APPENDIX_K_-_VEHICLE_HUMA_FEEDBACK_GUIDE-v3.2.pdf

Vehicle Health, Usage and Monitoring

DTC & RCM Feedback Guide for

Field Root Cause Analysis

Procedures Outlining the DTC Root Cause & RCM Cost Savings Analysis and

Feedback for Field CBM Techs

August 15, 2016

Revision Date: March 8, 2017

Diagnostic Trouble Code (DTC) & Reliability Centered Maintenance (RCM) Verification Process

Document Revision

March 8, 2017

• Added new version of Site Summary Form

January 6, 2017:

• Added new Site Summary Version 6.0 and directions

• Added new DTC Site list and Directions

November 27, 2016:

• Added section to address RCM Cost Analysis.

• Updated Appendix D with new Site Summary form and instructions.

• Added sections addressing RCM.

• Changed areas containing “DTC list” to “Vehicle DTC Spreadsheet”.

• Added Appendix G: RCM Vehicle Spreadsheet for Analysis.

• Changed Appendix E heading to “DTC Vehicle Spreadsheet for Analysis”.

• Fixed miscellaneous wording errors or formatting.

September 1, 2016:

• Section 1b (6): Note added to address additional Active DTCs found during analysis.

• Section 2a (1): Added sections (a & b) to explain road test.

• Appendix A: Provided report naming examples after each report explanation in sections 1 & 2.

• Appendix A: Moved ECM/Vehicle table to the end of section2.

• Appendix B: Changed component report file naming prefix to identify component.

o Engine report: Prefix changed to ENG o Transmission report: Prefix changed to TRAN o ABS Report: Prefix changed to ABS o CTIS Report Screenshot: Prefix changed to CTIS

• Appendix D: Section3 added to address failed components requiring Site Summary

• Appendix F: Added to explain road test procedures for certain DTCs.

Table of Contents

DTC Root Cause Analysis Overview 3 Vehicle DTC Spreadsheet 4 DTC Root Cause Analysis Process 5 Information Feedback from CBM Field Techs 6

RCM Cost Savings Analysis Overview 7

Vehicle RCM Spreadsheet 8 RCM Cost Savings Analysis Process 9 Information Feedback from CBM Field Techs 10

Appendix A: DTC Feedback Reports Required Section One 11

Section Two 12

Appendix B: File Structure and File/Folder Naming Format

Section One 13 Section Two 14 Section Three 15 Section Four 16 Section Five 17 Section Six 18

Appendix C: Diagnostic Trouble Code (DTC) Locked in ECM 19

Appendix D: Site Summary Example

Section One (Cost Savings Example) 20 Section Two (Instructions) 21

Appendix E: DTC Vehicle Spreadsheet for Analysis 24

Appendix F: Vehicle Road Test Overview 25

Appendix G: RCM Vehicle Spreadsheet for Analysis 26

Glossary 27

Diagnostic Trouble Code (DTC) Root Cause Analysis

AMSAA Vehicle Health, Usage and Monitoring Team will provide a Vehicle Diagnostic Trouble Code

(DTC) spreadsheet to CBM Field Techs for verification, diagnosis and root cause analysis.

The following should be used as a guide to provide root cause analysis feedback to AMSAA Vehicle

Health, Usage and Monitoring Team POC.

Purpose:

The intent of this program is root cause analysis of Diagnostic Trouble Codes (DTC) related to vehicles outfitted with Digital Source Collectors (DSC) devices.

• Track trends with DTC triggers or component failures

• Keep current collected DTCs relevant and remove previously analyzed or repair DTCs from our

Digital Source Collectors.

• Provide feedback to Health Usage and Monitoring Team Lead of DTC analysis.

For the purpose of eliminating or reducing repetitive DTC alerts with Inactive DTCs, CBM Field Techs will clear all Inactive DTCs from ALL ECMS/TCMs once root cause analysis is performed.

NOTE: In some cases, clearing of Inactive DTCs may trigger the ABS light to illuminate. This should NOT be considered a problem. The manufacturer has set the firmware for this action to occur in order to alert the technician that the vehicle needs to be road-tested. This road-test is required for the ECM to verify the condition has been resolved.

In most cases, once the vehicles exceed 5 mph the ABS lights will turn Off, if an Active DTC condition does not exist. If the DTC returns, the unit should take actions to diagnose/repair that condition.

If an ABS light illuminates after clearing the Inactive DTCs, alert the unit that the vehicle needs to be road-tested.

NOTE: Any ABS DTC relating to Wheel Speed Sensors (IE: Open circuit, No reading, abnormal speed, etc.) MUST have the vehicle road-tested to ensure issue is corrected.

Do not consider your action complete until the road test is performed and wheel speeds are registered on all wheels.

NOTE: Appendix C provides guidance concerning Diagnostic Trouble Codes that may not clear due to

OEM restricted access.

A successful program involves CBM Field Techs working with units to ensure they understand DTC cause/effect for vehicle operation. Once root cause analysis is performed for a DTC, the unit should be alerted to any repair parts suggested for repair. If a repair is made or part replaced, the Data Monitor for that unit should be contacted to input these actions into the SDC database.

Vehicle DTC Spreadsheet

1 A spreadsheet (see example in Appendix E) containing the following columns will be provided to the

CBM Field Tech.

a. Prepopulated columns include:

(1) Unit

(2) Vehicle Serial Number

(3) Vehicle Bumper Number

(4) Vehicle Model

(5) Electronic Control Module (ECM): ECM name that would contain the DTC.

(6) Diagnostic Trouble Code (DTC)

(7) DTC Description

b. Columns requiring information from CBM Field Techs.

(1) Product Status Report (PSR) Saved:

(a) All Caterpillar engines require a PSR with vehicle mileage annotated in comments block.

(b) The report should be run with Key On Engine Off (KOEO).

(2) Status (I or A): DTC current status during root cause analysis:

(a) I = Inactive

(b) A = Active

(3) Trans Controller: Type of Transmission Control used on vehicle:

(a) WTEC2

(b) WTEC3

(c) Gen4

(d) Gen5

(4) Miles: Current Mileage from vehicle odometer on the dash panel.

(6) Remarks: Include a brief statement (approx. 125 characters or less) of findings and/or actions taken for repair.

Examples could include:

(a) Reconnected sensor or Sensor Faulty

(b) RF WSS wire cut or sensor Broken

(c) Circuit Breaker 22 faulty

(d) Performed self-configuration

NOTE: If additional Active DTC(s) are found while downloading individual ECM reports, the Active

DTC(s) should be diagnosed then added to the Vehicle DTC Spreadsheet by the CBM Field Tech.

Root Cause Analysis Process

2. Using the supplied Vehicle DTC Spreadsheet, the CBM Field tech should work with the unit to determine DTC root cause by:

a. Performing a diagnostic test on sensor, ECM, wiring etc. with DVOM and/or software to determine exact cause for DTC trigger.

(1) This may require a road-test.

(a) DTC type will dictate road-test time or duration.

(b) Refer to Appendix F for road test suggestions

(2) Software recordings may be needed to aide in analysis.

(3) Working with other CBM techs as needed to determine root cause and seek help.

(4) Sharing facetime video or component pictures to aide in diagnostics.

b. Once a faulty component or system is located document:

(1) Your findings and vehicle information on supplied spreadsheet.

(2) Repair parts suggested (if required) on supplied spreadsheet.

(3) Any actual or potential cost savings. (Appendix D: Site Summary example).

(a) Complete a Site Summary if your analysis:

1. Reversed a unit’s position that the part they ordered was not required.

2. Displayed that the unit ordered the wrong repair part.

An example would be performing a self-configuration on Bendix ABS ECM. Unit should not order a new

ECM as outlined in the vehicle IETM.

(b) Complete a site summary also if reporting a failed component listed in

Appendix D.

(4) Save these files in vehicle subfolder. (IAW Appendix B).

Information Feedback from CBM Field Techs

3. Root Cause Analysis Results/Feedback to AMSAA is needed by Close of Business (COB) of the week the spreadsheet is dated.

IE: HoodDTC07182016 feedback should be returned by COB July 22, 2016

Note: (Close of Business (COB) will vary for each CBM Field Techs office dependent on their time zone).

a. A main folder containing the individual vehicle subfolders

b. A subfolder for each vehicle on AMSAA supplied spreadsheet analyzed by the CBM Field

Tech.

(1) Reports or downloads IAW Appendix A.

(2) A text or Microsoft Word document containing additional information (OPTIONAL).

c. Completed spreadsheet with all necessary information outlined in section 1 (b).

d. Consolidate all information in the main folder by using the Microsoft Windows

Compressed (Zipped) file tool or the WinZip program.

(1) File naming:

(a) Use the file structure and naming conventions outlined in Appendix B.

(b) This is required to keep files cataloged correctly from all of our sites.

(2) Send this file back to AMSAA CBM using the AMRDEC Safe File Transfer Site.

https://safe.amrdec.army.mil/safe/

Reliability Centered Maintenance (RCM) Cost Savings Analysis

AMSAA Vehicle Health, Usage and Monitoring Team will provide a RCM Vehicle List to CBM Field Techs for verification, diagnosis and possible cost savings analysis.

The following should be used as a guide to provide root cause analysis feedback to AMSAA Vehicle

Health, Usage and Monitoring Team.

Purpose:

The intent of this program is cost savings analysis of RCM candidate equipment. This equipment is found during daily/weekly analysis of available Non-Mission Capable (NMC) or Equipment Status Report

(ESR).

• Document Cost Savings in relation to unnecessary repair parts ordering or replacement

• Track trends with component failures

• Provide feedback to Health Usage and Monitoring Team Lead of RCM analysis

The RCM program will attempt to document any of the following conditions in regards to wheeled vehicle maintenance:

• Number of instances the wrong repair part is ordered for a NMC repair.

• Period of time a technician uses to perform a diagnosis on a vehicle. This will include the unit actions or repair parts needed to bring the vehicle to FMC status compared to our technician time.

Once an RCM Vehicle List is received, the Field CBM Techs should make every effort to work with a unit to diagnosis, determine correct repairs parts required and document these actions. Time is critical. If the CBM Tech does not make the attempt to contact and work with the unit, the chance for a cost savings dwindles daily. Remember, they have the parts on order and we have to act quickly to see if we can reverse that process.

In most cases, our diagnosis will determine the wrong repair part was ordered or replaced. In this case a

Site Summary (Cost Savings) report should be completed by the Field CBM Tech and submitted to the

AMSAA HUMA Team POC. Appendix D details the Site Summary form.

There are instances where the correct action or repair part was ordered by the unit. In this case, Site

Summary (Component Failure) report should be completed by the Field CBM Tech and submitted to the

AMSAA HUMA Team POC. Appendix D details the Site Summary form.

Vehicle RCM Spreadsheet

1. A RCM Vehicle spreadsheet (see example in Appendix G) containing the following columns will be provided to the CBM Field Tech.

a. Prepopulated columns include:

(1) Location

(2) Unit

(3) Serial Number

(4) Model

(5) Vehicle Number.

(6) ORGWON

(7) Niin

(8) Nomenclature

(9) DOC Number

(10) Status

(11) Quantity

(12) Received

(13) Estimated Ship Date (ESD)

(14) NMC Days

b. Column(s) requiring information from CBM Field Techs.

(1) Feedback Remarks

(a) Utilize this block to summarize any actions or diagnosis you performed.

(b) A few examples of these summaries could be:

1. Engine was not faulty. IAP sensor was faulty. Unit will cancel the engine. Cost savings

Site Summary submitted.

2. Unit diagnoses faulty injector. We tested, injector was faulty. Component Failure Site

Summary submitted.

NOTE: The AMSAA HUMA POC may annotate questions in the Feedback Remarks prior to sending this form to the CBM Field Tech. These questions or remarks should be addressed during your summary. If

Call When on Vehicle is annotated, call the AMSAA HUMA POC once you have access to the vehicle.

NOTE: It is important to inquire about what diagnostic/repair actions the unit performed or possibly how this failure occurred prior to starting your analysis. This could help with your diagnosis and also reduce your diagnostic time.

RCM Cost Savings Analysis Process

2. Using the supplied RCM Vehicle spreadsheet, the CBM Field tech should work with the unit to determine if the repair part is needed by:

a. Performing a diagnostic test on sensor, ECM, wiring etc. with DVOM and/or software to determine the failure or recreate the symptoms.

(1) This may require a road-test.

(a) The component or supplied symptoms will dictate road-test time or duration.

(b) Refer to Appendix F for road test suggestions

(2) Software recordings may be needed to aide in analysis.

(3) Utilizing one or several test modules from your CBM kit which may include ECMs or TCMs.

(a) Test modules should be a last resort.

(b) If the original failure cause cannot be isolated, a test module could be damaged.

(4) Working with other CBM techs as needed to determine root cause and seek help.

(5) Sharing facetime video or component pictures to aide in diagnostics.

NOTE: If diagnostic help is needed, call a fellow CBM tech or AMSAA HUMA POC while you are at the vehicle. If you wait until you are back at the office, it will be harder to provide help as you will not be able to answer certain questions without vehicle access.

b. Once a faulty component or system is located document:

(1) Your findings and vehicle information on supplied RCM Vehicle spreadsheet.

(2) Repair parts suggested (if required) on supplied RCM Vehicle spreadsheet.

(3) Any actual/potential cost savings or component failure. (Appendix D: Site Summary example).

(a) Complete a Site Summary if your analysis:

1. Reversed a unit’s position that the part they ordered was not required.

2. Displayed that the unit ordered the wrong repair part.

3. Confirms unit ordered the correct part and there is a component failure.

An example would be performing a self-configuration on Bendix ABS ECM. Unit should not order a new ECM as outlined in the vehicle IETM.

Information Feedback from CBM Field Techs

3. Root Cause Analysis Results/Feedback to AMSAA is needed by Close of Business (COB) of the week the spreadsheet is dated.

IE: HoodNMCVehicles11272016 feedback should be returned by COB December 2, 2016

Note: Close of Business (COB) will vary for each CBM Field Tech’s office dependent on their time zone.

a. A main folder containing the individual vehicle subfolder should be created.

b. A subfolder for each vehicle on AMSAA supplied spreadsheet analyzed by the CBM Field

Tech.

(1) Reports or downloads IAW Appendix A.

(2) A text or Microsoft Word document containing additional information (OPTIONAL).

c. Completed spreadsheet with all necessary information outlined in section 1 (b).

d. Consolidate all information in the main folder by using the Microsoft Windows

Compressed (Zipped) file tool or the WinZip program.

(1) File naming:

(c) Use the file structure and naming conventions outlined in Appendix B.

(d) This is required to keep files cataloged correctly from all of our sites.

(2) Send this file back to the AMSAA HUMA POC using the AMRDEC Safe File Transfer Site.

Appendix A: DTC Feedback Reports Required (section1)

NOTE: Refer to Appendix B for file/report naming formats.

1. Caterpillar Engine: Product Status Report (KOEO)

a. Required for all vehicles with Caterpillar engines.

b. Add vehicle mileage to comment section.

c. Save in Adobe PDF format for ALL vehicles with a Caterpillar engine.

Report Name Example:

2. Transmission:

a. Print Diagnostic Report ONLY if Active DTCs are present OR if supplied DTC does NOT match DTC stored in the TCM.

b. Located under Reports (Top Menu bar). Select all boxes.

c. Save in Adobe PDF format.

3. WABCO ABS:

a. Print DTC list ONLY if Active DTCs are present OR if supplied DTC does NOT match DTC stored in the ECM.

b. Select print at bottom of DTC screen.

4. Dana CTIS:

match DTC stored in the ECM.

b. Use Windows snipping tool to capture image of DTCs. Save as an image file.

Appendix A: DTC Feedback Reports Required (section2)

5. Bendix ABS:

a. Print DTC list ONLY if Active DTCs are present OR if supplied DTC does NOT match DTC stored in the ECM.

b. Select Report on right side of DTC screen.

NOTE: If a Self-Configuration is performed, print a 2nd report after the configuration is reset.

6. Detroit Diesel Engine:

match DTC stored in the ECM.

b. Select Diagnostics>Fault Codes then File Print.

Vehicles with Caterpillar Engines (ECMs Available)

ECM FMTV HEMTTA4 PLSA1 M1070A1 Stryker-DVH

Cat Engine X X X X X

Transmission X X X X X

ABS X X X X X

CTIS X X X

Vehicles with Detroit Diesel Engines (ECMs Available)

ECM HEMTTA2 PLS Base M915-M917 M1070 Base

Detroit Engine X X X X

Transmission X X X

ABS X

CTIS X

Appendix B: File Structure and File/Folder Naming Format (section1)

Individual Report Names

Report File Format Name Format Example

Allison Transmission Diagnostic Report PDF TRAN + Vehicle VIN TRANAT1023456EFGH

Bendix ABS DTC Report PDF ABS + Vehicle VIN ABSAT1023456EFGH

Caterpillar Product Status Report PDF ENG + Vehicle VIN ENGAT1023456EFGH

Dana CTIS Fault Codes JPEG CTIS + Vehicle VIN CTISAT1023456EFGH

Detroit Diesel Fault Code List PDF ENG + Vehicle VIN ENGAT1023456EFGH

WABCO ABS Fault Information PDF ABS + Vehicle VIN ABSAT1023456EFGH

Site Summary (If required) PDF SS + vehicle VIN SSAT1023456EFGH

Appendix B: File Structure and File/Folder Naming Format (section2)

Weekly DTC spreadsheet

1. Weekly DTC spreadsheet sent to sites.

a. Location + DTC + DateSent

b. Examples:

(1) HoodDTC07222016

(2) CarsonDTC07222016

Weekly DTC spreadsheet name Example

2. Weekly Main Vehicle Folder Created at Site.

a. Use name of Spreadsheet received for that week.

b. Examples:

(1) HoodDTC07222016

(2) CarsonDTC07222016

Weekly Main Vehicle Name Example

3. Vehicle Subfolders Created at Site.

a. Use the vehicle VIN to name individual vehicle subfolders.

b. Examples:

Vehicle Subfolders Name Example

Appendix B: File Structure and File/Folder Naming Format (section3)

4. Main Folder with Vehicle Subfolders Example.

Appendix B: File Structure and File/Folder Naming Format (section4)

Weekly RCM Vehicle Spreadsheet

1. Weekly RCM Vehicle Spreadsheet sent to sites.

c. Location + RCMVehicles + DateSent

d. Examples:

(1) HoodRCMVehicles11272016

(2) BlissRCMVehicles11272016

Weekly RCM Vehicle Spreadsheet Name Example

2. Weekly Main Vehicle Folder Created at Site.

a. Use name of Spreadsheet received for that week.

b. Examples:

(1) HoodRCMVehicles11272016

(2) BlissRCMVehicles11272016

Weekly Main Vehicle Name Example

3. Vehicle Subfolders Created at Site.

a. Use the vehicle VIN to name individual vehicle subfolders.

b. Examples:

Vehicle Subfolders Name Example

Appendix B: File Structure and File/Folder Naming Format (section5)

4. Main Folder with Vehicle Subfolders Example.

Appendix B: File Structure and File/Folder Naming Format (section6)

AMRDEC File Name

Prior to uploading into AMRDEC for return to AMSAA, the Zip file containing the individual vehicle subfolders/reports and the weekly DTC spreadsheet should be named:

NOTE: The AMRDEC file name should be the same as the Spreadsheet file received for that week.

DTC Feedback File Example

Location + DTCVehicles + Digital Date (mmddyyy) or CarsonDTCVehicles07222016

RCM Feedback File Example

Location + RCMVehicles + Digital Date (mmddyyy) or CarsonRCMVehicles11272016

Appendix C: Diagnostic Trouble Code (DTC) Locked in ECM

Certain Inactive or logged event DTCs may not clear from certain ECMs. These OEMs have locked out the ability for customers to clear certain DTCs. The following table outlines some of those DTCs.

DTC ECM Description Locked

0102-07 Cat Eng Boost Pressure not Responding Yes

0110-00 Cat Eng High Coolant Temperature Warning Yes

0110-11 Cat Eng Very High Coolant Temperature Yes

0111-01 Cat Eng Low Coolant Level Warning Yes

0111-11 Cat Eng Very Low Coolant Level Yes

Appendix D: Site Summary Example (section1)

Site Summary Example

Appendix D: Site Summary Example (section2)

Site Summary Instructions

Appendix D: Site Summary Report Instructions (section4)

The site summary provides feedback to AMSAA on Cost savings by the field techs or to report certain component failures to be cataloged.

Component Failures requiring a Site Summary.

1. Engine

2. Engine ECM

3. Injectors

4. HUEI Pumps

5. Transmission

6. TCM

7. Cab Harness

8. ABS ECM

Any other components found that have a value exceeding $1000.00

Appendix E: DTC Vehicle Spreadsheet for Analysis

Appendix F: Vehicle Road Test Overview

Certain Diagnostic Trouble Codes (DTC) may require a vehicle road test to determine if the conditions triggering the DTC have been repaired.

The field tech should schedule this road test with the unit, to have a driver available, in a timely manner preferably when arriving at the unit.

The information listed below provides guidance if a vehicle would require a road test. Alert the maintenance section when you arrive that you will require an operator for road testing.

NOTE: Road-testing should be accomplished prior to returning any feedback to AMSAA.

Antilock brake System DTC

ABS DTCs that involve wheel speed sensors exhibiting erratic or no readings. Examples would include:

• Excessive Air Gap

• Wheel Slip

• Intermittent Signal Loss (Drop out) or erratic signal

• Damaged or Incorrect Tone Wheel

These DTCs may appear Inactive when you first connect to the system but would become Active after a road test.

Once the issue is corrected a 2nd road test would be required to ensure the issue is resolved.

NOTE: In most cases, a road test for these issues involves moving the vehicle ahead (while monitoring wheel speed sensors with ABS software) in a straight line to safely reach 5 mph then stop. This may only require 150-200 feet of space.

Engine or Transmission DTC

This category of DTCs may require a road test that puts the engine under a heavier load (while monitoring the engine diagnostic software). These DTCs would be centered around performance or power issues.

To expose the engine to heavier operating loads may require:

• Vehicle having a payload

• Driving up inclines (hills)

• Stopping at the bottom or on incline and accelerate from stop.

Transmission DTCs usually require an area that the vehicle may accelerate through the effected gear ranges (while monitoring the transmission diagnostic software) to determine issues or if problems have been resolved.

Appendix G: RCM Vehicle Spreadsheet for Analysis

Glossary

ABS Antilock Brake System

AMSAA Army Material Systems Analytic Activity

CBM Condition Based maintenance

DDDL Detroit Diesel Diagnostic Link

DTC Diagnostic Trouble Code

DVOM Digital Volt Ohm Meter

ECM Electronic Control Module

KOEO Key ON Engine OFF

KOER Key ON Engine Running

NMC Non-Mission Capable

OEM Original Equipment Manufacturer

PSR Product Status Report

RCM Reliability Centered Maintenance

TCM Transmission Control Module

Tech Technician

TM Technical Manual