Subject

Prodrive Traction Motor Replacement 40’ RR

Issue Date

12/19/2022

Service Bulletin Number

SC-22-121

Models Affected

Service Specified Vehicles

Complete By

Next Service Opportunity

Labor Operation Code

PD46Z

Description

The procedure describes the process of replacing a defective
Prodrive traction motor on a 40’ RR.

Labor Table
Operation
1

Steps 1-10

Technicians

Hours

Labor Time (T x H)

1

6

6 Hours

Total Labor Time:

6 Hours

Contact the Proterra Customer Service Team with any
questions related to the following procedure.
864-438-0000
[email protected]
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Parts Required:
066171 SERVICE RETROFIT KIT, PRODRIVE 1 TRACTION MOTOR, 800V 40'
193-8870 MOTOR, TRACTION, 800V, 40'

Qty.
1

UOM
EA

Tools Required:
•

Wheel Lifts

•

Jack Stands

•

Lift Table

•

Transmission Jack

•

Approved Lifting Device

•

Impact Tool

•

Pry Bar

•

Ratchet

•

5 mm Socket

•

8 mm Socket

•

13 mm Socket

•

15 mm Socket

•

16 mm Socket

•

24 mm Socket

•

15 mm Combination Wrench

•

21 mm Combination Wrench

•

Calibrated Torque Wrench

•

Orange Torque Stripe Paint

•

Pinch Clamp Pliers

•

Spray Electronic Cleaner

•

Loctite 262

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Overview:

This will complete the uninstall of the old motor (040952) and the install of the new Prodrive motor
(193-8870).
Step 1:
Use the Proterra approved Lockout/Tagout procedure to make the bus safe for work.
Step 2:
Drain the air system by opening the three valves shown circled in the following photograph.

Step 3:
Using an 8mm Ratchet/Socket, remove the access panel from the Traction Motor Inverter. Retain
the screws and gasket for reuse.

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Step 4:

Using a 13mm Ratchet/Socket, disconnect the phase cable from the inverter.

Step 5:
Disconnect both HVIL Connectors shown.

Step 6:
Using a 13mm Ratchet/Socket, disconnect the ground connection from the inverter.
Using an 8mm Ratchet/Socket, replace the access panel and its gasket to prevent coolant from entering the inverter.

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Step 7:

Using the Wheel Lifts, safely raise the bus to access the motor from underneath.
Support the bus at the four lifting points with Jack Stands.
Step 8:
Using a 10mm Ratchet/Socket, remove the belly pans if the bus is so equipped.

Step 9:
Working underneath the bus, use a Ratchet with a 5mm Allen Socket, remove the screws that secure the right-angle phase and DC connectors to the inverter.

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Step 10:

Disconnect the interface cables shown from the Inverter.

Step 11:
Using a 16mm Ratchet/Socket and a 15mm Combination Wrench, remove the nuts and bolts that
secure the inverter to the mount.

Step 12:
Using an Impact Tool with a 10mm Socket, remove the bolts that secure the cross member shown to
the ProDrive frame as shown below. Remove the cross member and set it aside for reuse.

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Step 13:

Using Pinch Clamp Pliers, pinch the coolant hoses on the inverter.
Disconnect the coolant hoses from the inverter.

Step 14:
Using Pinch Clamp Pliers, pinch the coolant hoses on the motor.

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Step 15:

Disconnect the coolant hoses from the motor.

Step 16:
Allow the coolant to drain into a catch pan.

Step 17:
Pull the phase and DC cables away from the invertor so that it can be removed from the bus.

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Step 18:

Carefully remove the inverter from the bus.

Step 19:
Using an Impact Tool with a 15mm Socket, remove the bolts that secure the motor to the mounting
bracket.

Step 20:
Using a Lift Table, support the motor so that it can be safely removed. Use Straps to secure the motor to the Lift Table.
Using a 15mm Ratchet/Socket, remove the bolts that secure the motor to the transmission and
retain.

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Step 21:

Using an Impact Tool with a 24mm Socket and a 21mm Combination Wrench, remove the bolts and
isolators that secure the motor to the brackets. Save these parts. They will be reused.

Step 22:
Using the Lift Table, carefully move the motor and brackets away from the transmission and toward
the back of the bus. Leave the coupler attached to the transmission shaft.
Using the Lift Table, carefully lower the motor and move it away from the bus.
Using an approved lifting device, remove the old motor from the Lift Table.

Step 23:

Using an approved lifting device, place the new Traction Motor (193-8870) on the Lift Table in the
same position as the original motor. Secure the Motor using a Ratchet Strap.
Using the approved lifting device, move the Motor (193-8870) into position for installation under the
bus.

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Step 24:

Carefully position the Motor (193-8870) so that the shaft will slide into the coupler on the transmission.

Step 25:
Slide the shaft into the coupler.
Using the original fasteners, connect the Motor (040952) to the transmission.

Using a 15mm Ratchet/Socket, tighten the fasteners. Torque the fasteners to 53 ft-lbs.
Using Orange Torque Stripe Paint, mark the properly torqued fasteners.

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Step 26:

Install the Isolators and Flat Washers back onto the Bracket.
Using a 15mm Ratchet/Socket, install the bracket onto the Traction Motor (193-8870) using the original fasteners with Loctite 262 applied to the threads.
Using a Calibrated Torque Wrench with a 15mm Socket, torque the bolts to 48 ft-lbs.
Using Orange Torque Stripe Paint, mark the properly torqued fasteners.

Step 27:
Using a 24mm Ratchet/Socket and a 21mm Combination Wrench, installs the bolts and isolators
that secure the Traction Motor (193-8870) to the ProDrive frame.
Using a Calibrated Torque Wrench with a 24mm Socket and a 21mm Combination Wrench, torque
the isolator bolts to 184 ft-lbs.
Using Orange Torque Stripe Paint, mark the properly torqued fasteners.
Remove the approved lifting device from underneath the bus.

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Step 28:

Using Spray Electronic Cleaner, clean the phase and DC wires.
Apply a small amount of Grease to the gaskets.
Carefully install the gaskets onto the phase and DC connectors as shown in the following photograph.

Step 29:
Place the Inverter onto the approved lifting device and position it under the bus.

Carefully tilt the Inverter and slide it up into the ProDrive frame.
Using a 10mm Ratchet/Socket, reinstall the cross member using the original fasteners.
Using a Calibrated Torque Wrench with a 10mm Socket, torque the fasteners to 23 foot-pounds.
Using Orange Torque Stripe Paint, mark the properly torqued fasteners.

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Step 30:

Using a 16mm Ratchet/Socket and a 15mm Combination Wrench, install the inverter back onto the
mount using the original hardware.
Using a Calibrated Torque Wrench with a 16mm Socket and a 15mm Combination Wrench, torque
the fasteners to 44 ft-lbs.
Using Orange Torque Stripe Paint, mark the properly torqued fasteners.

Step 31:
Slide the phase and DC connections into the Inverter.
Using a Ratchet with a 5mm Allen Socket, install the screws that secure the right-angle phase and
DC connectors to the inverter.
Using a Calibrated Torque Wrench with a 5mm Allen Socket, torque the screws to 53 in-lbs.
Using Orange Torque Stripe Paint, mark the properly torqued fasteners.

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Step 32:

Connect the interface cables shown to the Inverter and Motor (193-8870).
Reconnect the coolant lines to the Traction Motor (193-8870) and the transmission. Remove the
Pinch Clamp Pliers.
Using a 13mm Ratchet/Socket, connect the phase cables to the Traction Motor (193-8870).
NOTE: Ensure that no insulation from the wiring is between the bolt head and cable lug.
Step 33:
Using a 5mm Ratchet/Socket, secure the Right-Angle Phase Connector to the inverter.

Using an 8mm Ratchet/Socket, secure the O-Ring and Access Panel to the inverter.
Using a Calibrated Torque Wrench with an 8mm Socket, torque the fasteners to 31 inch-pounds.
Using Orange Torque Stripe Paint, mark the properly torqued fasteners.

Step 34:
Close the Drain valves shown in the following photograph.
Remove the Lockout/Tagout devices and power on the bus.
Return the bus to service after verifying proper operation of the new Traction Motor (193-8870).

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