ISSUE DATE:

06/02/2023

SERVICE BULLETIN SUBJECT:

800V Cooling Hose Cap Retrofit

VINs or MODELS AFFECTED:

Service Specified Buses

COMPLETE BY:

Next Service Opportunity

SERVICE BULLETIN #:

SC-23-082

LABOR OPERATION CODE:

CC64Z

NOTICE! It is expected that this process will require 1 hour per bus. Please
schedule appropriately to minimize vehicle downtime.

800V COOLANT HOSE CAP RETROFIT

Retrofit Description:
This procedure adds improved caps to the coolant system.
.

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Headquarters:
East Coast Manufacturing:
West Coast Manufacturing:

Tools/Parts Required
Tools and Supplies Required:
•
•
•
•
•
•

3/8-Inch Allen Driver
15/16-Inch Combination Wrench
Slip Joint Pliers
Spring Clamp Pliers
Side Cutting Pliers
PTFE Tape (Teflon)

Kit Parts Required:
054448

KIT, RETROFIT, RADIATOR BLEED HOSE CAP (Consisting of)
001161

FITTING, BRASS, PLUG, SOCKET HEAD, 1/2 PT"

1 EA

002996-002

CLAMP, WORM, 7/32 - 5/8" DIA"

2 EA

017013

HOSE, COOLANT, EPDM. SAE J20R3 D2. 3/8 ID"

10 IN

033407

FITTING, HOSE BARB, 1/2" NPTF X 3/8" HOSE

1 EA

142-9214

PLUG, 5/16", THUMB NUT

1 EA

012138

CABLE TIE, HEAVY DUTY .5WIDE 9.1" BLACK

1 EA

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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

Procedure
1. Perform the Proterra approved Lockout/Tagout procedure to make the bus safe for work.
2. Using the appropriate safety measures, access the coolant system on the rooftop of the bus.
Note: It may be possible to reach the hose from the rooftop hatch, but all rooftop safety rules
apply.
3. Observe the Coolant System on the top of the bus shown in the following photograph.
A3/8Inch ID Hose may be installed in the location shown by the highlighted hose below.

4. If the Hose is still installed, remove it using Spring Clamp Pliers. Use Side Cutting Pliers,
remove any Cable Ties that secured the Hose.
5. If the hose is not installed, remove the caps from the areas circled in red above.
6. Apply PTFE tape to the threads on the Fitting (001161).

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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

7. Using a 3/8-Inch Allen Driver and a 15/16-Inch Combination Wrench, install the Fitting
(001161) into the Hose Barb (033407).

003407
001161

8. Torque the Fittings 2 to 3 turns past finger tight.
9. Install the Hose (017013) onto the radiator fitting as shown in the following photograph.

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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

10. Secure the Hose (017013) to the Cable Tie Mount using a Cable Tie (012138).
11. Installed the assembled Fittings (003407 and 001161) into the end of the Hose (017013).
12. Secure the Hose (017013) on each end with a Worm Drive Clamp (002996-002).
13. Install the Expansion Plug (142-9214) into the Expansion Tank Hose Barb as shown in the
following photograph.

14. Using Slip Joint Pliers, carefully tighten the Wing Nut on the Expansion Plug (142-9214).
15. Using Shop Towels, clean up any spilled coolant.
16. Remove the Lockout/Tagout devices and return the bus to service.

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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