NHTSA ID Number: 10163624
Manufacturer Communication Number: SC-19-58
TSB/Document Date: 2019-08-08
Summary
Voltage sags are causing the datalogger to reset, losing data used for monitoring and servicing the vehicles. Proterra issued this service bulletin to add a diode that will prevent voltage sags and loss of data.
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TSB/Document ID: SC-19-58
Replacement Service Bulletin Number:
MFR Communication Date: 2019-07-11
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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DOCUMENT CREATION DATE:
SERVICE CAMPAIGN SUBJECT:
VINs or MODELS AFFECTED:
SERVICE CAMPAIGN #:
4/5/2019
Catalyst 35 Telemetry Reliability Retrofit
Service Specified Catalyst 35 Buses
SC-19-58
CATALYST 35 TELEMETRY RELIABILITY RETROFIT
NOTICE! It is expected that this process will require 1 hour per bus. Please
schedule appropriately to minimize vehicle downtime.
Retrofit Description:
This retrofit installs a diode in series with the datalogger power input to prevent voltage sags from
resetting the unit.
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789
1|Page
Tools/Parts Required
Tools and Supplies Required:
•
•
•
•
•
•
•
•
Side Cutting Pliers
Deutsch Connector Tool
Deutsch Crimp Tool
T-30 Torx Driver
Ratchet
Calibrated Torque Wrench
13mm Socket
Wire Strippers
Parts Required:
•
044019
KIT, DATALOGGER DIODE RETROFIT (CONSISTING OF)
o 044018
Harness, Datalogger Diode Retrofit
o 003281
CABLE TIE, 8 IN BLACK
o 001301
TERMINAL, SIZE 16, SOCKET, 16-20 AWGH
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789
1 EA
1 EA
1 EA
1 EA
2|Page
Procedure
1. Complete the Proterra approved Lockout/Tagout procedure to make the bus safe for work.
2. Open the Curbside rear compartment of the bus to access the low voltage batteries.
3. Using a 13mm Ratchet/Socket, remove the two low voltage battery retaining bolts.
4. Slide the battery tray out. Using a 9/16-Inch Ratchet/Socket, remove the nuts that attach the
battery cables to the battery posts. Disconnect all three cables.
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789
3|Page
5. Access the electronics area at the rear of the bus by opening the doors.
6. Locate the Datalogger behind the ECAB panel.
Datalogger
7. Using a Deutsch Connector Tool, lift the locking tab on the Datalogger connector so that it can
be disconnected from the unit.
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789
4|Page
8. Disconnect the Datalogger from the harness.
9. Using a Deutsch Connector Tool, carefully pry the Wedglock away from the connector to
release the pins.
Note: Do not remove the Wedgelock completely.
10. Remove the Red Wire from Cavity 1 of the connector by rotating it 90 degrees and pulling it.
Using Side Cutting Pliers, cut the pin off the Red Wire.
Cut Here to Remove Pin
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789
5|Page
11. Remove the Diode from the new Harness (044018).
Remove Diode
12. Insert the pin from the new Harness (044018) into Cavity 1 on the Ampseal Connector.
13. Replace the Wedgelock on the Ampseal Connector.
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789
6|Page
14. Using Wire Strippers, strip the red wire that was removed from the Ampseal connector earlier.
15. Using a Deutsch Crimp Tool, crimp a Terminal (001301) on the wire.
16. Remove the Wedgelock from the new Harness (044018). Insert the Terminal into cavity two of
the two pin Deutsch Connector.
17. Replace the Wedgelock on the Connector.
Wedgelock
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789
7|Page
18. Replace the Diode on the two cavity Deutsch connector.
19. Using a Wire Tie (003281), secure the assembled Diode and Connector to the harness.
20. Reconnect the Bus Harness to the Datalogger.
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789
8|Page
21. Reconnect the Battery Terminals that were disconnected earlier.
22. Using a Torque Wrench with a 9/16-Inch Socket, torque the battery connections to 120inch pounds.
23. Slide the battery shelf back into position in the Bus and secure it with the bolts that were
removed earlier.
24. Using a Calibrated Torque Wrench with a 9/16-Inch Socket, torque the bolts to 180-inch
pounds.
25. Close and latch the Curbside rear compartment of the bus.
26. Remove the Lockout/Tagout devices and power on the bus.
27. Verify that the Datalogger is powered on by observing the status light on it.
Status Light Location
28. Return the bus to service.
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789
9|Page
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