22E065 – Battery Management System Shutdown – Proterra

SEOCONTENT-START

INTERIM LETTER
IMPORTANT SAFETY RECALL
NHTSA Recall Number: 22E-065
November 16, 2022 Dear Proterra Powered Battery Pack Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. This notice applies to certain battery packs, model S1-15, part # 129-6202, 139-6181, 163-3642. What is the reason for this notice? Proterra has decided that a defect that relates to motor vehicle safety exists in certain battery packs, where the joint connecting the voltage sense foil harness and the PCB adapter board lacks sufficient solder, resulting in a potentially weakened joint. A weakened joint may create an intermittent connectivity issue that causes the battery management system (“BMS”) to detect an erroneous voltage measurement which would lead to the BMS terminating power in order to isolate the battery pack from the remainder of the high voltage system on the vehicle. On a single-string battery pack application, the vehicle would experience the loss of propulsion if the BMS terminates power. Why is your equipment being recalled? Affected battery packs that are used in a single-string application are being recalled because the loss of propulsion could increase the risk of a crash without prior warning. Proterra will provide a repair of the components at no cost to you. We apologize for the inconvenience. We are committed to your safety, the safety of your customers, and your continued satisfaction with our
products, and we request that you remedy your bus(es) promptly. IMPORTANT • Your Proterra batteries are subject to NHTSA Safety Recall No. 22E-065 because a vehicle equipped with a defective battery may experience a loss of propulsion if the BMS terminates power due to a weakened joint in the voltage sense foil harness.
• Proterra is developing a remedy for the issue. Service instructions will be provided in a technical service bulletin after the remedy has been developed.
• The remedy will be provided free of charge.
• Contact Proterra’s customer service department at 864- 438-0000 or ServiceParts@Proterra.com if you have any questions. What will Proterra Do? The remedy is under development. A second notification letter with the proper instructions will be issued when the remedy become available. Service repair instructions will be provided in service campaign TBD. What Should You Do? Please stop driving vehicles equipped with the recalled batteries until the defect is remedied. What If You Have Already Repaired the Defect? If you have previously paid for a repair that addresses the defect described in this letter, you still need to have this recall performed by Proterra to ensure the correct remedy was applied. However, you may be eligible for a reimbursement of the previous repair. Please contact Proterra’s customer service team at 864-438-0000 or ServiceParts@Proterra.com to verify eligibility and process your reimbursement request. What If You Have Other Questions? Please contact Proterra’s customer service department at 864-438-0000 or ServiceParts@Proterra.com 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 22V-114. Sincerely,
Juliano Palma
Head of Supplier Quality – Proterra Powered
Proterra Operating Company, Inc.

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FINAL LETTER
IMPORTANT SAFETY RECALL
NHTSA Recall Number: 22E-065
November 21, 2022 Dear Proterra Powered Battery Pack Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. This notice applies to certain battery packs, model S1-15, part # 129-6202, 139-6181, 163-3642. What is the reason for this notice? Proterra has decided that a defect that relates to motor vehicle safety exists in certain battery packs, where the joint connecting the voltage sense foil harness and the PCB adapter board lacks sufficient solder, resulting in a potentially weakened joint. A weakened joint may create an intermittent connectivity issue that causes the battery management system (“BMS”) to detect an erroneous voltage measurement which would lead to the BMS terminating power in order to isolate the battery pack from the remainder of the high voltage system on the vehicle. On a single-string battery pack application, the vehicle would experience a loss of propulsion if the BMS terminates power. Why is your equipment being recalled? Affected battery packs that are used in a single-string application are being recalled because the loss of propulsion could increase the risk of a crash without prior warning. Proterra will provide a repair of the affected battery packs at no cost to you. We apologize for the inconvenience. We are committed to your safety, the safety of your customers, and your continued satisfaction
with our products. IMPORTANT • Your Proterra batteries are subject to NHTSA Safety Recall No. 22E-065 because a vehicle equipped with a defective battery may experience a loss of propulsion if the BMS terminates power due to a weakened joint in the voltage sense foil harness.
• Affected battery packs within the recall population will be removed and replaced with non- defective battery packs by Proterra. Proterra is providing this remedy to you free of charge. Service instructions will be provided in a technical service bulletin after the remedy has been developed.
• Contact Proterra’s customer service department at 864- 438-0000 or ServiceParts@Proterra.com if you have any questions. What will Proterra Do? Affected battery packs within the recall population will be removed and replaced with non- defective battery packs by Proterra. Proterra is providing this remedy to you free of charge. A Proterra service representative will contact you to make arrangements for the remedy to be implemented. What Should You Do? Please do not use the battery packs within the recall population for any purpose, including but not limited to manufacturing, sale, or driving vehicles equipped with the recalled batteries. What If You Have Already Repaired the Defect? If you have previously paid for a repair that addresses the defect described in this letter, you still need to have this recall performed by Proterra to ensure the correct remedy was applied. However, you may be eligible for a reimbursement of the previous repair. Please contact Proterra’s customer service team at 864-438-0000 or ServiceParts@Proterra.com to verify eligibility and process your reimbursement request. What If You Have Other Questions? Please contact Proterra’s customer service department at 864-438-0000 or ServiceParts@Proterra.com 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 22V-114. Sincerely,
Juliano Palma
Head of Supplier Quality – Proterra Powered
Proterra Operating Company, Inc.

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-065
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Proterra Operating Company, Inc. MAR 07, 2023 NHTSA Recall No. : 22E-065 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Proterra Operating Company, Inc.
Address : 1815 Rollins Road
Burlingame CA 94010 Company phone : 4380000
Population :
Number of potentially involved : 99 Estimated percentage with defect : 85 %
Equipment Information : Brand / Trade 1 :
Model : Proterra Powered S1-15 Part No. : 129-6202 Size : NR Function : HV Battery
Descriptive Information : Certain battery packs manufactured by Proterra between December 1, 2021, and July 15, 2022, have a potentially weakened joint in a foil harness that could cause an intermittent connectivity issue that leads to the battery management system (BMS) terminating power. After parts inspections and discussions with the supplier of the affected parts, Proterra determined that the termination of power would only occur in battery packs with a single-string application. Battery packs outside of the recall population use a multi-string application.
Production Dates : DEC 01, 2021 – JUL 15, 2022 Brand / Trade 2 :
Model : Proterra Powered S1-15 Part No. : 139-6181 Size : NR Function : HV Battery
Descriptive Information : Certain battery packs manufactured by Proterra between December 1, 2021, and July 15, 2022, have a potentially weakened joint in a foil harness that could cause an intermittent connectivity issue that leads to the battery management system (BMS) terminating power. After parts inspections and discussions with the supplier of the affected parts, Proterra determined that the termination of power would only occur in battery packs with a single-string application. Battery packs outside of the recall population use a multi-string application. Production Dates : DEC 01, 2021 – JUL 15, 2022 Part 573 Safety Recall Report 22E-065 Page 2 Brand / Trade 3 :
Model : Proterra Powered S1-15 Part No. : 163-3642 Size : NR Function : HV Battery
Descriptive Information : Certain battery packs manufactured by Proterra between December 1, 2021, and July 15, 2022, have a potentially weakened joint in a foil harness that could cause an intermittent connectivity issue that leads to the battery management system (BMS) terminating power. After parts inspections and discussions with the supplier of the affected parts, Proterra determined that the termination of power would only occur in battery packs with a single-string application. Battery packs outside of the recall population use a multi-string application.
Production Dates : DEC 01, 2021 – JUL 15, 2022 Description of Defect :
Description of the Defect : The joint connecting the voltage sense foil harness and the PCB adapter board lacks sufficient solder, resulting in a potentially weakened joint. A weakened joint may create an intermittent connectivity issue that causes the BMS to detect an erroneous voltage measurement which would lead to the BMS terminating power, in order to isolate the battery pack from the remainder of the high voltage system on the vehicle. As a result, on a single-string battery pack application, the vehicle would experience the loss of propulsion. If the power is so terminated on one of the packs in a multi-string battery pack application, the vehicle would not lose propulsion because the additional battery pack would not be terminated.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Loss of vehicle propulsion could increase the risk of a crash.
Description of the Cause : An error in a supplier’s production process resulted in insufficient solder in the joint connecting the voltage sense foil harness and the PCB adapter board. Identification of Any Warning NR
that can Occur : Involved Components : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-065 Page 3 Component Name : Manaflex Foil Harness Component Description : Manaflex Foil Harness Component Part Number : 050029 Supplier Identification : Component Manufacturer
Name : Taicang Manaflex Technology Co., LTD Address : No. 3 Building
No. 100 Chenmenjing Road Taicang Foreign States
Country : China Chronology :
In March 2022, Proterra identified a continuity issue based on intermittent signals from the module controls to the battery controls. Our internal investigation identified a lack of signals that suggested an issue with the foil harness during battery production. In March – May 2022, additional parts were rejected as a result of continuity testing, after which Proterra sent the supplier an identified failed foil harness and requested that the supplier begin 100% sorting based on continuity readings. In June 2022, Proterra performed further inspections at its own production facilities for this continuity issue. By early July 2022, upon further engineering analysis, Proterra confirmed the foil harness as the source of the low voltage readings. On July 25, 2022, Proterra’s Safety Committee reviewed the issue and decided to conduct a voluntary safety recall. The Safety Committee determined that the loss of propulsion would only result in a single-string application. As of July 25, 2022, Proterra is not aware of any warranty claims or any field or service reports. No injuries or accidents have been reported related to this issue. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-065
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Affected battery packs within the recall population will be removed and
replaced with non-defective battery packs. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
All battery packs within the recall population are covered by Proterra’s warranty, and the remedy will be provided at no cost to the customer.
The remedied component will not have the weakened joint in a foil harness that could cause an intermittent connectivity issue.
Voltage sense foil harnesses produced by Manaflex and installed into battery packs by Proterra after July 15, 2022, were produced with sufficient solder at the connection to the PCB adaptor board. Recall Schedule :
Description of Recall Schedule : Proterra will mail notification letters to affected vehicle manufacturer
customers by September 27, 2022. Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : AUG 03, 2022 – SEP 27, 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 : Daimler Truck North America LLC Address : 552 Hyatt St
Gaffney SC 29341 Country : US
Company Phone : 8642068745
Name : Optimal Address : 29449 Old US Hwy 33
Elkhart IN 46516 Country : US
Company Phone : 7344147933
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-065
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Proterra Operating Company, Inc. JUL 29, 2022 NHTSA Recall No. : 22E-065 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Proterra Operating Company, Inc.
Address : 1815 Rollins Road
Burlingame CA 94010 Company phone : 4380000
Population :
Number of potentially involved : 99 Estimated percentage with defect : 85 %
Equipment Information : Brand / Trade 1 :
Model : Proterra Powered S1-15 Part No. : 129-6202/139-6181 +1 Size : NR Function : HV Battery
Descriptive Information : Certain battery packs manufactured by Proterra between December 1, 2021, and July 15, 2022, have a potentially weakened joint in a foil harness that could cause an intermittent connectivity issue that leads to the battery management system (BMS) terminating power. After parts inspections and discussions with the supplier of the affected parts, Proterra determined that the termination of power would only occur in battery packs with a single-string application. Battery packs outside of the recall population use a multi-string application.
Production Dates : DEC 01, 2021 – JUL 15, 2022
Description of Defect :
Description of the Defect : The joint connecting the voltage sense foil harness and the PCB adapter board lacks sufficient solder, resulting in a potentially weakened joint. A weakened joint may create an intermittent connectivity issue that causes the BMS to detect an erroneous voltage measurement which would lead to the BMS terminating power, in order to isolate the battery pack from the remainder of the high voltage system on the vehicle. As a result, on a single-string battery pack application, the vehicle would experience the loss of propulsion. If the power is so terminated on one of the packs in a multi-string battery pack application, the vehicle would not lose propulsion because the additional battery pack would not be terminated. FMVSS 1 : NR Part 573 Safety Recall Report 22E-065 Page 2 FMVSS 2 : NR
Description of the Safety Risk : Loss of vehicle propulsion could increase the risk of a crash.
Description of the Cause : An error in a supplier’s production process resulted in insufficient solder in the joint connecting the voltage sense foil harness and the PCB adapter board. Identification of Any Warning NR
that can Occur : Involved Components : Component Name : Manaflex Foil Harness Component Description : NR
Component Part Number : 050029 Supplier Identification : Component Manufacturer
Name : Taicang Manaflex Technology Co., LTD Address : No. 3 Building
No. 100 Chenmenjing Road Taicang Foreign States
Country : China Chronology :
In March 2022, Proterra identified a continuity issue based on intermittent signals from the module controls to the battery controls. Our internal investigation identified a lack of signals that suggested an issue with the foil harness during battery production. In March – May 2022, additional parts were rejected as a result of continuity testing, after which Proterra sent the supplier an identified failed foil harness and requested that the supplier begin 100% sorting based on continuity readings. In June 2022, Proterra performed further inspections at its own production facilities for this continuity issue. By early July 2022, upon further engineering analysis, Proterra confirmed the foil harness as the source of the low voltage readings. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-065
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
On July 25, 2022, Proterra’s Safety Committee reviewed the issue and decided to conduct a voluntary safety recall. The Safety Committee determined that the loss of propulsion would only result in a single-string application. As of July 25, 2022, Proterra is not aware of any warranty claims or any field or service reports. No injuries or accidents have been reported related to this issue.
Description of Remedy : Description of Remedy Program : The remedy is under development. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
All battery packs within the recall population are covered by Proterra’s warranty, and the remedy will be provided at no cost to the customer.
NR Voltage sense foil harnesses produced by Manaflex and installed into battery packs by Proterra after July 15, 2022, were produced with sufficient solder at the connection to the PCB adaptor board. Recall Schedule :
Description of Recall Schedule : Proterra will mail notification letters to affected vehicle manufacturer
customers by September 27, 2022. Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : AUG 03, 2022 – SEP 27, 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-065
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Proterra Operating Company, Inc. AUG 09, 2022 NHTSA Recall No. : 22E-065 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Proterra Operating Company, Inc.
Address : 1815 Rollins Road
Burlingame CA 94010 Company phone : 4380000
Population :
Number of potentially involved : 99 Estimated percentage with defect : 85 %
Equipment Information : Brand / Trade 1 :
Model : Proterra Powered S1-15 Part No. : 129-6202 Size : NR Function : HV Battery
Descriptive Information : Certain battery packs manufactured by Proterra between December 1, 2021, and July 15, 2022, have a potentially weakened joint in a foil harness that could cause an intermittent connectivity issue that leads to the battery management system (BMS) terminating power. After parts inspections and discussions with the supplier of the affected parts, Proterra determined that the termination of power would only occur in battery packs with a single-string application. Battery packs outside of the recall population use a multi-string application.
Production Dates : DEC 01, 2021 – JUL 15, 2022 Brand / Trade 2 :
Model : Proterra Powered S1-15 Part No. : 139-6181 Size : NR Function : HV Battery
Descriptive Information : Certain battery packs manufactured by Proterra between December 1, 2021, and July 15, 2022, have a potentially weakened joint in a foil harness that could cause an intermittent connectivity issue that leads to the battery management system (BMS) terminating power. After parts inspections and discussions with the supplier of the affected parts, Proterra determined that the termination of power would only occur in battery packs with a single-string application. Battery packs outside of the recall population use a multi-string application. Production Dates : DEC 01, 2021 – JUL 15, 2022 Part 573 Safety Recall Report 22E-065 Page 2 Brand / Trade 3 :
Model : Proterra Powered S1-15 Part No. : 163-3642 Size : NR Function : HV Battery
Descriptive Information : Certain battery packs manufactured by Proterra between December 1, 2021, and July 15, 2022, have a potentially weakened joint in a foil harness that could cause an intermittent connectivity issue that leads to the battery management system (BMS) terminating power. After parts inspections and discussions with the supplier of the affected parts, Proterra determined that the termination of power would only occur in battery packs with a single-string application. Battery packs outside of the recall population use a multi-string application.
Production Dates : DEC 01, 2021 – JUL 15, 2022 Description of Defect :
Description of the Defect : The joint connecting the voltage sense foil harness and the PCB adapter board lacks sufficient solder, resulting in a potentially weakened joint. A weakened joint may create an intermittent connectivity issue that causes the BMS to detect an erroneous voltage measurement which would lead to the BMS terminating power, in order to isolate the battery pack from the remainder of the high voltage system on the vehicle. As a result, on a single-string battery pack application, the vehicle would experience the loss of propulsion. If the power is so terminated on one of the packs in a multi-string battery pack application, the vehicle would not lose propulsion because the additional battery pack would not be terminated.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Loss of vehicle propulsion could increase the risk of a crash.
Description of the Cause : An error in a supplier’s production process resulted in insufficient solder in the joint connecting the voltage sense foil harness and the PCB adapter board. Identification of Any Warning NR
that can Occur : Involved Components : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-065 Page 3 Component Name : Manaflex Foil Harness Component Description : NR
Component Part Number : 050029 Supplier Identification : Component Manufacturer
Name : Taicang Manaflex Technology Co., LTD Address : No. 3 Building
No. 100 Chenmenjing Road Taicang Foreign States
Country : China Chronology :
In March 2022, Proterra identified a continuity issue based on intermittent signals from the module controls to the battery controls. Our internal investigation identified a lack of signals that suggested an issue with the foil harness during battery production. In March – May 2022, additional parts were rejected as a result of continuity testing, after which Proterra sent the supplier an identified failed foil harness and requested that the supplier begin 100% sorting based on continuity readings. In June 2022, Proterra performed further inspections at its own production facilities for this continuity issue. By early July 2022, upon further engineering analysis, Proterra confirmed the foil harness as the source of the low voltage readings. On July 25, 2022, Proterra’s Safety Committee reviewed the issue and decided to conduct a voluntary safety recall. The Safety Committee determined that the loss of propulsion would only result in a single-string application. As of July 25, 2022, Proterra is not aware of any warranty claims or any field or service reports. No injuries or accidents have been reported related to this issue. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-065
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy : Description of Remedy Program : The remedy is under development. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
All battery packs within the recall population are covered by Proterra’s warranty, and the remedy will be provided at no cost to the customer.
NR Voltage sense foil harnesses produced by Manaflex and installed into battery packs by Proterra after July 15, 2022, were produced with sufficient solder at the connection to the PCB adaptor board. Recall Schedule :
Description of Recall Schedule : Proterra will mail notification letters to affected vehicle manufacturer
customers by September 27, 2022. Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : AUG 03, 2022 – SEP 27, 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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