ISSUE DATE:
SERVICE BULLETIN SUBJECT:
VINs or MODELS AFFECTED:
COMPLETE BY:
SERVICE BULLETIN #:
Labor Operation Code:

10-13-2020
Lower Rear Access Door Opening Angle and LV Battery Tray
Retrofit
Service Specified Buses
Next Service Opportunity
SC-20-145
N/A

NOTICE! It is expected that this process will require 8 hours per bus. Please
schedule appropriately to minimize vehicle downtime.

LOWER REAR ACCESS DOOR OPENING ANGLE AND LV
BATTERY TRAY RETROFIT
Retrofit Description:

This procedure updates the rear hatch door struts and the low voltage battery tray for improved
operation.

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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Tools/Parts Required
Tools and Supplies Required:
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Heat gun.
Plexus gun Mixpac Manual (DM 400-01)
Plexus gun tip MC 13-18.
Power Drill
36-Grit Sandpaper
36- Grit Sanding Disk
Flat Blade Screwdriver
#2 Phillips Screwdriver
Chisel
Side Grinder
Super Glue
Two Differently Colored Permanent Markers
Super Glue
Isopropyl Alcohol
Adjustable Prop Rod to Support Hatches
Shop Towels
Cotton Swabs
Ratchet
13mm Socket
Calibrated Torque Wrench
Orange Torque Stripe Paint

Parts Required:
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018307-001
018933
019482
014662
015452
012138
009479
027017
009499
043223
018362
020990

SCREW, DIN 7981, TYP C, SST A2, M5.5X13
WSHR, DIN 9021, STL, HDN, ZPL, M6
MOUNT, GAS SPRING
GAS SPRING, LOWER SIDE HATCH, 1432EB
GAS SPRING, LOWER, HATCH REAR, 6542IN
CABLE TIE, HEAVY DUTY .5WIDE 9.1" BLACK
RESIN, EPOXY, WEST SYSTEMS
FILLER, HIGH DENSITY, WEST SYSTEMS
HARDENER, EPOXY, FAST, WEST SYSTEMS
EQUIPMENT, SERVICE, ADHESIVE, WEST SYSTEM PUMP
PLEXUS, MA-530
PRIMER,COND.,0-RMD,PLE QT.IP120 PC 120

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 EA
4 EA
2 EA
2 EA
2 EA
10 EA
1 EA
1 EA
1 EA
1 EA
1 EA
1 EA

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Procedure:
1. Complete the Proterra approved Lockout/Tagout procedure to make the bus safe for work.

Rear Hatch Inspection and Repair:
2. Using the following illustration as a guide, inspect both rear hatches and the gas struts
installed on them.

3. Verify that the forward strut on both hatches is Proterra Part Number (014662) or Vendor Part
Number (1432EB).
4. Verify that the rear strut on both hatches is Proterra Part Number (015452) or Vendor Part
Number (6542IN).
5. Replace any struts that are damaged or are not the correct part number.
6. Once the correct struts are installed on both doors, inspect the opening angle of the doors.
Each door should open approximately 120 degrees and not contact the bus body as shown in
the following photograph.

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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7. If the doors open correctly, proceed to the section of this document labeled “LV Battery Tray
Retrofit”. Do not complete the remainder of this section. Proceed to the section labeled “LV
Battery Tray Retrofit”.
8. If either door opens less than 120 degrees or it opens far enough to contact the body, the
hatch or hatches must be repaired by following the remaining instructions in this section.
9. Disconnect the gas struts from a hatch that needs repair and support it as shown in the
following illustration. An adjustable rod or other device may be used.

10. Using a Permanent Marker, mark both sides of the bracket 35mm down from the top as
shown in the following illustration.

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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11. Using a #2 Phillips Screwdriver, remove the three self-tapping screws that attach the ball stud
bracket to the hatch.

12. Using a Heat Gun, heat the Plexus Adhesive (018362) that secures the ball stud bracket to
the hatch to soften it.
13. Remove the Bracket.
14. Using a Side Grinder, carefully remove any Plexus (018362) remaining on the hatch.
15. Using Alcohol and Shop Towels, clean the area on the hatch where the bracket and Plexus
were removed.
16. Using the marks made earlier, position a new Bracket (019482) as shown in the following
illustration.

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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17. Using a Permanent Marker, mark the top and sides of the Bracket (019482) as shown in the
previous illustration.
18. Temporarily attach the front gas strut to the ball on the Bracket (019482) and hold the bracket
in the position marked previously.
19. While holding the Bracket (019482) in position, test the operation of the door. It should be
able to open to an angle greater that 120 degrees without contacting the body. If it does, this
is the final position for mounting the bracket.
20. If the hatch cannot open more that 120 degrees, move the Bracket (019482) closer to the
hinge. Find a position that allows the door to open more than 120 degrees without contacting
the body. Mark this position for mounting the Bracket with a different color permanent marker
than used previously. This is the final position for mounting the bracket.
21. If the hatch opening angle is greater than 120 degrees and the hatch contacts the body, move
the Bracket (019482) further from the hinge. Find a position that allows the door to open more
than 120 degrees without contacting the body. Mark this position for mounting the Bracket
with a different color permanent marker than used previously. This is the final position for
mounting the bracket.
22. Using Alcohol and a Cotton Swab, clean and degrease the holes from the self-tapping screws
from the original bracket.
23. Mix West Systems 105 Epoxy Resin with West Systems 205 Hardener to get the amount
required to fill the three holes.
24. Mix in West Systems 404 High Density Filler until the mixture has the consistency of
mayonnaise.
25. Using a plastic bag with a corner cut off or a tongue depressor, apply the Epoxy to fill the
screw holes.
26. Remove any excess Epoxy.
27. Allow 8 hours for the Epoxy to cure before returning the bus to service.
28. Using 26-Grit Sandpaper, scuff the area that was marked previously to install the new Bracket
(019482).
29. Using Alcohol and Shop Towels, clean the scuffed area.
30. Using a Power Drill with a 36-Grit Sanding Disk, scuff the mounting surface of the new
Bracket (019482).
31. Using Alcohol and Shop Towels, clean the Bracket (019482).
32. Using a Shop Towel, apply Plexus Primer (020990) to the bonding surface of the Bracket
(019482).
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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33. Using Super Glue, attach 2 Washers (018933) to the scuffed and primed surface of the
Bracket (019482) to provide a bond gap.
34. Using a Plexus Gun, apply Plexus (018362) to the bonding surface of the Bracket (019482).
35. Place the Bracket (019482) in the final mounting position that was marked earlier.
36. Using a #2 Phillips Screwdriver, attach the Bracket (019482) to the hatch.
37. Allow the Plexus (018362) to cure for 1 hour before attaching the struts to the hatch.
38. Repeat the previous process to repair the other hatch if it is needed.

LV Battery Tray Retrofit:
39. Working inside the Curbside hatch, access the low voltage batteries.
40. Using an 13mm Ratchet/Socket, reroute the Cable (EPWR 109) shown by the red arrow. The
new routing is shown by the curved red line. The cable should enter the fuse panel from the
bottom as shown by the red line and be routed in an “S” pattern to prevent chaffing.

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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41. Using an 13mm Ratchet/Socket, reroute the cable shown by the red arrow. The new routing is
shown by the curved red line. The cable should enter the fuse panel from the top as shown by
the red line.

42. The following photographs show the new routing.

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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43. Using an 13mm Ratchet/Socket, reroute the Cable (EPWR 106) shown by the red arrow. The
new routing is shown by the curved red line. The original route of this cable should be
swapped with the Negative Cable from the Charge Plug and straightened so that it doesn’t
chaff against the battery box when it is slid from the hatch. The negative cable is on the top of
the Charge Plug.

Charge Plug

44. Using an 13mm Ratchet/Socket, reroute the cable shown by the red arrow. This is the
negative cable from the Charge Plug. The new routing is shown by the curved red line. Note
that the cable from the previous step swaps sides on the battery lug.

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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45. The following photograph shows the new routing.

46. Using an 13mm Ratchet/Socket, reroute the Cable (EPWR 108) shown by the red arrow.

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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47. The new routing is shown in the following illustration. The Cable (EPWR 108) should be
secured to Cable (EPWR) 106 using Cable Ties (012138).

48. The new routing should appear as shown in the following photograph. The red arrow shows
the Cable Ties (012138) securing Cable (EPWR 108) to Cable (EPWR 106).

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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49. Using a Calibrated Torque Wrench with an 13mm Socket, torque the fuse panel fasteners
to 15 Foot Pounds.
50. Using a Calibrated Torque Wrench with an 13mm Socket, torque the battery fasteners to
15 Foot Pounds.
51. Using Orange Torque Stripe Paint, mark the properly torqued fasteners.
52. Close the rear hatches.
53. Remove the Lockout/Tagout devices and 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

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