22E052 – SC-22-025 – Improperly Connected High Voltage Battery Cable – Proterra

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Notice
IMPORTANT SAFETY RECALL
NHTSA Recall Number: 22E-052
This notice applies to Proterra High Voltage Junction Box (HVJB) DC Link, Part No. 051071
July 20, 2022 Dear Proterra Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. What is the reason for this notice? Proterra has determined that the HVJB DC Link may not have been sufficiently crimped during the assembly process. As a result, the cable may fail inside the HVJB enclosure and cause the vehicle to lose propulsion due to a loss of electrical power. A loss of propulsion could increase the risk of injury due to the need to transfer passengers to alternate transportation in a potentially uncontrolled traffic condition. Proterra has not received any reports of injuries or fatalities resulting from this issue.
Why is your equipment being recalled? Certain HVJB DC Links may not be adequately crimped. As a result, the HVJB performance may be compromised and cause the vehicle to lose propulsion.
IMPORTANT
• The HVJB DC Links identified by Proterra are involved in Safety Recall 22E-052. • Proterra is providing this remedy free of charge. Parts are available. • Contact Proterra’s customer service department at 864- 438- 0000 or [email protected] if you have any questions. We apologize for the inconvenience. We are committed to your safety, the safety of your
customers, and your continued satisfaction with our products.
What should you do? Parts for the recall remedy are now available, and in this remedy, we request that you complete the updated service campaign (SC-22-025) bulletin. The updated procedure describes the process to verify the proper crimping of the HVJB DC Link. If the HVJB DC Link is not damaged but has an improper crimp, Proterra will re-crimp the lugs. If the cable is damaged but only on the end, Proterra will blunt cut the cable and crimp a new lug if there is an adequate length of remaining cable. If the cable is not long enough to blunt cut, or is otherwise damaged, Proterra will replace the cable. Further, if the HVJB has been damaged due to an improperly crimped HVJB DC Link, Proterra will replace the HVJB. Proterra will cover the cost of all the above-stated repairs or replacements. You may submit a warranty claim for the labor associated with this campaign, which is estimated to be 1 hour per bus. What precautions can you take? Impact to the HVJB may be indicated by a red battery light and/or the vehicle’s power flickering or indicating a loss of propulsion. We advise that you inspect all HVJB DC Links and HVJBs as soon as possible in accordance with the updated service campaign (SC-22-025) bulletin. What will Proterra do? We are hereby providing notice that the updated service campaign (SC-22-025) bulletin, remedy parts and repair kits are available, at no cost to you. What if you have already addressed this issue in your equipment? You should confirm that any repairs or replacements are aligned with the updated service campaign (SC-22-025) bulletin. You may submit a warranty claim for the parts and labor associated with this campaign. What if you have other questions? Please contact Proterra’s customer service department at 864- 438-0000 or [email protected] with any questions or concerns about this information. If, after contacting Proterra’s customer service department, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. The National Highway Traffic Safety Administration Campaign ID Number for this recall is 22E-052.
Sincerely, Juliano Palma
Vice President, Quality
Proterra Operating Company, Inc.

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-052
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Proterra Operating Company, Inc. NOV 10, 2022 NHTSA Recall No. : 22E-052 Manufacturer Recall No. : SC-22-025 Manufacturer Information :
Manufacturer Name : Proterra Operating Company, Inc.
Address : 1815 Rollins Road
Burlingame CA 94010 Company phone : 4380000
Population :
Number of potentially involved : 185 Estimated percentage with defect : 1 %
Equipment Information : Brand / Trade 1 :
Model : Proterra HVJB DC Link Part No. : 051071 Size : NR Function : Cable
Descriptive Information : All high voltage junction box DC Links delivered to Daimler (Thomas Built Buses) are included in the population. The HVJB DC Links were built to order and only sold to Daimler. Proterra does not sell the HVJB DC Links to other customers. Production Dates : AUG 01, 2019 – DEC 31, 2021
Description of Defect :
Description of the Defect : The HVJB DC Links may not be properly crimped which could cause the cable to fail inside the HVJB enclosure. FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If the HVJB DC Link becomes separated because it is not properly crimped,
the vehicle could shut down due to a loss of electrical power and lose propulsion. In the event of a loss of propulsion, there could be an increased risk of injury due to the need to transfer passengers to alternate transportation in a potentially uncontrolled traffic condition. Proterra has not
received any reports of any injuries or fatalities resulting from this issue. Part 573 Safety Recall Report 22E-052 Page 2 Description of the Cause : The HVJB DC Link may not have been properly crimped during the assembly process. Identification of Any Warning
that can Occur : Separation of the HVJB DC Link may be indicated by a red battery light and/or the vehicle’s power flickering or indicating a loss of propulsion. Involved Components : Component Name : SUBASSY, DC LINK, PRODRIVE, eC2
Component Description : HVJB DC Link Component Part Number : 051071 Supplier Identification : Component Manufacturer
Name : Proterra Operating Company, Inc.
Address : 1815 Rollins Road
Burlingame 94010 Country : United States Chronology :
On May 12, 2022, Proterra notified Daimler that a single prior incident related to the HVJB DC Link was likely the result of an improper crimp. At that time, Proterra issued Service Bulletin (SC-22-25) to inspect HVJB DC Links Daimler battery electric school buses. On June 13, 2022, Daimler notified Proterra that 163 battery electric school buses would be removed from service until the inspections are completed. On June 16, 2022, NHTSA was notified of the issue via a Part 573 Safety Recall Report (22V-418). The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-052
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Proterra previously provided Service Bulletin (SC-22-25) to Daimler to
inspect and repair the HVJB DC Link in the field. If the HVJB DC Link has an improper crimp, Proterra will repair or replace the cable at no cost to Daimler. Further, if the HVJB is damaged by an improperly crimped HVJB DC Link, Proterra will repair or replace the HVJB at no cost to Daimler. All inspections and repairs (if needed) will be performed by Daimler, or its authorized service facilities, in conjunction with Proterra’s field service managers. How Remedy Component Differs from Recalled Component : In the event of an improperly crimped HVJB DC Link, it will be either repaired or replaced in the field with a properly crimped HVJB DC Link. Identify How/When Recall Condition was Corrected in Production : No more HVJBs will be produced for Daimler, because they were built to order. Only 168 HVJBs were provided and delivered to Daimler. Recall Schedule :
Description of Recall Schedule : Daimler was notified the week of September 12, 2022. NOTE – Daimler
has Service Bulletin (SC-22-25), which is the basis for the remedy program. Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : SEP 12, 2022 – SEP 16, 2022 Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR Address : NR
NR Country : NR Company Phone : NR
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-052
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Proterra Operating Company, Inc. JUN 21, 2022 NHTSA Recall No. : 22E-052 Manufacturer Recall No. : SC-22-025 Manufacturer Information :
Manufacturer Name : Proterra Operating Company, Inc.
Address : 1815 Rollins Road
Burlingame CA 94010 Company phone : 4380000
Population :
Number of potentially involved : 185 Estimated percentage with defect : 1 %
Equipment Information : Brand / Trade 1 :
Model : Proterra HVJB DC Link Part No. : 051071 Size : NR Function : Cable
Descriptive Information : All high voltage junction box DC Links delivered to Daimler (Thomas Built Buses) are included in the population. The HVJB DC Links were built to order and only sold to Daimler. Proterra does not sell the HVJB DC Links to other customers. Production Dates : AUG 01, 2019 – DEC 31, 2021
Description of Defect :
Description of the Defect : The HVJB DC Links may not be properly crimped which could cause the cable to fail inside the HVJB enclosure. FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If the HVJB DC Link becomes separated because it is not properly crimped,
the vehicle could shut down due to a loss of electrical power and lose propulsion. In the event of a loss of propulsion, there could be an increased risk of injury due to the need to transfer passengers to alternate transportation in a potentially uncontrolled traffic condition. Proterra has not
received any reports of any injuries or fatalities resulting from this issue. Part 573 Safety Recall Report 22E-052 Page 2 Description of the Cause : The HVJB DC Link may not have been properly crimped during the assembly process. Identification of Any Warning
that can Occur : Separation of the HVJB DC Link may be indicated by a red battery light and/or the vehicle’s power flickering or indicating a loss of propulsion. Involved Components : Component Name : SUBASSY, DC LINK, PRODRIVE, eC2
Component Description : HVJB DC Link Component Part Number : 051071 Supplier Identification : Component Manufacturer
Name : Proterra Operating Company, Inc.
Address : 1815 Rollins Road
Burlingame California 94010 Country : United States Chronology :
On May 12, 2022, Proterra notified Daimler that a single prior incident related to the HVJB DC Link was likely the result of an improper crimp. At that time, Proterra issued Service Bulletin (SC-22-25) to inspect HVJB DC Links Daimler battery electric school buses. On June 13, 2022, Daimler notified Proterra that 163 battery electric school buses would be removed from service until the inspections are completed. On June 16, 2022, NHTSA was notified of the issue via a Part 573 Safety Recall Report (22V-418). The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-052
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Proterra previously provided Service Bulletin (SC-22-25) to Daimler to
inspect and repair the HVJB DC Link in the field. If the HVJB DC Link has an improper crimp, Proterra will repair or replace the cable at no cost to Daimler. Further, if the HVJB is damaged by an improperly crimped HVJB DC Link, Proterra will repair or replace the HVJB at no cost to Daimler. All inspections and repairs (if needed) will be performed by Daimler, or its authorized service facilities, in conjunction with Proterra’s field service managers. How Remedy Component Differs from Recalled Component : In the event of an improperly crimped HVJB DC Link, it will be either repaired or replaced in the field with a properly crimped HVJB DC Link. Identify How/When Recall Condition was Corrected in Production : No more HVJBs will be produced for Daimler, because they were built to order. Only 168 HVJBs were provided and delivered to Daimler. Recall Schedule :
Description of Recall Schedule : Daimler will be notified on June 29, 2022. NOTE – Daimler has Service
Bulletin (SC-22-25), which is the basis for the remedy program. Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : JUN 29, 2022 – JUN 29, 2022 Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR Address : NR
NR Country : NR Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-052
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Proterra Operating Company, Inc. NOV 10, 2022 NHTSA Recall No. : 22E-052 Manufacturer Recall No. : SC-22-025 Manufacturer Information :
Manufacturer Name : Proterra Operating Company, Inc.
Address : 1815 Rollins Road
Burlingame CA 94010 Company phone : 4380000
Population :
Number of potentially involved : 185 Estimated percentage with defect : 1 %
Equipment Information : Brand / Trade 1 :
Model : Proterra HVJB DC Link Part No. : 051071 Size : NR Function : Cable
Descriptive Information : All high voltage junction box DC Links delivered to Daimler (Thomas Built Buses) are included in the population. The HVJB DC Links were built to order and only sold to Daimler. Proterra does not sell the HVJB DC Links to other customers. Production Dates : AUG 01, 2019 – DEC 31, 2021
Description of Defect :
Description of the Defect : The HVJB DC Links may not be properly crimped which could cause the cable to fail inside the HVJB enclosure. FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If the HVJB DC Link becomes separated because it is not properly crimped,
the vehicle could shut down due to a loss of electrical power and lose propulsion. In the event of a loss of propulsion, there could be an increased risk of injury due to the need to transfer passengers to alternate transportation in a potentially uncontrolled traffic condition. Proterra has not
received any reports of any injuries or fatalities resulting from this issue. Part 573 Safety Recall Report 22E-052 Page 2 Description of the Cause : The HVJB DC Link may not have been properly crimped during the assembly process. Identification of Any Warning
that can Occur : Separation of the HVJB DC Link may be indicated by a red battery light and/or the vehicle’s power flickering or indicating a loss of propulsion. Involved Components : Component Name : SUBASSY, DC LINK, PRODRIVE, eC2
Component Description : HVJB DC Link Component Part Number : 051071 Supplier Identification : Component Manufacturer
Name : Proterra Operating Company, Inc.
Address : 1815 Rollins Road
Burlingame 94010 Country : United States Chronology :
On May 12, 2022, Proterra notified Daimler that a single prior incident related to the HVJB DC Link was likely the result of an improper crimp. At that time, Proterra issued Service Bulletin (SC-22-25) to inspect HVJB DC Links Daimler battery electric school buses. On June 13, 2022, Daimler notified Proterra that 163 battery electric school buses would be removed from service until the inspections are completed. On June 16, 2022, NHTSA was notified of the issue via a Part 573 Safety Recall Report (22V-418). The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-052
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Proterra previously provided Service Bulletin (SC-22-25) to Daimler to
inspect and repair the HVJB DC Link in the field. If the HVJB DC Link has an improper crimp, Proterra will repair or replace the cable at no cost to Daimler. Further, if the HVJB is damaged by an improperly crimped HVJB DC Link, Proterra will repair or replace the HVJB at no cost to Daimler. All inspections and repairs (if needed) will be performed by Daimler, or its authorized service facilities, in conjunction with Proterra’s field service managers. How Remedy Component Differs from Recalled Component : In the event of an improperly crimped HVJB DC Link, it will be either repaired or replaced in the field with a properly crimped HVJB DC Link. Identify How/When Recall Condition was Corrected in Production : No more HVJBs will be produced for Daimler, because they were built to order. Only 168 HVJBs were provided and delivered to Daimler. Recall Schedule :
Description of Recall Schedule : Daimler was notified the week of September 12, 2022. NOTE – Daimler
has Service Bulletin (SC-22-25), which is the basis for the remedy program. Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : SEP 12, 2022 – SEP 16, 2022 Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR Address : NR
NR Country : NR Company Phone : NR
* NR – Not Reported

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