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Peterbilt 520EV Operator's Manual
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Peterbilt 520EV Operator's Manual

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Summary of Contents for Peterbilt 520EV

  • Page 2 © 2017 PACCAR Inc. - All Rights Reserved. This manual illustrates and describes the operation of features or equipment that may be either standard or optional on this vehicle. This manual may also include a description of features and equipment that are no longer available or were not ordered on this vehicle.
  • Page 3 520EV Y53-6158-1B1 (06/21)

  • Page 5: Table Of Contents

    Contents ___________________________________________________________________________________________________________________________________________ Safety ..........................6 Emergency ........................18 Controls ......................... 24 Operation ........................32 Maintenance ......................... 38 Y53-6158-1B1 (06/21)
  • Page 6 Contents __________________________________________________________________________________________________________________________________________...

  • Page 7: Safety

    Safety Y53-6158-1B1 (06/21)
  • Page 9 Applies To 520EV This manual is for the 520EV, a battery This supplemental operator’s manual electric vehicle. This truck does not have provides information that is not part of an engine. The 520EV powertrain and the base 520 chassis. Please refer to the auxiliary components require different base chassis operator’s manual for...
  • Page 10 Peterbilt Motors Company and efficient operation of the 520EV. It that, if not avoided, will cause injury or reserves the right to make changes at also provides some service information, death.
  • Page 11 equipment or property damage. The Notes General Safety Instructions alert will identify the hazard, how to Important safety notices about avoid it, and the probable consequence operating and servicing your vehicle are of not avoiding the hazard. included in this section. Cautions The message following this symbol and California Proposition 65 Warning...
  • Page 12 (EDR) or “sensing and diagnostic Contact your local government agency WARNING! for proper disposal guidelines. modules” (SDM). If you are involved in an accident, the device(s) may have the A Special Word about Repairs ability to record vehicle data that Only allow qualified...
  • Page 13 If you are not a qualified Before modifying your vehicle, check Vehicle Loading mechanic for the Peterbilt 520EV, leave with your dealer to ensure the Refer to the 520 Operator’s Manual for all repairs to an authorized service...
  • Page 14 Two coolant pumps are used to circulate cab. Powertrain Fan the coolant through several coolant loops on the 520EV. The powertrain fan is electric and has Charger little to no impact on the powertrain This truck is equipped with a DC fast DC-DC Converter capabilities.
  • Page 15 WARNING! CAUTION! Each eAxle has one propulsion motor and inverter. The inverter converts DC The 520EV contains a sealed lithium-ion Do not store the battery pack in ambient voltage into time-averaged pulses that high voltage battery. If the battery is temperatures above 95 °F (35 °C).
  • Page 16 Vehicle Layout...
  • Page 17 Additional Components on the PCAS (PCAS: Power Electronics and Controls Subsystem) (Not Shown) The Power Electronics Coolant Reservoir is located behind the 520 cab on the passenger side. Y53-6158-1B1 (06/21)

  • Page 19: Emergency

    Emergency Y53-6158-1B1 (06/21)
  • Page 20 Towing QR Code (Scan with Phone chains, towing, hazardous clean-up, The 520EV can be transported on a Camera to Navigate to URL) mechanical repairs and preventive lowboy trailer with all 520EV wheels off maintenance services. If they cannot the ground.
  • Page 21 Towing the voltage, lead acid batteries can be used property damage. 520EV (with the propulsion motors for jump-starting. Failure to heed this spinning) will generate unsafe voltage warning WILL result in personal injury,...
  • Page 22 2. Select a jumper cable that is long WARNING! WARNING! enough to be attached to both vehicles in a way that ensures the Remove all metal jewelry, metal belt Never climb into the cab while it is tilted vehicles do not contact each other. buckles, etc.
  • Page 23 11. Attach the other end of the Recovering a Vehicle WARNING! negative cable on to a bare metal Follow the steps in the first responders part on the truck with the dead field guide for recovering a vehicle from battery. a precarious position.

  • Page 25: Controls

    Controls Y53-6158-1B1 (06/21)
  • Page 26 This section contains information on the battery electric vehicle cluster, switches, and HVAC. For reference, the 520EV cluster is shown below. Each new gauge and telltale is described in the following section. The speedometer will either have MPH or KPH as the primary unit.
  • Page 27 Gauges in the Center Cluster Guide to the Battery Electric Truck 1. This telltale illuminates when the electric PTO (ePTO) is enabled. Symbols 2. This telltale flashes when there is Ready to Move an ePTO error. External Plug Connect Location: Physical Telltales (Position 8 on Cluster) 1.
  • Page 28 Service Limited Performance Mode drive will need to rely on the foundation brakes when the RBS telltale is illuminated. The RBS telltale can be illuminated due to normal operating Location: conditions (e.g. high state of charge) or Physical Telltale (Position 8 on Cluster) due to severe operating conditions (e.g.
  • Page 29 High Voltage Hazard Power Output Gauge “ECO” and the green Ready to Move telltale will illuminate. Location: Physical Telltale (Position 8 on Cluster) Color: Red Purpose: This telltale illuminates when there is a high voltage hazard (e.g. High Voltage Interlock Loop Broken, Isolation Resistance Too Low, etc.).
  • Page 30 Battery Gauge (State of Charge) component power consumption is considered any power that is not The BATTERY Gauge will be labeled Location: consumed by the propulsion motor. with either “BATTERY” or Position 2 on Cluster When the needle is within the green “CHARGE LEVEL.”...
  • Page 31 Heating and Air Conditioning WARNING! Heating and Air Conditioning switches have the same functions for the battery electric truck as the diesel powertrain. Turn the Retarder ON/OFF switch to the OFF position when low traction Since this truck is powered by a battery road conditions exist (e.g.
  • Page 32 Aftertreatment Switches Since the truck uses a battery electric powertrain, there is no need of a Regen Aftertreatment Switch. This switch will not be included with the 520EV. Gear Selector This electric powertrain contains eAxles with either 2-speed or 3-speed transmissions integrated on each eAxle.

  • Page 33: Operation

    Operation Y53-6158-1B1 (06/21)
  • Page 34 WARNING! adequately filled. inspection. Only authorized technicians for the 520EV should conduct repairs. 3. Ensure the radiator fan is free of Do not attempt to check the coolant Failure to heed this warning could result debris.
  • Page 35 Startup WARNING! WARNING! 1. Remove the charger plug if necessary. Pull over if the digital Stop Lamp is Vehicle noise may be reduced in some 2. Turn the ignition key fully present. Continuing to discharge the operation modes. The vehicle operator clockwise and let it spring back.
  • Page 36 Shutdown 1. Put the truck in neutral. 2. Pull the park brake to ensure that it is applied. 3. Remove the key from the ignition. 4. Ensure the Ready to Move telltale is extinguished. Pull to Apply Park Brake Park Brake Position For reference, drawings of the park brake knob in its released position (park brake disengaged) and applied position...
  • Page 37 Charge Port Description The 520EV has a DC fast charger and an optional AC charger. Both are SAE J1772 compliant. The CCS1 charge port is located on the driver’s side on the propulsion battery pack. Use the Charge Port LED (next to the truck’s charge...
  • Page 38 Initiating Charging If the charger plug has a button, you may need to press the charger plug button to disengage it too. WARNING! Ensure the park brake is engaged before connecting the truck to a vehicle charger. Failure to engage the park brake before connecting the charger cable could result in injury, death, or equipment damage.

  • Page 39: Maintenance

    Maintenance Y53-6158-1B1 (06/21)
  • Page 40 o Ensure all clamps or zip ties Daily Checks Ensure the usual telltales are holding the cables are in good illuminated during the lamp The driver should perform these condition too. check. checks of the vehicle daily, at a  Hood Latch minimum.
  • Page 41 Maintenance Schedule WARNING! CAUTION! WARNING! Exercise extreme caution to prevent Do not perform welding procedures on neckties, jewelry, long hair, or loose the truck. Welding could damage the Turn off the truck and wait until all clothing from catching in the fan blades heat treated rails, the high voltage radiators are cool before checking the or any other moving parts.
  • Page 42 Service Interval System Type of fluid Capacities 10.5 gallons (39.7 L) Chiller TRP ELC 50/50 1.25 gallons (4.7 L) 2 Years Cab Heater 10.25 gallons (38.8 L) Radiator 50/50 Low Conductivity GM Propulsion 12378390-DEX-Cool 50/50 Premix To center line of reservoir sight glass 2 Years Battery Pack Coolant...
  • Page 43 Cleaning the Vehicle CAUTION! WARNING! Do not power wash the PCAS. Clean Perform vehicle shutdown the components by hand as needed. procedure prior to washing the truck. Failure to heed this warning could result CAUTION! in personal injury, death, or equipment damage.