ISSUE DATE:
SERVICE BULLETIN SUBJECT:
VINs or MODELS AFFECTED:
COMPLETE BY:
SERVICE BULLETIN #:
LABOR OPERATION CODE:

11/17/2023
ZX5.A02 PCM V5.1.0 Limited Release
Service Specified Buses
Next Service Opportunity
SC-23-154
PE49Z

NOTICE! It is expected that this process may require up to .5 hour per bus.
Please schedule appropriately to minimize vehicle downtime.

ZX5.A02 PCM V5.1.0 Limited Release
Description:
The procedure describes the process of updating the PCM to latest Software.
Notice: Service Bulletin SC-23-109 - ZX5.A02 PHX Spring Software Release and Shutdown
Override Momentary Must be Performed before installing Software or past.

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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

Tools/Parts Required:
Tools and Supplies Required:
Proterra Diagnostic Tool
USB Nesiq
T30 Bit

Kit Parts Required:
Kit PN
065772

Kit Name
SOFTWARE, POWERTRAIN, 800V, PHOENIX, REMINGTON, V5.1.0

2 | Page
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

Procedure:

PRODRIVE 2.0 POWERTRAIN SOFTWARE UPDATE PROCEDURE
Software Files Required / Preparation:
IMPORTANT! NEVER access the software from the USB memory device, ALWAYS copy the software
files to your computer hard drive and access the software from this location. Secure the bus with the
Vehicle Master Disconnect in the rear ON.

Component

Part Number

Version

PCM PD

065772

5.1.0

Preparing the Vehicle to be Programmed:
When programming a vehicle, it is critical that the low-voltage batteries remain connected
throughout the process. Ensure that the LV batteries are fully charged before starting the
process. If they are low, use the vehicle to recharge them by turning on high-voltage or place
the bus on a low-voltage charger for the duration of the process.

1.

Turn ON the 12/24V rear Vehicle Master Disconnect located at the curbside rear charge port
access panel and the LV Battery Saver Switch near the LV batteries.

2.

Turn the Master Switch to the “DAY RUN” position and turn the Hazard Switch ON.
a. NOTE – DO NOT PRESS THE START PB. THIS WILL ENGAGE HV.
b. NOTE – Other systems may cause the hazard lights to be on. Ensure the Hazard Switch is
on for flashing purposes.

3 | Page
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.

Access the Rear Deck above the rear window and remove the protective cap.

4.

Connect to the vehicle using the Nexiq USB Link2 and PDT similarly to the steps above in the
Vehicle controller flashing procedure.

5.

On the laptop, double-click on the Proterra Diagnostics Tool software icon to start the software.

4 | Page
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.

When the program opens, read and click “OK” for the prompt.

7.

On the Home tab, select the appropriate device from the drop down and click “Connect”.

8.

Once the diagnostic tool has connected to the vehicle, a VIN number and connection status will
appear on the Home screen, along with selectable tabs to navigate.

9.

Ensure you have the latest software file 065772.hex on the computer's hard drive.

10. Click on the “Powertrain Config” tab on the left-hand side of the screen.

5 | Page
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. On the Powertrain Configurations tab, Click on “Get Values”
12. After clicking on Get Values, note down the values set for Forward Speed limit, Backward
Speed Limit, Tire Size, Performance Mode, RNDL Configuration, Yard Speed Limit, and
Odometer for future reference.

13. Next, click the Powertrain Firmware “Start Flash” button.

6 | Page
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

14. The following screen will be displayed. Navigate to the location where you stored the
configuration file earlier. Select the software file downloaded previously and click “Open” to load
the file
NOTE: The file name displayed should be 065772.hex

Select File
Click “Open”

15. The Proterra Diagnostic Tool will attempt to connect to the device.

16. When the software update begins, the following screens will be displayed

7 | Page
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

17. The software update may take several minutes to complete. When the update is complete the
following will be displayed. Click the “OK” button to complete the update process.

18. Disconnect the diagnostic tool and turn the Master Switch to OFF, the Hazard Switch OFF, and
then turn the Master Switch back to DAY RUN and the Hazard Switch back ON

19. Reconnect the Proterra Diagnostic Tool.
20. Check the odometer value displayed on the dash, if it doesn’t match the recorded value, then
proceed to the next step. If it does match the recorded value then proceed to step 12.
21. Navigate to the Powertrain tab and type the recorded odometer value in the Odometer value
field, then click “Set odometer value.”

8 | Page
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

22. The Proterra Diagnostic Tool will display the following while updating the odometer value.

23. The Proterra Diagnostic Tool will display the following when the odometer update process
completes successfully. If the Proterra Diagnostic Tool displays Failed or Timeout please check
for active faults on the Diagnostics tab.

24. Verify that the odometer value displayed on the dash matches the recorded odometer value.
Note that it’s okay if the new odometer value differs by up to 1 mile. The odometer update
process is now complete.
25. Navigate to the “Powertrain Config” tab and click on “Get Values”
Verify all the configurations are same as noted in step 12. If configurations do not match update
each configuration one at a time.
(NOTE: The RNDL configuration = 0 is not a valid configuration. RNDL configuration 14 has
replaced 0 else configure it as previously seen on step 12.

9 | Page
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

26. After configuring all the parameters, turn the Master Switch to “OFF” and the Hazard Switch
OFF. Then, turn the Master Switch back to “DAY RUN” and the Hazard Switch back to ON.
27. Reconnect the PDT and click on “GET VALUES” inside the “POWERTRAIN CONFIG” tab.
28. Verify the Powertrain Configuration values are the same as in step 12.
29. The flash process is complete.
30. Verify that no DTCs are present and conduct a basic functional check by shifting between
RNDL, then performing a short drive.
31. Power off the bus by turning the Master Switch OFF, and turning the Hazard Switch OFF.

32. Power down the bus by opening the main disconnect at the curbside rear of the bus and turning
off the Battery Saver switch.
33. Close the PDT.

10| Page
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