C250403_IFB_Exhibit_A_SOW_ATTACHMENT_6_-_Maintenance_Manual.pdf

ATTACHMENT 6 – MAINTENANCE MANUAL

DOCUMENT INFORMATION AND CHANGE HISTORY On-Board Equipment Maintenance Technician Manual OCTA-VEM4001 Rev - — September 4, 2012 ii ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

Document Information and Change History

Rev Date Author Description

- September 4, 2012 ACS Data, Documentation, and Training group

Initial release

On-Board Equipment Maintenance Technician Manual TABLE OF CONTENTS

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Table of Contents

CHAPTER 1 SAFETY

General System Safety Electrical Systems Equipment

CHAPTER 2 EQUIPMENT OVERVIEW

Driver Control Module In-Vehicle Unit Mobile Radio Voice Radio Handset/Speaker Radio/GPS/WLAN Antenna OBD-II Scan Tool

CHAPTER 3 INSPECTIONS

Equipment Inspections Cleanliness Inspections

CHAPTER 4 TROUBLESHOOTING & DIAGNOSTIC PROCEDURES

System Confidence Testing with Vehicle Acceptance Test Procedure Return Materials Authorization Repairs Problem Reports Troubleshooting Procedures

CHAPTER 5 ORBSTAR DIAGNOSTIC TOOLS

OrbStar 8400 Control Head Screen Layout Common Display Area Powering Up Powering Down Setup/Diagnostic Tabs Volume Controls and Display Settings Screens GPS Status Screen DIS Status Screen Odometer Status Screen OrbStar Status Screen Vehicle Processor Status Screen Vehicle Equipment Status Screen

APPENDIX A VEHICLE ACCEPTANCE TEST PROCEDURE ................................. A-1

APPENDIX B RETURN MATERIALS AUTHORIZATION FORM ............................. B-1

APPENDIX C SCAN TOOL FLASH UTILITY INSTRUCTIONS ................................ C-1

APPENDIX D LOADING CODE PLUG INTO RADIO ............................................... D-1

APPENDIX E IN-VEHICLE EQUIPMENT SCHEMATIC ............................................E-1

APPENDIX F SYSTEM GLOSSARY ......................................................................... F-1

TABLE OF CONTENTS On-Board Equipment Maintenance Technician Manual iv ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

List of Figures

Figure 2-1. In-Vehicle Subsystem Block Diagram

Figure 2-2. OrbStar Driver Control Module

Figure 2-3. IVU-2100T

Figure 2-4. M7300 Radio

Figure 2-5. Radio Schematic

Figure 2-6. Voice Radio Handset/Speaker

Figure 2-7. Radio/GPS/WLAN Antenna

Figure 2-8. OBD-II Scan Tool

Figure 4-1. Bootup Troubleshooting Procedure

Figure 4-2. Auto-Reboot Troubleshooting Procedure

Figure 4-3. Radio Antenna Troubleshooting Procedure

Figure 4-4. Data Communications Troubleshooting Procedure

Figure 4-5. Voice Communications Troubleshooting Procedure

Figure 4-6. Radio Troubleshooting Procedure

Figure 4-7. Silent Alarm Troubleshooting Procedure

Figure 4-8. OBD-II Scan Tool Troubleshooting Procedure

Figure 5-1. OrbStar 8400 Control Head Components

Figure 5-2. Screen Components

Figure 5-3. Common Display Area Layout

Figure 5-4. Logon Screen appears after Successful System Registration

Figure 5-5. Volume Controls And Backlight Settings Screens

Figure 5-6. Password Entry Screen

Figure 5-7. GPS Status Screens

Figure 5-8. Operator Action Display Status

Figure 5-9. DIS Status Screen Showing DIS Disconnected

Figure 5-10. DIS Status Screen Showing File Transfer

Figure 5-11. Odometer Status Screen

Figure 5-12. OrbStar Status Screens for Paratransit Vehicles

Figure 5-13. OrbStar Restart Confirmation Prompt

Figure 5-14. Vehicle Processor Status Screens

Figure 5-15. In-Vehicle Subsystem Shutdown Confirmation Prompt

Figure 5-16. Set Vehicle ID and Type Screens

Figure 5-17. Vehicle Equipment Status Screen

On-Board Equipment Maintenance Technician Manual LIST OF TABLES

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List of Tables

Table 5-1. OrbStar 8400 Control Head Keys

Table 5-2. Common Display Area’s Display Descriptions and Control Actions

Table 5-3. Diagnostic Screens

Table 5-4. GPS Status Screen Showing Status

Table 5-5. Odometer Status Screen Showing Status

ABOUT THIS MANUAL On-Board Equipment Maintenance Technician Manual vi ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

About This Manual

The On-Board Equipment Maintenance Technician Manual provides users with information about maintaining ACS-provided in-vehicle equipment. This manual is organized into the following chapters:

Chapter 1 – Safety – describes vehicle safety, general system safety, and electrical equipment procedures.

Chapter 2 – Equipment Overview – provides summary descriptions of ACS-provided vehicle components.

Chapter 3 – Inspections – describes basic preliminary vehicle inspection, equipment inspection, and cleanliness inspection procedures.

Chapter 4 – Troubleshooting & Diagnostic Procedures – describes the Vehicle Acceptance Test Procedure, the Return Materials Authorization (RMA) form, and how repairs are handled.

Chapter 5 – OrbStar Diagnostic Tools – describes use of the OrbStar and its built-in diagnostic functions.

Appendix A– Vehicle Acceptance Test Procedure – is used in system confidence testing after maintenance or repair activities.

Appendix B– Return Materials Authorization Form – is used to document authorization of material returns and to describe hardware problems.

Appendix C– Scan Tool Flash Utility Instructions – contains the prerequisite requirements and the procedures for loading the Scan Tool software.

Appendix D– Loading Code Plug Into Radio – describes how to program the mobile radio.

Appendix E– In-Vehicle Equipment Schematic – illustrates the in-vehicle equipment and their connections.

Appendix F– System Glossary – provides definitions for terms and acronyms used in this and other ACS-provided documents.

On-Board Equipment Maintenance Technician Manual CONVENTIONS USED

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Conventions Used

This manual uses the following document conventions to promote easy access to information and readability:

When describing OrbStar functionality, the following terminology is used in this document:

Touch (or tap) buttons, controls, fields, and tabs on the touch-screen;

Press keys;

Select messages and list options.

System Status messages are shown as bold text. For example:

Verify that System OK appears on the screen.

Buttons and keys are shown with background shading, for instance when referenced in procedure steps. For example:

Touch the Send button to send the message.

Press the key to request a voice call.

Device components are often identified using figures, which may include text callouts. Such figures may be followed by a table that describes these components.

Important cautions or warnings are shown in bold and are indicated by the symbol.

Useful reminders, instructions, and notes are shown in italics and are indicated by the symbol.

CONVENTIONS USED On-Board Equipment Maintenance Technician Manual viii ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

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On-Board Equipment Maintenance Technician Manual SAFETY

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CHAPTER 1 SAFETY

This chapter describes the various aspects of system safety, including its management, general guidelines, and the electrical system. The system will operate safely over many years of demanding service. Despite this, the key to maintaining and operating the OrbStar and associated equipment safely is largely the responsibility of the operator and the maintenance personnel. In general, maintenance personnel must be alert at all times when performing maintenance on equipment installed on transit vehicles.

Personnel with access to the system must adhere to the guidelines set down both in this manual and by their employer when performing maintenance on vehicle equipment. To ensure the general safety of maintenance personnel, extreme care must be taken when performing equipment maintenance on vehicles in high-traffic areas.

No components in the installed vehicle equipment should be repaired in the field and no attempt should be made to open and/or repair the individual components of the installed vehicle system. All malfunctioning field-replaceable components should be returned to ACS or the original equipment manufacturer, as directed by the ACS Customer Service Department. Customer Service should be contacted for a Return Merchandise Authorization (RMA) number prior to returning malfunctioning components for repair and/or replacement.

Regular maintenance of all equipment can ultimately determine the safety and reliability of the system. Failure to notice and repair minor problems can result in vehicle equipment failures that could endanger the safety of transit personnel and/or passengers. Coordination between all levels of operation must be established, from maintenance to operator to dispatcher.

CHAPTER 1 On-Board Equipment Maintenance Technician Manual

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General System Safety

Maintenance personnel must adhere to the following general safety procedures:

1. Do not attempt to open or repair any of the individual components (modules) in the system. If a component fails, call your customer service representative for instructions on returning the component to ACS or the ACS-approved manufacturer for repair or replacement.

2. Read and comply with all safety guidelines.

3. Ensure all electrical power to the device (ignition and battery) is off before performing physical hardware adjustments, removal and replacement of cabling or components, or other radio equipment maintenance.

4. Adhere to guidelines for routine maintenance set forth in this manual.

On-Board Equipment Maintenance Technician Manual SAFETY

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Electrical Systems Equipment

When interacting with electrical equipment, follow these procedures:

1. Only properly trained personnel should attempt repairs on the installed equipment.

2. To ensure maintenance safety, turn off vehicle power (both run power (ignition) from the engine and prime power from the battery) before any electrical wiring repair work. The main battery power switch(es), must be turned off prior to beginning work on radio equipment electrical power wiring, connecting or disconnecting any cabling, or connecting or disconnecting system components (radios, IVU, etc.).

3. Maintenance personnel must have and use the correct tools and instructions when performing equipment maintenance.

4. All fuses, wires, and other electrical equipment must be replaced with parts that adhere to manufacturer’s voltage, current ratings, and other specifications.

CAUTION: Personal injury, damage to equipment, or fire can result from the improper operation or maintenance of electrical equipment. Only qualified and properly trained personnel should be allowed to perform scheduled preventative and unscheduled maintenance on the bus equipment. Care must be exercised to avoid accidental shorting of the vehicle’s battery supply voltages (+12 VDC and/or +24 VDC) while performing repairs to the installed radio equipment.

CHAPTER 2 On-Board Equipment Maintenance Technician Manual

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CHAPTER 2 EQUIPMENT OVERVIEW

The basic In-Vehicle Subsystem equipment suite includes the following components:

Driver Control Module (DCM): The OrbStar unit (also known as a Mobile Data Terminal) provides functional computing, management and user input for the vehicle system. This is the operator’s man-machine interface to the AVL system.

In-Vehicle Unit (IVU): The main system processor that manages all communications and control of the on-board system equipment ancillary interfaces and equipment subsystems.

Mobile Radio: Vehicles are equipped with one M7300 radio used for both data and voice communications.

Figure 2-1 shows a high-level in-vehicle subsystem block diagram. The components shown are described in greater detail in the following sections.

FIGURE 2-1. IN-VEHICLE SUBSYSTEM BLOCK DIAGRAM.

On-Board Equipment Maintenance Technician Manual EQUIPMENT OVERVIEW

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Driver Control Module

The OrbStar Driver Control Module is the operator’s interface to the vehicle system. It consists of a touch-sensitive Liquid Crystal Display (LCD), backlit function keys, has an integrated covert microphone for SAS monitoring, and a speaker for audio output.

The operator uses this unit to view and perform manifest activities, send Request-to- Talk (RTT) and Priority Request-to-Talk (PRTT) messages, and send and receive text messages to/from the dispatch center. Maintenance personnel use the OrbStar to access built-in diagnostic tools.

FIGURE 2-2. ORBSTAR DRIVER CONTROL MODULE.

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In-Vehicle Unit

The In-Vehicle Unit is the main system processor that manages all communications and control of the on-board system equipment ancillary interfaces and equipment subsystems.

FIGURE 2-3. IVU-2100T.

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Mobile Radio

The ACS-provided in-vehicle equipment suite includes a mobile radio, shown in Figure 2-4. The radio supports data messaging and voice calls (when commanded by the IVU to switch to a voice channel).

While in data mode, the radio handles data communications between the In-Vehicle Subsystem and Fixed-End Subsystem. Data messaging commands the IVU to switch the radio to voice mode when a Dispatcher calls a vehicle. While in voice mode on the radio system, the radio affiliates with the trunking controller and the operator is allowed to use the handset for voice calls. Upon completion of the call either by a timeout or by hanging up the handset, the radio reverts to data mode.

The radio has three cables interfacing to it:

1. The antenna coaxial cable,

2. The 12 VDC power cable, and

3. The radio interface cable 141015.

FIGURE 2-4. M7300 RADIO.

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Refer to Appendix E In-Vehicle Equipment Schematic for the complete radio schematic (System Schematic, In-Vehicle Equipment, IVU-2100T, OCTA Paratransit drawing no.

170359).

FIGURE 2-5. RADIO SCHEMATIC.

To test the radio in Voice and Data modes

1. As a precondition for testing the radio, verify that OrbStar’s System Status Display shows System OK.

2. Send an RTT. Verify that the OrbStar’s Operator Action Display reflects receipt of the request at the fixed-end subsystem by showing the RTT Accepted status.

3. Receive a voice call from dispatch center. Verify that the users on the two ends can hear and understand one another.

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Voice Radio Handset/Speaker

The voice radio handset/speaker used is the Audio Sears model QEY04, shown in Figure 2-6, below. Specifications:

Integrated handset & speaker with hook-switch assembly.

Microphone: Audio Sears P/N 6349.

Maximum current: 150 mA.

Earphone impedance: 210 ohms +/-15%.

Speaker: 8 ohms, 6 Watts RMS.

Housing material: ABS.

Mounting plate material: aluminum.

Handset cable: 7-conductor coiled handset cable.

Magnetic on-hook cradle switch.

Environmental:

Temperature: –20 to +50°C operating, –40 to +70°C storage.

Humidity: 10 to 95% non-condensing.

Handset and cradle switches will not accidentally actuate under typical vehicle motion.

FIGURE 2-6. VOICE RADIO HANDSET/SPEAKER.

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Radio/GPS/WLAN Antenna

The In-Vehicle Subsystem uses a combined RF/GPS/WLAN antenna radome to support radio communications, vehicle location, and WLAN communications with the Data Interface Station (DIS). Specifications:

Frequency & Gain:

Cable 1 694-894 MHz, 2 dBi

1650-2000 MHz, 5 dBi

2100-2700 MHz, 3 dBi

Cable 2 2.4 & 4.9-6.0 GHz, 5 dBi

Cable 3 (GPS) 1575.42 +/- 2 MHz, LNA 26 dB

5 dBi nominal RHCP, Antenna

Data Modem:

VSWR 2:1 max over range

Nominal Inpedance 50 ohms

Power 700 MHz: 30 Watts, 800-6.0: 10 Watts

GPS:

Noise Figure 2.0 dBmax, 1.7 dB typical

Amplifier Bias 2.7 to 5 VDC

Amplifier Current 20 mA, 10 mA typical

Case: 4.2‖D x 3.2‖H [107 mm x 81mm add ½‖

(1.3 cm) for mag base mm]

Case Material: White or Black UV resistant ASA

Cable:

Cable 1 & 2 Separate RF – 195, 15ft (4.5 meters)

Cable 3 (GPS) RG-174, 15 ft (4.5 meters)

Connectors: SMA Plug (Male)

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Mounting: Threaded metal stud ¾‖ dia. x ½‖ long

(19 mm x 13 mm) for ¼‖ (6mm) thick metal; supplied with gasket and nut

Operating Temp: -40 to + 85° C

Shock & Vibration: IEEE 1478, EN 61373, MIL-810G

TIA 329.2-C

Dust/Water Ingress: SMW:IP67, MGW:IPx5

FIGURE 2-7. RADIO/GPS/WLAN ANTENNA.

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OBD-II Scan Tool

The OBD-II Scan Tool provides the interface between the vehicle diagnostics and the IVU 2100T. This interface provides mileage information to the OrbStar.

NOTE: Refer to Appendix C for instructions on how to load the Scan Tool Software.

Specifications:

Vehicle protocols:

CAN 11-bit

CAN 29-bit

J1850 PWM

J1850 VPW

Host protocols:

RS232

8 data bits

1 stop bit

No parity

57.6k baud

CTS implemented

FIGURE 2-8. OBD-II SCAN TOOL.

On-Board Equipment Maintenance Technician Manual INSPECTIONS

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CHAPTER 3 INSPECTIONS

Routine inspections and regular cleaning are critical to keeping the OrbStar and its systems operating properly. Many physical problems that plague mobile electronic systems can be avoided by performing regular inspections for signs of degraded system performance, wear and tear, and prompt corrective maintenance to repair the deficiencies. The proper frequency of inspections and cleaning depend on the local maintenance and operating environments. In general, inspections and cleaning should be performed during all unscheduled maintenance and at intervals no greater than 30 days.

Prior to beginning routine or unscheduled radio maintenance, perform the following inspection steps:

1. Inspect for obvious problems before removing or replacing components.

2. Ensure all parts are properly installed.

3. Test for the correct power-source voltages by measuring input voltages to the system.

4. Ensure all fuses are installed (not blown) and that all cable connections are secure.

CHAPTER 3 On-Board Equipment Maintenance Technician Manual

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Equipment Inspections

Use the following inspection steps when performing routine detailed inspections of the ACS-provided in-vehicle equipment:

1. Inspect all OrbStar wire and cable assemblies on the vehicle for chafing.

a. If the wires and cables are damaged but still serviceable, apply appropriate insulation and strain relief to protect the cables from further damage.

b. If wire and/or cable assemblies are severely pinched, or cut with exposed bare wire, discontinue use of the OrbStar and replace the damaged wiring and/or cable assembly.

2. Ensure all cables are connected with completely engaged connectors.

3. Ensure all connectors and locking hardware are properly locked in place.

4. Check all systems for loose hardware (nuts, bolts, screws) and unrestrained wiring and/or cabling. Secure and/or reinstall any loose hardware and allow for cabling strain relief. Replace parts that cannot be satisfactorily reinstalled.

5. Check for open fuses and replace only with a new fuse bearing the same rating as specified in the installation documentation (provided separately).

6. Check for missing or damaged antennas.

7. Check power source voltages for consistency.

On-Board Equipment Maintenance Technician Manual INSPECTIONS

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Cleanliness Inspections

When servicing vehicle systems, use the following steps to inspect for cleanliness:

1. Check all equipment for debris.

2. Brush debris away gently.

3. Carefully wipe the area with a soft cloth to remove any remaining dust and grime.

NOTE: When wiping down the OrbStar data screen use extra care. The technician must not use detergents, solvents, or glass cleaners as they may scratch or otherwise damage the data screen. Use only a clean, soft damp cloth and the approved SafeZone cleanser that can be obtained from Miller Stephenson Chemical (part number: MS-260). This aerosol cleanser can be used to clean plastic, glass, and metal.

CHAPTER 4 On-Board Equipment Maintenance Technician Manual

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CHAPTER 4 TROUBLESHOOTING & DIAGNOSTIC

PROCEDURES

The initial step in troubleshooting any reported radio equipment problem is to isolate the problem to the in-vehicle equipment to eliminate any possibility that the reported problem is or could be a broader radio system problem. After confirming and isolating the problem to the in-vehicle radio equipment, the maintenance technician must perform a physical inspection of the installed radio equipment to determine whether it is a physical hardware problem (loose or broken connections, missing parts, etc.) or something else that requires further troubleshooting to isolate the source of the reported failure.

When troubleshooting and diagnosing the installed equipment, the radio is tested. Radio testing identifies specific symptomatic indicators to isolate the failure to the radio or eliminate the radio as the cause of the reported radio system problem. Typical indications of a failed radio include radio in fallback indicating a possible failed data channel and/or the failure of the IVU processor to register with the fixed end after the boot process is complete. Prior to troubleshooting the system, always verify the power is good to the radio, and if available, use an RF wattmeter to verify the output power and VSWR of the radio before troubleshooting the system further. The experienced radio maintenance technician will quickly recognize the symptomatic failure conditions associated with a failed radio. The failed radio should be removed and replaced. After confirming the failure, the technician should complete the RMA form providing all required information and failure symptoms requested on the form.

The preceding paragraph is one example of diagnosing (troubleshooting) the in-vehicle radio equipment with a reported radio communications problem. It illustrates the basic process that, in general, applies to troubleshooting. The paragraph also indicates that radio equipment problems may be reported in a trouble ticket by the operator and referred to radio maintenance for repair.

The basic process is as follows:

1. Confirm/isolate reported problem to the in-vehicle radio equipment.

2. Check for obvious loose connections and/or hardware that may be the source of the reported failure.

3. Use the system performance to isolate the problem to a component of a specific in-vehicle radio equipment function.

4. Check all electrical power (IGN, 12 VDC, 24VDC) to the in-vehicle radio equipment for tripped breakers and/or blown fuses.

5. Verify transmit RF power and VSWR.

On-Board Equipment Maintenance Technician Manual TROUBLESHOOTING & DIAGNOSTIC PROCEDURES

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System Confidence Testing with Vehicle Acceptance Test Procedure

Technicians perform the System Confidence Test (SCT) to isolate the source of a reported problem and to verify that OrbStar in-vehicle components are operating properly. Using the Vehicle Acceptance Test Procedure (ATP) form, technicians can perform one or more of the acceptance test procedures to isolate and repair a reported problem. Designed as a checklist, the ATP form contains a standard set of tests that allow technicians to test CAD Communications and Non-CAD Communications components. A copy of the ATP is located in the Appendix A of this manual.

When the ATP is performed, it will verify the operational status of implemented radio system functions. Depending on the reported radio equipment problem that radio maintenance technicians may find, performing all or parts of the ATP enables technicians to identify the source of the reported in-vehicle equipment problem. In running an ATP, the technician documents the troubleshooting process. The documentation can be helpful when completing the Return Materials Authorization (RMA) form required to return repairable units to ACS and/or an authorized part manufacturer for repair and/or replacement.

18 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

Return Materials Authorization

The Return Materials Authorization (RMA) form is provided by ACS to satisfy this requirement for both warranty and post warranty periods. A reproducible copy of the RMA form is located in Appendix B of this manual.

Use the information recorded on the ATP or radio equipment maintenance repair ticket to complete an RMA request form. After completing the form, call the telephone number on the RMA form (upper right corner of the form) to obtain an RMA number.

The customer is responsible for the shipping charges and the safe transit of the failed equipment. A completed copy of the RMA form must be included with the shipment. It is important that as much information about the component’s failure mode that is known be provided. The information will assist ACS and/or vender personnel to more quickly isolate and repair the equipment.

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Repairs

There are no field repairable components in the installed vehicle equipment. No attempt should be made to open and/or repair the individual components of the installed vehicle system. All malfunctioning field replaceable components should be returned to ACS and/or, as directed by the Customer Service Department, to the original equipment manufacturer. Service Department should be contacted for a return authorization number prior to returning any malfunctioning components for repair. Regular maintenance of all of the equipment can ultimately determine the safety and reliability of the system. Failure to notice and repair minor problems could result in vehicle equipment failures that could endanger the safety of maintenance personnel, the operator, and/or passengers.

20 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

Problem Reports

The operator’s primary responsibility is to operate the vehicle safely. There are many things competing for the operator’s attention when they are on the road that can result in system radio problems being reported as hard radio equipment problems by the operator. Many system generated reports such as the Vehicle Problem, Diagnostic, and Equipment Reports are available to technicians for troubleshooting the radio system.

These reports are helpful in isolating radio equipment failures and system problems that have been reported by the operator.

The radio trouble tickets generated by the operator can be helpful in isolating, identifying and repairing the reported radio equipment problems. However, while it may point directly to the source of the problem reported in the trouble ticket, it can also mislead. An example might be that the operator reports not being able to log onto the system. This may lead the technician to falsely conclude that there is something wrong with the OrbStar when the problem is really a system issue where the operator is not in the system database. Another example is the reporting of ―GPS UNAVAILABLE‖ by the operator. In this example, the operator could be reporting a GPS failure caused by one or more radio equipment hardware components; or the reported failure could be symptomatic of the physical location of the vehicle where the GPS antenna does not have clear access to GPS satellite system (e.g. In a base, tunnel, or blocked by tall buildings).

Analyzing reports, generated by the system, provides a useful tool that can be used to identify subtle hardware failures when symptoms occur repeatedly on the same vehicle over several days (a one day occurrence may indicate that the operator failed to test the function). Similarly by analysis of another incident report on GPS performance by vehicle, one can identify vehicles with non-performing GPS antennas.

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Troubleshooting Procedures

The problems and troubleshooting procedures listed in this chapter are by no means all-inclusive. At times, several problems occur simultaneously or as a result of other problems. Often one or more problems will occur that mask other reported (or unreported) symptoms. There is no set rule that a single problem must have a single symptom or vice versa.

Troubleshooting the system as a whole can prove to be a formidable task for the unprepared. As a result, for all procedures in this manual, a working knowledge of digital multimeters and an ability to trace wiring from a vehicle system's schematic are assumed.

NOTE: The following experience is necessary for completing the procedures in this manual:

(1) Electronic troubleshooting

(2) Proper use of RF test equipment and digital multimeters, and

(3) Ability to trace wiring using the vehicle system’s schematics.

The following troubleshooting procedures (flow charts) are included in this section:

Figure 4-1. Bootup Troubleshooting Procedure

Figure 4-2. Auto-Reboot Troubleshooting Procedure

Figure 4-3. Radio Antenna Troubleshooting Procedure

Figure 4-4. Data Communications Troubleshooting Procedure

Figure 4-5. Voice Communications Troubleshooting Procedure

Figure 4-6. Radio Troubleshooting Procedure

Figure 4-7. Silent Alarm Troubleshooting Procedure

Figure 4-8. OBD-II Scan Tool Troubleshooting Procedure

22 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

START

Attempt Manual

Boot

Does Unit

Boot?

Does Unit

Auto-Reboot?

Does Unit

Indicate

Comms

Failed?

PROCEED TO

Data Comms.

Troubleshooting

Yes

No

Check Primary

Ignition/Power

Fuses

No

Are Fuses

Good?

Check Ignition and

12-Volt Fuses

Yes

Are Fuses

Good?

Check Power

Cable

Yes

Is Cable Good?

Replace IVU

Replace Power

Cable

Replace Blown

Fuses

Replace Blown

Fuses

Yes

No

PROCEED TO

Auto-Reboot

Troubleshooting

BOOTUP

SUCCESSFUL

Yes

Yes

No

No

FIGURE 4-1. BOOTUP TROUBLESHOOTING PROCEDURE.

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Power OK?

Replace Radio and Reprogram

START

Does Unit

Auto-Reboot?

Does Unit Still

Auto-Reboot?

Does Unit Still

Auto-Reboot?

Check Radio

Power

Replace IVU

Replace W04

Cable

Yes

Replace Radio

Power Cable or

Radio Fuse

No

Yes

Yes

BOOTUP

SUCCESSFUL

No

No

No

Yes

Attempt Manual

Boot

FIGURE 4-2. AUTO-REBOOT TROUBLESHOOTING PROCEDURE.

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START

(Successful Boot)

SYSTEM OK

Displayed?

Yes

Check Radio

Antenna

Replace Damaged

Radio Antenna

Repair and/or

Replace Defective

Antenna Cable

Troubleshooting

Complete?

Radio Antenna

Damaged?

VSWR OK?

PROCEED TO

Vehicle ATP

PROCEED TO

Radio

Troubleshooting

No

Check VSWR

Antenna

Yes

No

Yes

No Yes

No

Check radio for

Power up using

Power LED on

Accessory cable.

Power

Yes

No

Check Radio Fuse

Fuse Open Yes

Yes

No

Replace Fuse

Using spare units, isolate the problem to one or more of the following:

1. Verify that the radio is enabled in the WNG database.

2. Swap out the W4 cable

3. Swap out radio

4. Swap out IVU

FIGURE 4-3. RADIO ANTENNA TROUBLESHOOTING PROCEDURE.

*NOTE: A Significant delay in System OK can indicate an issue with the Antenna and or the Antenna cable, which may be degraded. Follow the ―No‖ path to Troubleshoot issue.

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START

Attempt Manual

Boot

Does Unit

Boot?

DONE

RETURN TO

Manual Bootup

Troubleshooting

SYSTEM OK

Displayed?

RTT

ACCEPTED

Displayed?

Loose

Connection(s)?

Press RTT

Check Cable

Connections

Tighten

Connection(s)

Using spare units, isolate the problem to one or more of the components listed below:

1. Troubleshoot Data Antenna & Antenna Cable (W20A)

2. Replace Radio Cable (W04)

3. Replace IVU

4. Reprogram and/or Replace Radio

Yes

No

Yes

Yes

No

YesNo

FIGURE 4-4. DATA COMMUNICATIONS TROUBLESHOOTING PROCEDURE.

26 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

Using spare units, isolate the problem to one or more of the components listed below:

1. Replace Handset

2. Replace Handset Cable (W09)

3. Replace Radio Cable (W04)

4. Replace IVU

5. Reprogram and/or Replace Radio

6. Verify proper programming for unit ID in the SmartNet

SAC database

START

(Successful Boot)

SYSTEM OK

Displayed?

Log onto the

OrbStar

RTT Received by Dispatcher?

Obtain Valid

Logon Data

PROCEED TO

Data Comms.

Troubleshooting

DONE

Logon

Successful?

INVALID [Data]

Message

Displayed?

Can Dispatcher be Heard?

Can Dispatcher

Hear Vehicle?

Press RTT

Yes

Yes

Yes

Yes

No

Yes

No

No Yes

No

No

No

Dispatcher Sets

Up Voice Call

FIGURE 4-5. VOICE COMMUNICATIONS TROUBLESHOOTING PROCEDURE.

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SYSTEM OK

Displayed?

Log On to the

OrbStar

Logon

Successful?

Press RTT

RTT

Received by Dispatcher?

Can Dispatcher Be Heard?

Yes

Yes

Yes

Proceed to

Antenna Troubleshooting

No

Check Cables

INVALID

Logon Message

Displayed?

No

No

Obtain Valid

Logon Data

Cables

Tight / Seated

Properly?

Tighten / Re-seat

Cables

No

Yes

No

No

Hear Vehicle?

Change VID to

Known Good ID

Can Dispatcher

Send Data

Msg?

Reboot

IVU

No

No

Yes

No

Yes Yes Can

Vehicle Send

Data Msg?

Yes Yes

Yes

Complete

ATP

Replace Radio

Can Vehicle

Send Data

Msg?

Reinstall Radio and Replace IVU

No

No

Yes

Reinstall W04

Replace Radio

Can Dispatcher

Be Heard?

Reinstall Radio &

Replace IVU

Yes

No No

Replace Handset

Can Dispatcher

Be Heard?

Yes No

Reinstall Handset and Replace W09

Cable

Can Dispatcher

Be Heard?

Yes No

Can Dispatcher

Be Heard?

Yes No

Reinstall W09 &

Replace W04 Cable

START

(Successful Boot)

Dispatcher

Sets Up

Voice Call

Can Dispatcher Can Dispatcher

Send Data

Msg?

FIGURE 4-6. RADIO TROUBLESHOOTING PROCEDURE.

28 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

Using spare units, isolate the problem to one or more of the components listed below:

1. Replace IVU

2. Replace Radio Cable (W04)

3. Replace (Data) Radio

4. Replace OrbStar

Using spare units, isolate the problem to one or more of the components listed below:

1. Replace OrbStar

2. Replace Radio Cable (W04)

3. Replace IVU

4. Replace W01 Cable

5. Replace W06 Cable

6. Replace (Voice) Radio

START

(Successful Boot)

Troubleshoot and

Repair Open SAS

Switch Circuit

Alarm SELF

TEST Passed?

RETURN TO

Data Comms.

Troubleshooting

Can Dispatcher

Hear Vehicle?

RTT Received by Dispatcher?

SYSTEM OK

Displayed?

Seconds Colon

Disappears?

Seconds Colon

Turns Solid?

Start Alarm Test:

Press RTT and

Request

Permission to Test

Dispatch Center

Grants Permission to Test

Press Alarm

Switch

Dispatcher Clears

Covert Call

Attempt Manual

Boot

RETURN TO

Manual Bootup

Troubleshooting

ALARM TEST

COMPLETE

Yes No

Yes

No

Yes Yes Yes

NoNo No

Yes

FIGURE 4-7. SILENT ALARM TROUBLESHOOTING PROCEDURE.

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Using spare units, isolate the problem to one or more of the components listed below:

1. OBD-II ―Y‖ Cable

2. Scan Tool Cable

3. Scan Tool

4. IVU to Scan Tool Cable

5. IVU

START

(Successful Boot)

Load latest S/W as required

See the Appendix for instructions

Does OrbStar indicate correct

ODOM mileage?

Does OrbStar indicate correct

ODOM mileage

Done

Done

Yes

Yes

No

Yes

Connections

OK

No

Verify cable connections between vehicle, scan tool, and IVU.

Repair

Connections

Does OrbStar indicate correct

ODOM mileage?

DoneYes

FIGURE 4-8. OBD-II SCAN TOOL TROUBLESHOOTING PROCEDURE.

Note: Some Vehicle Interlock Systems are not compatible with scan tool connection to OBD-II. Confirm vehicle interlock system still permits correct vehicle operation when OBD-II connection/changes are made.

CHAPTER 5 On-Board Equipment Maintenance Technician Manual

30 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

CHAPTER 5 ORBSTAR DIAGNOSTIC TOOLS

This chapter describes how to use the OrbStar Driver Control Module and its diagnostic tools. These tools are available via the OrbStar’s setup and diagnostic tabs, which may be accessed by touching the Common Display Area’s System/Communications Status control.

OrbStar 8400 Control Head

The OrbStar 8400 control head, shown in Figure 5-1, provides touch-screen and manual functionality. The touch-screen buttons are used to enter data, make selections, and move through various screens.

The OrbStar 8400 has six (6) dedicated-function hard keys that are used to manually access screens and perform functions. The dedicated keys (e.g., RTT, PRTT) always perform the same function, no matter what screen appears. Refer to Table 5-1 for a description of the keys.

FIGURE 5-1. ORBSTAR 8400 CONTROL HEAD COMPONENTS.

Touch- Screen

Button

Function

Hard Keys

On-Board Equipment Maintenance Technician Manual ORBSTAR DIAGNOSTIC TOOLS

ACS Proprietary: Information herein is subject to the restrictions on the title page of this document. 31

TABLE 5-1. ORBSTAR 8400 CONTROL HEAD KEYS.

Key Name Key Appearance Key Function

RTT

Send a Request-to-Talk message to the dispatch center.

PRTT

Send a Priority Request-to-Talk message to the dispatch center.

Canned Messages

Display the Canned Message screen to send a text message. Incoming messages cannot be processed using this button.

On-Board Navigation

Display the Map Navigation screen to access the current activity.

Manifest Summary List

Display the Manifest Summary List screen to access the current activity.

Incoming Messages

Display the Incoming Message screen to view incoming messages.

32 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

Screen Layout

OrbStar screens generally comprise standard screen areas, as shown in Figure 5-2.

The user touches specific screen areas, depending on each individual screen’s layout, to view information and perform routine tasks.

FIGURE 5-2. SCREEN COMPONENTS.

Touch- Screen

Button

Screen Specific

Area

Setup/ Diagnostic

Tabs

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Common Display Area

The Common Display Area (CDA) appears at the top of most OrbStar screens. It provides a standardized display of mission-critical status information, and embeds touchable controls that allow the user to navigate to other screens. The Common Display Area comprises four touchable controls, each of which contains two display lines. Figure 5-3 illustrates the composition of controls and displays. Table 5-2 describes the eight displays and the action that will result from touching each of the four controls.

TIME/WORK ASSIGNMENT

CONTROL

COUNTDOWN/

ODOMETER CONTROL

SYSTEM/

COMMUNICATIONS

STATUS CONTROL

MESSAGE COUNT/

OPERATOR

ACTION CONTROL

Time Display Countdown Display

System Status Display

Message Count

12:34:56 AM 00:05 Early System OK 7 Messages

Route: 106 0 7 8 6 3 3 Data Normal Logon OK

Work Assignment

Odometer Display

Communications Status Display

Operator Action

FIGURE 5-3. COMMON DISPLAY AREA LAYOUT.

34 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

TABLE 5-2. COMMON DISPLAY AREA’S DISPLAY DESCRIPTIONS AND CONTROL ACTIONS.

Display Name Description Screen Control Action

Time Shows the current local time. Indicates whether or not the silent alarm has been sent and the covert microphone activated.

Touch the Time/Work Assignment Control to go to the Logon Data Entry screen.

Work Assignment Shows the logged-on user’s work assignment.

Countdown Shows the minutes to the next event.

The color and text change when an event moves from early to late.

Touch the Countdown/Odometer Control to go to the Current Odometer Reading screen.

Odometer Shows the current odometer reading.

System Status Shows System Status messages. Touch the System/ Communications Status Control to go to the Volume Control tab or other Setup and Diagnostic tabs.

Communications Status

Shows Communications Status messages.

Message Count Shows the number of messages contained on the Incoming Message List.

Touch the Message Count/Operator Action Control to toggle between the Outgoing Canned Messages and the Incoming Message Summary screens. Operator Action Shows the status and provides direction to the user.

ACS Proprietary: Information herein is subject to the restrictions on the title page of this document. 35

Powering Up

When the vehicle ignition is turned on, power is applied and the OrbStar’s in-vehicle equipment is booted from an ―off‖, or ―cold‖, state. During the power-up sequence, the in-vehicle subsystem performs a series of diagnostic checks (self-tests) and displays status information from these checks.

NOTE: The OrbStar does not have its own power switch.

Successful System Registration

Following successful completion of the self-test, the OrbStar attempts to establish a data connection (that is, register) with the Intelligent Transit Management System Fixed- End Subsystem.

Once the data connection is established, the Logon Data Entry Screen appears (see Figure 5-4), permitting the user to log on.

FIGURE 5-4. LOGON SCREEN APPEARS AFTER SUCCESSFUL SYSTEM REGISTRATION.

Unsuccessful System Registration

If this data connection is not established, the in-vehicle subsystem continues to attempt to register with the system until eventually successful. The System Status Display will show Voice Only, the Communications Status Display will alternate between Data Search and Voice Fallback to indicate the current state of the data connection with the fixed-end subsystem, and the Operator Action Display will show Use Handset.

36 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

Powering Down

In normal operation, the OrbStar in-vehicle equipment is powered down gracefully after the user logs off and turns the vehicle ignition off. In this scenario, the in-vehicle equipment does not power down immediately. To command a more immediate shutdown, use the Shut Down function on the Vehicle Processor Status screen.

Delayed Power Down

The OrbStar and other components are on a delay timer, during which the in-vehicle subsystem continues to send status information to the dispatch center. The duration of this delay period, also known as ―keep alive‖ time, is set to accommodate a typical operator break. During the ―keep alive‖ time, voice call requests can be made and data messages can be sent and received. The Silent Alarm feature is also functional.

At the end of the ―keep alive‖ time period, the in-vehicle subsystem performs an orderly shutdown, during which time the OrbStar goes dark and communications with the dispatch center ceases.

NOTE: Refer to the Paratransit Operator Quick Reference Guide for logon and logoff instructions.

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Setup/Diagnostic Tabs

The user navigates to the Setup/Diagnostic Tabs and then selects the screen of choice.

Depending upon which screen is selected, the user may be required to enter a password. The operator logon is not required to access these screens.

Available Setup/Diagnostic tabs and corresponding screens are listed in the following table. These screens are described in more detail in the following sections of the manual.

TABLE 5-3. DIAGNOSTIC SCREENS.

Tab Symbol Diagnostic Screen Name Description

Volume Controls Displays adjustable System, Handset, and Navigation Volume controls.

Display Settings Displays adjustable LCD and Keypad Backlight controls. Also includes Language and Theme settings with an example of the selected color palette.

GPS Status Displays status of the on-board GPS Receiver, including differential correction status, and quality of the last position fix.

DIS Status Displays WLAN connectivity status of this vehicle’s OrbStar and In-Vehicle Processor units with the Data Interface Station (DIS). Includes functions to re-check connectivity status and force a software download.

OrbStar Status Displays Vehicle ID and Type values and OrbStar software version details. Includes functions to restart the OrbStar.

Vehicle Processor Status Displays Vehicle ID and Type values, Processor Type, and In-Vehicle Unit software version details.

Includes functions to restart the IVU, shut the in-vehicle equipment down, and set Vehicle ID.

Odometer Status Displays status information including Odometer Source, Distance, Calibration Type and Factor, Reliability, and Number of Ticks.

Vehicle Equipment Status Displays the vehicle’s equipment status including alarm test, GPS receiver, etc.

38 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

Volume Controls and Display Settings Screens

The Setup screens provide access to volume controls and display settings. Volume levels are increased or decreased and backlight levels are dimmed or darkened by touching the area above or below the slider button controls. Language and themes are selected from the drop-down lists.

FIGURE 5-5. VOLUME CONTROLS AND BACKLIGHT SETTINGS SCREENS.

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To access Setup/Diagnostic screens

1. From any OrbStar screen incorporating the Common Display Area, touch the System/Communications Status Control. The Volume Controls screen including the Setup/Diagnostic Tabs appear.

2. Touch one of the displayed Setup/Diagnostic tabs or touch the ―page left‖ or ―page right‖ arrow to view other Setup/Diagnostic tabs. When one of the password-protected diagnostic tabs is first selected, the Password Entry screen appears.

3. At the Password Entry screen, use the Numeric Keypad to enter the four-digit password. After the fourth digit is entered, the Confirm button appears.

4. Touch the Confirm button. If the correct password was entered, the selected diagnostic screen appears.

5. If the correct password was not entered, the ―Enter Password:‖ data entry field is cleared, and the ―Failed‖ sound is played. Try again, or speak with the ITMS Administrator for assistance.

FIGURE 5-6. PASSWORD ENTRY SCREEN.

Once the user successfully enters the password-protected diagnostic screen area, the user may navigate between diagnostic screens without needing to re-enter the password. If the user exits the diagnostic screens to return to an operational screen and subsequently attempts to access a diagnostic screen, the Password Entry screen is presented again.

To exit Diagnostic screens

When finished with the diagnostic screens, exit these screens by touching any of the Common Display Area’s controls.

Setup/ Diagnostic Tabs

System/ Communications

Status Control Page

Arrows

40 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

GPS Status Screen

The GPS Status Screen (Figure 5-7) displays status information for the on-board GPS Receiver.

NOTE: If the vehicle is not in clear view of the sky, the IVU may not receive GPS data.

FIGURE 5-7. GPS STATUS SCREENS.

ACS Proprietary: Information herein is subject to the restrictions on the title page of this document. 41

TABLE 5-4. GPS STATUS SCREEN SHOWING STATUS.

Status Description

UTC Time Is the Coordinated Universal Time provided by the GPS receiver.

Satellites (View/Fix) Displays the number of satellites in view/ number of satellites in the fix as reported by the GPS receiver.

GPS Status Displays the GPS receiver status.

Awaiting First Fix: Indicates the device has never had a valid fix Data Invalid: Indicates the receiver could not generate data Fix Lost: Indicates the fix was lost 2D Fix: Indicates the altitude component not accounted for in the solution 3D Fix: Indicates the full 3D solution DGPS 2D Fix: Indicates the 2D solution was corrected differentially DGPS 3D Fix: Indicates the 3D solution was corrected differentially

Accuracy (HDOP) Indicates latitude/longitude solution accuracy based on the visible satellite positions. Horizontal Dilution Of Precision (HDOP)

HDOP less than 2: Indicates best accuracy HDOP between 2 and 8: Indicates acceptable accuracy HDOP greater than 8: Indicates poor accuracy

Latitude 0 and above: Displays the latitude (in degrees) north of the equator.

0 and below (negative value): Displays the latitude (in degrees) for the southern hemisphere.

Longitude 0 and above: Displays the longitude (in degrees) east of the prime meridian.

0 and below (negative value): Displays the longitude (in degrees) for the western hemisphere.

Altitude Displays the distance (in meters) that the vehicle is above sea level.

Heading Indicates the vehicle’s heading in cardinal directions such as N, NE, E, SE, S, SW, W, and NW. Is followed by the heading in degrees (North=0;

South=180).

Speed Indicates the vehicle’s speed.

Acceleration 0 and above: Indicates vehicle acceleration

0 or below (negative value): Indicates vehicle deceleration, not moving

Last Update Received Indicates the date/time the vehicle received updated status information.

42 ACS Proprietary: Information herein is subject to the restrictions on the title page of this document.

DIS Status Screen

The DIS Status Screen (Figure 5-10) displays wireless local-area network (WLAN) connectivity status information.