NHTSA ID Number: 10179592
Manufacturer Communication Number: SC-20-103
TSB/Document Date: 2020-09-11
Summary
This procedure adds electromagnetic interference filters to the variable frequency drive systems on the bus to resolve potential charging and startup issues.
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TSB/Document ID: SC-20-103
Replacement Service Bulletin Number:
MFR Communication Date: 2020-08-07
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
ISSUE DATE:
SERVICE BULLETIN SUBJECT:
VINs or MODELS AFFECTED:
COMPLETE BY:
SERVICE BULLETIN #:
7-24-2020
800 Volt VFD EMI Filters Retrofit
Service Specified 40 Foot Buses
Next Service Opportunity
SC-20-103
NOTICE! It is expected that this process will require 3 hours per bus. Please
schedule appropriately to minimize vehicle downtime.
800 VOLT VFD EMI FILTERS RETROFIT
Retrofit Description:
This procedure adds electromagnetic interference filters to the variable frequency drive systems on
the bus to resolve potential issues caused by EMI noise.
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:
•
•
•
•
•
•
•
Ratchet
11/16-Inch Socket
5/8-Inch Socket
8mm Socket
Calibrated Torque Wrench
Side Cutting Pliers
#2 Phillips Screwdriver
Kit Parts Required:
•
052071
RETROFIT KIT, EMI FILTER, 40' (Consisting of)
o 052069
PLATE, STUD, EMI FILTER
o 052070
SPACER, HVJB FILTER
o 051628
EMI FILTER,800V 30ADC,50nF Y-cap, 2 Stage 2.3mH
o 052313
CABLE ASSY, EMI FILTER JUMPER (HVAC)
o 013570-023
BOLT: HEX: M10-1.50X90X26
o 052314
CABLE ASSY, EMI FILTER JUMPER (PS/AIRCOMP)
o 018574
LKNT, HEX FLANGE NYLON, SS, M5-0.8
o 052370
HARNESS, FILTER-OVERLAY (FGND)
o 012108
SWIVEL BUNDLE, SPACER
o 012138
CABLE TIE, HEAVY DUTY .5WIDE 9.1" BLACK
2 EA
2 EA
2 EA
1 EA
2 EA
1 EA
8 EA
1 EA
1 EA
1 EA
Parts Required but not Included in Kit:
•
012138
CABLE TIE, HEAVY DUTY .5WIDE 9.1" BLACK
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
10 EA
2|Page
Procedure
1. Perform the Proterra approved Lockout/Tagout procedure to make the bus safe for work.
2. Open the Trunk Panel to access the rear electronics compartment.
3. Using an 11/16-Inch Ratchet/Socket, remove the Bolt shown in the following photograph from
the Streetside VFD.
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
4. Using an 8mm Ratchet/Socket, remove the two screws on the left of the VFD to install a Plate
(052069).
5. Place a Plate (052069) on the VFD as shown in the following photograph.
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
6. Using a 5/8-Inch Ratchet/Socket, install a Spacer (052070) and Bolt (013570-023) as shown in
the following photograph.
7. Using a Calibrated Torque Wrench with a 5/8-Inch Socket, torque the Bolt to 35 foot
pounds.
8. Using an 8mm Ratchet/Socket, secure the Plate (052069) with the screws that were removed
earlier.
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
9. Using a Calibrated Torque Wrench with an 8mm Socket, torque the screws to 32 inch
pounds.
10. Place an EMI Filter (051628) on the Plate (052069) as shown in the following photograph.
Note: The connectors on the Streetside EMI filter must face the front of the bus.
11. Connect a Ring Terminal from the wire labeled 2CM001 on the Ground Harness (052370) to
forwardmost Curbside mounting stud on the Plate (052069).
12. Using an 8mm Ratchet/Socket, secure the EMI Filter (051628) and Ring Terminal to the Plate
(052069) using 4 Locknuts (018574).
13. Repeat the previous process to install a Plate (052069) and EMI Filter (051628) on the
Curbside VFD as shown in the following photograph. Use the same hardware as the Streetside
installation. The wire labeled 1CM001 on the Ground Harness (052370) should connect to the
forwardmost Curbside mounting stud on the Plate (052069).
Note: The connectors on the Curbside EMI filter must face the rear of the bus.
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. Disconnect the HVJB Connector shown circled in red in the following illustration. The
connector is labeled PM507.
15. Using Side Cutting Pliers, cut and remove the Cable Ties shown circled in red below.
16. Route the end of the cable that was disconnected to the Curbside EMI Filter (051628).
17. Connect the cable to the output of the Curbside EMI Filter (051628). The output is the
connector on the right of the EMI Filter when it is viewed from the front.
Note: The cables are keyed. Ensure that the correctly keyed end is connected to the HVJB.
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. Connect the HVAC Cable (052313) from the kit to the to connector on the HVJB as shown.
Note: The cables are keyed. Ensure that the correctly keyed end is connected to the HVJB.
19. Connect the free end of the HVAC Cable (052313) to the input of the Curbside EMI Filter
(051628).
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
20. Disconnect the HVJB Connector shown circled in red in the following illustration.
21. Route the connector that was disconnected to the output of Streetside EMI Filter (051628).
22. Connect the cable to the output of the Streetside EMI Filter (051628). The output is the
connector on the right of the EMI Filter when it is viewed from the front.
23. Connect the Air Compressor Cable (052314) from the kit to the connector on the HVJB as
shown. Connect the other end of the Cable to the input of the Streetside EMI Filter as shown in
the following photograph.
Note: The cables are keyed. Ensure that the correctly keyed end is connected to the HVJB
Air Compressor Cable
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
24. Using Cable Ties (012138) and Swivel Spacers (012108) neatly secure the wiring as shown in
the following photograph.
25. Carefully route the free end of the Ground Harness (052370) along with the other wiring to the
Ground Block on the Curbside of the bus.
26. Using a #2 Phillips Screwdriver, connect the ring terminals on the Ground Harness (052370) to
the Ground Block.
27. Secure the Ground Harness (052370) to the other wiring using Cable Ties (012138).
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
10 | P a g e
28. Close the Trunk Panel.
29. Remove the Lockout/Tagout devices and power on the bus.
30. Ensure that no faults are present before returning 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
11 | P a g e
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