NHTSA ID Number: 11007833
Manufacturer Communication Number: SC-23-079
TSB/Document Date: 2024-09-17
Summary
This procedure describes the process for updating the 800V DuoPower Body, Vehicle and Powertrain Controllers software to the latest version.
ISSUE DATE:
05/15/2023
SERVICE BULLETIN SUBJECT:
800v RR Duopower Spring Software Release
VINs or MODELS AFFECTED:
Service Specified Buses
COMPLETE BY:
Next Service Opportunity
SERVICE BULLETIN #:
SC-23-079
Labor Operation Code:
PP57Z
NOTICE! It is expected that this process may require up to 1.5 hours per bus.
Please schedule appropriately to minimize vehicle downtime.
800v RR Duopower Spring Software Release
Description
This procedure describes the process for updating the DuoPower Body, Vehicle and Powertrain
Controllers software to the latest version.
Headquarters:
East Coast Manufacturing:
West Coast Manufacturing:
1 | Page
Summary of Software Changes:
1. HV Faulted Shutdown improvement to prevent Fuse Clearing
-
Increased VIC HV sensing and robustness to prevent closing contactor under load on
startup after faulted shutdown.
2. Overhead Charging Robustness Improvements
- Added time outs and state resets to avoid getting stuck waiting in certain overhead
charge process states.
- Added robustness to no WIFI connection.
3. Compressor Diagnostic Robustness improvements
- SPN 1351 FMI 7 false failure fix
4. Power steering Diagnostic Robustness improvements
-
Power steering compressor RPM target and diagnostic maturity time change to prevent
false failure during normal operation.
5. Compressor Faulted Audible Alert Improvement.
-
Change to make air compressor faulted Dash display constantly drive buzzer to prevent
being ignored.
6. Dash saturating and showing “0” at high value.
-
Update to only send highest value the dash is capable of displaying.
7. Radiator Fan Fault Robustness improvement
- Fix to remove false failure diagnostic setting tied to reverse speed on startup.
8. Push Button Door Button lights with door closed while moving.
- Issue noticed in final validation mileage testing.
- Verified that push button doors no longer light when not able to open and operate
appropriately.
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
2 | Page
Tools/Programs Required
Tools Required:
• Laptop Computer
• Nexiq USB-Link 2
Programs Required:
• Proterra Diagnostics Tool
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
Vehicle Controller
064390
4.9.3
Powertrain Controller
064360
4.0.0
Body Controller
064579
6.14.0
It is recommended that you copy the files from ServiceMax campaign page to your local machine in
order to more effectively keep track of the software versions you are deploying:
https://proterra.lightning.force.com/lightning/r/P_Service_Campaign__c/a7V8W000000slCXUAY/view
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
BODY SOFTWARE UPDATE PROCEDURE
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 you can use the vehicle to recharge them by turning on high-voltage, or you can place the bus on
a low-voltage charger for the duration of the process.
Connecting to the Vehicle
This process will guide the user to connect to the vehicle with the Proterra Diagnostics Tool.
1. Power on and login to the Proterra-Supplied laptop or a comparable PC that has the Proterra
Diagnostics Tool software installed with a valid license.
2. Turn on the 12/24V rear Vehicle Master Disconnect located at the curbside rear charge port
access panel.
Vehicle Master
Disconnect
3. Connect the Nexiq USB Link2 device to the laptop and to the OBD-II Diagnostic Port located in
the streetside wheel well box. Use the J1939 port if the OBD-II port is unavailable.
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
4. Turn the Driver’s Master Switch to the “ACC” position.
5. On the laptop, double-click on the Proterra Diagnostics Tool software icon to start the software.
6. When the program opens, read and click “OK” for the high-voltage safety prompt.
7. On the Home tab, select the appropriate device from the drop-down menu and click “Connect”.
8. Once the Proterra Diagnostics Tool has connected to the vehicle, you will have a VIN number
and connection status displayed on the Home screen, and tabs available to navigate. If you do
not, double check that the low-voltage batteries are connected and that the Nexiq tool is
plugged in.
Download and Store Existing Parameters
Sometimes you might want to download and store the customer specific parameters from the vehicle.
This can be useful when comparing two vehicles that are behaving differently, or if you are replacing
the ZR32A controller on a vehicle.
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
1. After the first vehicle has been completed and verified, disconnect the Proterra Diagnostics
Tool and then reconnect.
2. Navigate to the Configuration tab and click the “Get Parameters” button. This will download the
latest parameter set to the “C:\Logs” folder on your machine.
Get Parameters
Button
3. In windows file explorer, navigate to the “C:\Logs” folder. Copy the latest downloaded *.zip file
to a folder for the specific customer and vehicle.
Copy!
4. Do not rename the file as the tool will follow the naming convention when reloading the file.
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
Update Using the Proterra Diagnostic Tool
1. Navigate to the CONFIGURATION tab in the left menu.
Click
CONFIGURATION
2. If this is a replacement controller, select the “SET VIN” and program the controller to match the
vehicle VIN, then proceed to step 3. If not a replacement controller, proceed to step 3.
3. Select the option for Body Firmware “START FLASH”.
Beside Body Firmware,
Click START FLASH
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
4. In the pop-up window, select the software flash file to load to the controller. The correct file is
named “Body_6_14_0_064579”
5. The Programming window will come up and will take a few minutes to complete. The process
will flash five different files to the controller.
6. After the controller is updated the tool will automatically try to copy the original configuration to
the new software. Since there is a possibility that configuration options change it is important
to check the configuration after restarting the vehicle.
7. Once the process has finished, cycle power to the bus by moving the Driver’s Master Switch
back to the “OFF” position before continuing.
8. Shut down the PDT software program. This allows the cache to clear from the system.
9. 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
8 | Page
VEHICLE SOFTWARE UPDATE PROCEDURE
Description
This section contains the necessary information to update the Proterra Vehicle Integration Controller.
This controller provides the electrical integration of ancillary systems on 800V models. It owns the
vehicle operational state control, startup and shutdown, steering, pneumatics, thermal management,
and brake interlock controls.
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.
Connecting to the Vehicle
1. Power up and login to the Proterra-Supplied laptop or a comparable PC that has the Proterra
Diagnostics Tool software installed with a valid license.
2. Turn ON the 12/24V rear Vehicle Master Disconnect located at the curbside rear charge port
access panel.
Vehicle Master
Disconnect
3. Connect the Nexiq USB Link2 device to the laptop and to the OBD-II Diagnostic Port located in
the streetside wheel well box. Use the J1939 port if OBD-II is unavailable.
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
4. Press and hold the streetside wheel well WORK LIGHT switch until the work lights turn on.
5. On the laptop, double-click on the Proterra Diagnostics Tool software icon to start the software.
6. When the program opens, read and click “OK” for the high-voltage safety 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 be displayed on the Home screen, and tabs available to navigate. If you do not see the
Home Screen, check that the low-voltage batteries are connected and that the Nexiq tool is
plugged in.
NOTE: 800V Proterra vehicles are equipped with an automatic battery disconnect that will
protect the low-voltage batteries from a deep discharge.
9. Before beginning the programming process, check the bus for existing faults by clicking on the
“Diagnostics” button below and make a note of any found.
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| Page
Update Using the Proterra Diagnostic Tool
1. Click on the “Overhead Charging” button on the left side of the screen.
NOTE: If the bus that you are working on is not capable of overhead charging, skip to step 3
below.
Click “Overhead
Charging”
2. Record the value displayed in the “Vehicle Tag” data field. This will be re-entered into the
controller after the software update.
Record Vehicle Tag
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| Page
3. Navigate to the CONFIGURATION tab in the left menu.
Click
CONFIGURATION
4. Select the option for Vehicle Controller “START FLASH”.
NOTICE: The “INITIAL FLASH” button is only for offline programing of the Vehicle Controller
with an Offline Programming Kit.
Beside Vehicle Controller,
Click START FLASH
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
12| Page
5. The PDT will instruct to turn the bus off with the hazard lights on. Set the bus to this mode.
This will put the bus into Flashing Mode.
6. Click on the START FLASH button again to flash the controller.
7. In the pop-up window, select the software flash file to load the controller. The correct file is
named SW_VIC_4.9.3.hex
Select the file and
Click Open
8. The Programming window will come up and may take a few minutes to complete.
9. After completing the software update, a bus key cycle is required.
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
13| Page
10. Click on the “Overhead Charging” button on the left side of the screen.
NOTE: If the bus that you are working on is not capable of overhead charging, skip to step 10
below.
Click “Overhead
Charging”
11. The following screen will appear. Enter the “Vehicle Tag” that you recorded previously into the
field circled in red below. Click the button under the field. This will populate the “Vehicle Tag”
into the field above and into the controller.
Click “Button”
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| Page
12. Click on the “Configuration” button at the bottom left of the screen.
Click “Configuration”
13. Scroll through the list of “Body Parameters” on this screen.
14. Turn OFF the 12/24V rear Vehicle Master Disconnect located behind the vehicle curbside rear
charge port access panel, wait ten seconds, and then turn back to ON.
Vehicle Master
Disconnect
15. Verify that the vehicle turns on with no faults and that it is capable of charging.
16. Shut down the PDT software program. This allows the cache to clear from the system.
17. Return the vehicle 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
15| Page
POWERTRAIN SOFTWARE UPDATE PROCEDURE
Description
This procedure updates the Duopower Powertrain software to the latest version for improved
powertrain performance.
Connecting to the Vehicle
This process will guide the user to connect to the vehicle with the Proterra Diagnostics Tool.
1. Turn on the 12/24V rear Vehicle Master Disconnect located behind the vehicle curbside rear
charge port access panel.
2. Turn on the bus “Master Switch” at the Driver's Workplace and ensure the Dash screen is on to
display “KEY ACC”.
Master Switch
“ACC”
3. Silence dash alarm.
4. Open the streetside wheel well box to access to the OBD-II Port. Use the J1939 port if the
OBD-II port is unavailable.
OBD-II Port
5. Power up (boot) the Proterra-supplied laptop containing the Proterra Diagnostic Tool.
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
16| Page
6. Connect the Nexiq USB Link2 device to the laptop and to the appropriate OBD-II Diagnostic
Port. Use the J1939 port if the OBD-II port is unavailable.
7. On the laptop, double-click on the Proterra Diagnostics Tool software icon to start the software.
8. When the program opens, read and click “OK” for the prompt.
9. On the Home tab, select the appropriate device from the drop down and click “Connect”.
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| Page
10. 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.
1. Ensure you have the latest software file 064360.hex in a known location on the service
technician’s computer (Folder or Desktop).
IMPORTANT! NEVER access the software from a remote server or from a USB memory device.
ALWAYS copy the software files to your computer hard drive and access the software from this
location. It is recommended that you copy the files from ServiceMax campaign page to your
local machine in order to more effectively keep track of the software versions you are
deploying:
https://proterra.lightning.force.com/lightning/r/P_Service_Campaign__c/a7V8W000000slCXUA
Y/view
2. Turn on the 12/24V rear Vehicle Master Disconnect located behind the vehicle curbside rear
upper access panel.
3. Turn on the bus Master Switch at the Driver's Workplace and ensure the dash screen is ACC.
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
18| Page
4. After connecting to the vehicle using the Proterra Diagnostic tool at the front OBD-II Port
(SSWW Box), navigate to the “Configuration Tab”.
5. Wait at least 10 seconds after starting the tool, then click the “Get Parameters” button at the
top of the page.
a. NOTE: This ensures that a backup copy of the original configuration parameters
stored in a “zip” file, contained in the C:/Logs folder on your computer in case we
need to refer to it later.
6. Click on the “SOFTWARE VERSION” button at the bottom left of the screen. Verify that the
Body Controller Software is version 6.3.0. or later.
Click Software
Version
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
19| Page
7. Next, click the Powertrain Firmware “Start Flash” button.
Click Powertrain Start Flash
8. 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 064360.hex.
Select File
Click “Open”
9. The Proterra Diagnostic Tool will attempt to connect to the device.
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
20| Page
10. When the software update begins, the following screens will be displayed.
11. 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.
12. Power off the bus by selecting off on the Master Switch.
13. The software update is now complete.
14. Disconnect the cable from the OBD-II port or J1939 port.
15. Shut down the PDT software program. This allows the cache to clear from the system.
16. Close the streetside wheel well box.
17. Re-enable the dash alarm that was silenced.
18. Power down the bus by opening the main disconnect at the Curbside rear of the bus.
19. Turn the main disconnect back on 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
21| 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| Page
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TSB/Document ID: SC-23-079
Replacement Service Bulletin Number:
MFR Communication Date: 2023-05-24
MFR Internal Campaign ID/Software Version: SC-23-079
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
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