NHTSA ID Number: 11007774
Manufacturer Communication Number: SC-23-109
TSB/Document Date: 2024-09-13
Summary
The procedure describes the process of updating the vehicles software along with a hardware change to improve the vehicles experience and diagnostics on ZX5.A02 buses.
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
64. Select Identification and verify that Transmission Model Number is EV 4 MD
65. Select vehicle and select the following options for weight. Note that you may need to update
Vehicle Loaded Gross Weight first, then update Vehicle Empty Gross Weight. See image below
for values.
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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
66. Select Gear and verify all values are 1rst.
67. Select motor and verify the following values.
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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
68. Select Options and set the following values. This is done by selecting the desired setting from
the drop down and then hitting apply.
69. Select PTO and verify the following options.
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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
70. Power off the bus at the driver’s workplace switch and wait for 3 minutes.
71. Power on the bus at the driver’s workplace and verify all configurations set correctly per the
above values.
72. Place the bus on a flat surface and make sure ride height is correct for driving.
73. Select service routines from the go to menu.
74. Start grade sensor calibration.
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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
75. Confirm on the service ranger tool to start calibration.
76. Verify successful calibration.
77. Turn off bus at driver’s workplace switch and wait for 3 minutes.
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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
78. Turn on bus at driver’s workplace switch and use PDT to verify no faults.
79. Turn Vehicle off at the Drivers workplace then turn off Curbside Master Switch and battery
saver switch.
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
064858
5.0.0
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.
30| 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
80. 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.
81.
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.
82. Access the Rear Deck above the rear window and remove the protective cap.
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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
83. Connect to the vehicle using the Nexiq USB Link2 and PDT similarly to the steps above in the
Vehicle controller flashing procedure.
84. On the laptop, double-click on the Proterra Diagnostics Tool software icon to start the software.
85. When the program opens, read and click “OK” for the prompt.
86. On the Home tab, select the appropriate device from the drop down and click “Connect”.
32| 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
87. 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.
Update Powertrain Software
This procedure updates the Powertrain software version and maintains the Powertrain
parameter configuration data across the flash download of new software.
88. Ensure you have the latest software file 064858 PCM PHX 5.0.0.hex on the computer's hard
drive.
89. Click on the “Powertrain Config” tab on the left-hand side of the screen.
33| 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
90. On the Powertrain Configurations tab, Click on “Get Values”.
91. 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.
92. Next, click the Powertrain Firmware “Start Flash” button.
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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
93. 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 064858 PCM PHX 5.0.0.hex
Select File
Click “Open”
94. The Proterra Diagnostic Tool will attempt to connect to the device.
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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
95. When the software update begins, the following screens will be displayed.
96. 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.
97. 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.
Master Switch Off, Hazards Off
36| 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
Master Switch Off, Hazards Off
98. Reconnect the Proterra Diagnostic Tool
99. 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 103.
100. Navigate to the Powertrain tab and type the recorded odometer value in the Odometer value
field, then click “Set odometer value.”
101. The Proterra Diagnostic Tool will display the following while updating the odometer value.
37| 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
102. 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.
103. 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.
104. Navigate to the “Powertrain Config” tab and click on “Get Values”.
105. Verify all the configurations are same as noted in step 91.
NOTE: RNDL configuration = 0 is not a valid configuration. If the configuration on step 109 was
0, then proceed to step 91.
106. If the configurations are same, then the programming process is complete, else go to the next
step.
107. Reset the configurations by selecting each configuration parameter individually.
108. Enter the value noted in step 91 in the “New Value” box and click on the “WRITE” button for
each parameter.
(NOTE: The RNDL configuration = 0 is not a valid configuration. RNDL configuration 14 has
replaced 0. If the configuration on step 91 was 0, replace it with 14, else configure it as
previous)
Name
Forward Speed Limit
Backward Speed Limit
Tire Size
Powertrain
Configurations
Default Value
Step 91 Value or
Customer Config
Step 91 Value or
Customer Config
Step 91 Value or
Customer Config
CMTA Value
38| 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
Performance Mode
RNDL Config
Yard Speed Limit
Miami Auto Neutral
Feature
Step 91 Value or
Customer Config
Step 91 Value or
Customer Config
65
0
5
Default (0)
109. 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.
110. Reconnect the PDT and click on “GET VALUES” inside the “POWERTRAIN CONFIG” tab.
111. Verify the Powertrain Configuration values are the same as in step 54.
39| 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
112. The flash process is complete.
113. Verify that no DTCs are present and conduct a basic functional check by shifting between
RNDL, then performing a short drive.
114. Power off the bus by turning the Master Switch OFF, and turning the Hazard Switch OFF.
115. Power down the bus by opening the main disconnect at the curbside rear of the bus and turning
off the Battery Saver switch.
116. Close the PDT.
MVP DASH 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
MVP DASH
064677
4.0.0
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
40| 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
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.
117. Turn on the 12/24V rear Vehicle Master Disconnect located behind the vehicle curbside rear
charge port access panel.
118. Access the dash and record the odometer value to be reinserted to the vehicle.
119. Make sure the Master Switch is OFF and the Hazard Switch is ON.
41| 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
120. Access the Rear Deck above the rear window and remove the protective cap.
121. Connect to the vehicle using the Nexiq USB Link2 and PDT similarly to the steps above in the
Vehicle controller flashing procedure.
42| 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
122. On the laptop, double-click on the Proterra Diagnostics Tool software icon to start the software.
123. When the program opens, read and click “OK” for the prompt.
124. On the Home tab, select the appropriate device from the drop down and click “Connect”.
125. 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.
43| 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
Update MVP Dash Software
This procedure updates the MVP Dash software version and maintains the Dash parameter
configuration data across the flash download of new software.
126. Ensure you have the latest software file 064677 MVP12_Flashing_v4.0.0.MVP12_A on the
computers hard drive.
127. Make sure the Master Switch is OFF and Hazard Switch is ON, as described in Step 82.
128. After connecting to the vehicle using the Proterra Diagnostic tool at the Diagnostic Port,
navigate to the “Dash Config”
44| 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
129. Select the Dash Parameter “Get Value” button to save the EEPROMs for later. To access the
files later they will save in your C: Drive -> Logs -> UDSConfigs -> MVP12 folder.
130. Select the Dash Firmware “Start Flash” button.
131. When prompted select the file 064677 MVP12_Flashing_v4.0.0.MVP12 from your hard drive.
132. Once you get the pop up below, turn on the working light in the SSWB. Select “OK”. Software
update is complete.
133. Power down the bus at the Curbside Rear of the vehicle and at the Battery Saver Switch.
45| 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
134. Close the PDT.
135. Cycle the vehicle and verify there is no faults on the dash.
BODY CONTROLLER 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.
136.
Component
Part Number
Version
Body Controller
064580
2.0.1
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 buy turning on high-voltage or place
the bus on a low-voltage charger for the duration of the process.
137. Turn on the 12/24V rear Vehicle Master Disconnect located behind the vehicle curbside rear
charge port access panel.
138. Make sure the Master Switch is OFF and the Hazard Switch is ON.
46| 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
139. Access the Rear Deck above the rear window and remove the protective cap.
47| 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
140. Connect to the vehicle using the Nexiq USB Link2 and PDT.
141. On the laptop, double-click on the Proterra Diagnostics Tool software icon to start the software.
142. When the program opens, read and click “OK” for the prompt.
143. On the Home tab, select the appropriate device from the drop down and click “Connect”.
144. 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.
48| 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
Update Body Controller Software
This procedure updates the Body Controller software version and maintains the Body Controller
parameter configuration data across the flash download of new software.
145. Ensure you have the latest software file Body_2_0_1_064580_PDT.MHX on the computer’s
hard drive.
146. Make sure the Master Switch is OFF and Hazard Switch is ON, as described in Step 100.
49| 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
147. After connecting to the vehicle using the Proterra Diagnostic tool at the Diagnostic Port,
navigate to the “Body Config” tab.
148. Select start Flash on the “Body Config” Tab.
50| 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
149. As directed above, recognize that you must be plugged into the rear deck port. Then select
“Ok”.
150. Select the Body SW Body_2_0_1_064580_PDT.mhx. The extension type must be .MHX.
151. Once the SW is flashed the following screen will pop up. Select “Ok”. Then close the PDT and
remove connection to the bus.
51| 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
152. Power down the bus at the Curbside Rear, turn both the Vehicle Master Disconnect and LV
Battery Switch to OFF.
153. Wait 2 minutes from powering down the bus, then cycle the vehicle on and verify there is no
faults.
52| 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
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TSB/Document ID: SC-23-109
Replacement Service Bulletin Number:
MFR Communication Date: 2023-08-17
MFR Internal Campaign ID/Software Version: SC-23-109
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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