenoid Driver Cylinder 3 Circuit - Current Below Normal, or Open
Circuit. Current detected at injector Number 3 when the voltage is turned off.
10 J1939 (SA Cummins CM2150 325
Injector Solenoid Driver Cylinder 6 Circuit - Current Below Normal, or Open
Circuit. Current detected at injector Number 6 when the voltage is turned off.
Presentation Notes
54 Critical Events that Worcester Mechanics Chose to Be Notified Of
11 J1939 (SA Cummins CM2150 331
Injector Solenoid Driver Cylinder 2 Circuit - Current Below Normal, or Open Circuit.
Current detected at injector Number 2 when the voltage is turned off.
12 J1939 (SA Cummins CM2150 332
Injector Solenoid Driver Cylinder 4 Circuit - Current Below Normal, or Open Circuit.
Current detected at injector Number 4 when the voltage is turned off.
13 J1939 (SA Cummins CM2150 418
Water in Fuel Indicator - Data Valid but Above Normal Operational Range - Least
Severe Level. Water has been detected in the fuel filter.
14 J1939 (SA Cummins CM2150 435
Engine Oil Rifle Pressure - Data Erratic, Intermittent, or Incorrect. The engine oil
pressure sensor is reading an erratic value at initial key-on.
15 J1939 (SA Cummins CM2150 471
Engine Oil Level -Data Valid but Below Normal Operational Range - Least Severe
Level. Low oil level has been detected by the oil level sensor.
16 J1939 (SA Cummins CM2150 555
Crankcase Pressure -Data Valid but Above Normal Operational Range - Moderately
Severe Level. The crankcase breather filter requires maintenance.
17 J1939 (SA Cummins CM2150 596
Electrical Charging System Voltage -Data Valid but Above Normal Operational
Range - Moderately Severe Level. High battery voltage detected by the battery
voltage monitor feature.
18 J1939 (SA Cummins CM2150 597
Electrical Charging System Voltage -Data Valid but Below Normal Operational
Range - Moderately Severe Level. Low battery voltage detected by the battery
voltage monitor feature.
19 J1939 (SA Cummins CM2150 687
Turbocharger 1 Speed - Data Valid but Below Normal Operational Range Moderately Severe Level. Low turbocharger speed detected by the ECM.
20 J1939 (SA Cummins CM2150 1866
Exhaust Gas Recirculation Valve Delta Pressure - Data Erratic, Intermittent, or
Incorrect. An error in the EGR delta pressure signal was detected at initial key-on or
the sensor failed the autozero test.
Presentation Notes
54 Critical Events that Worcester Mechanics Chose to Be Notified Of
21 J1939 (SA Cummins CM2150 1896
22 J1939 (SA Cummins CM2150 1921
EGR Valve Controller - Out of Calibration. The EGR valve has failed the automatic
calibration procedure at initial key-on.
Aftertreatment Particulate Filter Differential Pressure - Data Valid but Above
Normal Operational Range - Moderately Severe Level. The soot load of the
aftertreatment diesel particulate filter has exceeded the recommended limits.
23 J1939 (SA Cummins CM2150 1942
Crankcase Pressure -Data Erratic, Intermittent, or Incorrect. The ECM has
detected that the crankcase pressure signal is not changing with engine
operating conditions.
24 J1939 (SA Cummins CM2150 2346
Turbocharger Turbine Inlet Temperature (Calculated) - Data Valid but Above
Normal Operational Range - Least Severe Level. Turbocharger turbine inlet
temperature has exceeded the engine protection limit.
25 J1939 (SA Cummins CM2150 2357
EGR Valve Control Circuit - Mechanical System Not Responding Properly or Out
of Adjustment. The EGR motor has exceeded the duty cycle limit indicating a
stuck open EGR valve.
26 J1939 (SA Cummins CM2150 2387
VGT Actuator Driver Circuit (Motor) - Mechanical System Not Responding
Properly or Out of Adjustment. The smart VGT controller has detected incorrect
stop limits or the VGT is unable to move to the closed position.
27 J1939 (SA Cummins CM2150 2448
Coolant Level - Data Valid but Below Normal Operational Range - Least Severe
Level. Low engine coolant level detected.
VGT Actuator Controller - Out of Calibration. The VGT has failed the automatic
calibration procedure at initial key-on. VGT will be in the open position.
28 J1939 (SA Cummins CM2150 2449
29 J1939 (SA Cummins CM2150 2554
30 J1939 (SA Cummins CM2150 2636
Exhaust Gas Pressure - Data Erratic, Intermittent, or Incorrect. The exhaust gas
pressure sensor is reading an erratic value at initial key-on.
VGT Actuator Driver Circuit - Abnormal Update Rate. No communications on the
J1939 datalink between the engine ECM and the smart VGT controller.
Presentation Notes
54 Critical Events that Worcester Mechanics Chose to Be Notified Of
31 J1939 (SA Cummins CM2150 2637
Catalyst Face Plugged - Root Cause Not Known. The front face of the aftertreatment
diesel oxidation catalyst has been detected to be plugged with soot.
32 J1939 (SA Cummins CM2150 2754
Engine Particulate Trap Inlet Pressure - Data Valid but Above Normal Operational
Range - Moderately Severe Level. Excessive black smoke has been detected exiting
the engine and entering the aftertreatment diesel particulate filter.
33 J1939 (SA
34 J1939 (SA
35 J1939 (SA
36 J1939 (SA
37 J1708
38 J1708
39 J1708
40 J1708
41 J1708
42 J1708
43 J1708
44 J1708
45 J1708
46 J1708
47 J1708
48 J1708
49 J1708
50 J1708
51 J1708
52 J1708
53 J1708
54 J1708
Equalizer Fault
Voltage Imbalance Fault
Over Voltage Fault
Under Voltage Fault
Too many SRS (missing TRS)
Too few SRS (missing SRS)
Coolant Level Low
Coolant Temperature High
Oil Temperature High
Oil Pressure Low
Vehicle Speed Sensor Fault
J1939 Data Link Fault
Injector 1 Response Time Long
Injector 2 Response Time Long
Injector 3 Response Time Long
Injector 4 Response Time Long
Injector 1 Response Time Short
Injector 2 Response Time Short
Injector 3 Response Time Short
Injector 4 Response Time Short
ECM Battery Voltage High
Oil Level Low
Vanner
Vanner
Vanner
Vanner
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
Detroit
70 Series
70 Series
70 Series
70 Series
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
DDEC-IV
EQFLT
IMB
OVF
UVF
41
42
43
44
44
45
54
55
61
61
61
61
71
71
71
71
75
84