NHTSA ID Number: 11012920
Manufacturer Communication Number: FC-23-003
TSB/Document Date: 2025-01-17
Summary
Repair instruction to inspect heavy duty transit vehicles for humidity in the battery pack
and perform preventative maintenance.
ISSUE DATE:
SERVICE BULLETIN SUBJECT:
VINs or MODELS AFFECTED:
COMPLETE BY:
SERVICE BULLETIN #:
LABOR OPERATION CODE:
1/10/2023
High-Voltage Battery Pack Inspection
Service Specified Buses
Next Service Opportunity
SC-23-3
HB46Z
NOTICE! It is expected that this process may require up to one hour per bus.
Please schedule appropriately to minimize vehicle downtime.
HIGH-VOLTAGE BATTERY PACK INSPECTION
Description:
The procedure describes the process of inspection the High-Voltage Battery Pack.
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
1|Page
Tools/Parts Required:
Tools and Supplies Required:
•
•
•
•
•
•
•
•
•
Service Laptop with Proterra Diagnostics Tool
Nexiq USB-Link 2
Yellow MSD Dummy Cover
Jameson Glow Rod
Ratchet
Calibrated Torque Wrench
17mm Allen Socket
Vibra-Tite 42050 Thread Sealant
Jameson Glow Rod
Parts Required:
• 022358
• 022385
DESICCANT,PACK
ASY,FLOOD PORT
1 EA
2 EA
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
Procedure:
1.
Turn on the 12/24V rear “Vehicle Master Disconnect” located at the curbside rear charge port
access panel.
Master Disconnect
Diagnostic Port
2.
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.
3.
Connect the Nexiq USB Link2 device to the laptop and to the OBDII Diagnostic Port shown in
the previous illustration.
4.
In the driver’s workplace, start the bus.
5.
On the laptop, double-click on the Proterra Diagnostics Tool software icon to start the software.
6.
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
3|Page
7.
In the Proterra Diagnostic Tool, take screenshots of the battery packs and upload them to the
work order in ServiceMax.
8.
In the Proterra Diagnostic Tool, take screenshots of the isolation levels for all battery packs
and upload them to the work order in ServiceMax.
9.
Prior to inspecting a battery pack, verify that the physical location of the battery pack matches
what is reported in the Proterra Diagnostic Tool by disconnecting the low-voltage harness from
the pack in question. If the correct pack is disconnected, it will stop communicating with the
Proterra Diagnostic Tool.
10.
Perform the Proterra Approved Lockout/Tagout procedure to make the vehicle safe for work.
11.
Remove the pack if that is required. Ensure that the pack is safely positioned on a suitable
working surface or attached to a bus.
12.
Remove the MSD from the pack and replace it with a yellow MSD Dummy Cover.
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
13.
Check the ancillary bay of the battery pack to determine if it has a desiccant plug. Not all packs
will have a desiccant plug. An example of an ancillary bay with a desiccant plug is shown in the
following photograph.
14.
If the pack is so equipped, inspect the desiccant plug. If the window is showing a pink or blue
discoloration, take a photograph of the plug and upload it to the work order in ServiceMax.
15.
Inspect and document the condition of the two green Coolant Flood Ports (022385).
Dormant
Active Open
16.
If either Coolant Flood Port (022385) is in the “Active Open” state as shown in the previous
photograph, this indicates that there may be a significant amount of liquid inside the battery
pack and the pack likely needs to be replaced.
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
17.
Using a 17mm Allen Socket, remove the Coolant Flood Port (022385) that is easiest to access.
18.
Carefully remove the Desiccant (022358) from the battery pack.
19.
Inspect the white Tyvek bag for any signs of moisture staining or saturation. A transparent
discoloration may indicate moisture egress into the pack. Tinted saturation that resembles the
color of the coolant used in the vehicle may indicate a coolant lead that is internal to the
battery pack.
20.
Record the condition of the desiccant in the work order in ServiceMax.
21.
Using a 17mm Allen Socket, remove the remaining Coolant Flood Port (022385) from the
pack.
22.
Attach the hooked end of the Jameson Glow Rod to a strait section of rod.
23.
Attach the hook on the Jameson Glow Rod to the grommet on the Desiccant (022358).
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
24.
Push the Glow Rod into the opening in the pack. Carefully pull the rod and guide the Desiccant
(022358) into the pack.
25.
Tuck both ends of the Desiccant (022358) into the battery pack.
26.
Apply Vibra-Tite 42050 Thread Sealant as needed to the new Coolant Flood Ports (022385).
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
27.
Using a Calibrated Torque Wrench with a 17mm Allen Socket, install the new Coolant Flood
Ports (022385) and torque them to 22 foot-pounds.
28.
Reinstall the battery pack if it was removed from the vehicle.
29.
Reconnect the low-voltage harness to the battery pack.
30.
Remove the yellow MSD Dummy Cover from the battery pack and replace it with the original
MSD.
31.
Remove the Lockout/Tagout devices and power on the vehicle.
32.
Using the Laptop and the Proterra Diagnostic Tool, verify that the battery pack is online and
communicating.
33.
Use the following procedure to reset the Replace Desiccant Timer.
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
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TSB/Document ID: FC-23-003
Replacement Service Bulletin Number:
MFR Communication Date: 2023-10-02
MFR Internal Campaign ID/Software Version: FC-23-003
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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