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Paccar Peterbilt 520EV 2022 Operator's Manual
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Paccar Peterbilt 520EV 2022 Operator's Manual

Paccar Peterbilt 520EV 2022 Operator's Manual

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OPERATOR'S MANUAL
Y53-6158-1C1 (07/18/2022)

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Summary of Contents for Paccar Peterbilt 520EV 2022

  • Page 1 OPERATOR’S MANUAL Y53-6158-1C1 (07/18/2022)
  • Page 2 © 2022 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 Y53-6158-1C1 (07/18/2022)

  • Page 5: Table Of Contents

    Contents ___________________________________________________________________________________________________________________________________________ Safety ..........................6 Emergency ........................18 Controls ......................... 24 Operation ........................32 Maintenance ......................... 38 Y53-6158-1C1 (07/18/2022)
  • Page 6 Contents __________________________________________________________________________________________________________________________________________...

  • Page 7: Safety

    Safety Y53-6158-1C1 (07/18/2022)
  • 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 operating procedures and service...
  • Page 10 Dangers equipment or options not discussed in Using this Manual this manual, consult your dealer or the Please take time to become acquainted manufacturer of the equipment. All with your vehicle by reading this information contained in this manual is operator’s manual.
  • Page 11 Notes equipment or property damage. The 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! modules” (SDM). If you are involved in for proper disposal guidelines. an accident, the device(s) may have the A Special Word about Repairs ability to record vehicle data that Only allow qualified...
  • Page 13 Safe Vehicle Operation Even a well-maintained vehicle must be and reliable operation greatly depends operated within the range of its upon regular vehicle maintenance. WARNING! mechanical capabilities, electrical Follow the maintenance capabilities, and load rating limits. See recommendations found in the the Weight Ratings label on the driver’s Vehicle noise may be reduced in some Preventative Maintenance section.
  • Page 14 Air Conditioning Compressor Chiller eAxle Transmission The air conditioning compressor is also The chiller maintains the maximum driven by an electric motor. battery operation temperature Each eAxle has a 2-speed or 3-speed threshold by circulating chilled coolant transmission. Cab Heater through the battery packs.
  • Page 15 Propulsion Motor and Inverter Each eAxle has one propulsion motor and inverter. The inverter converts DC voltage into time-averaged pulses that approximate the AC voltage needed to drive the propulsion motors. Propulsion Battery Packs There are several high voltage propulsion battery packs on this truck. Careful maintenance and operation is required to maximize the propulsion battery pack’s life.
  • 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. Y53-6158-1C1 (07/18/2022)

  • Page 19: Emergency

    Emergency Y53-6158-1C1 (07/18/2022)
  • Page 20 Emergency Procedures Call toll-free to talk to someone at the First Responder instructions are If an accident occurs, follow the below PACCAR Customer Center. available through the QR below. steps: Download and print the documentation 1. If possible, park the truck and...
  • Page 21 Towing WARNING! NOTE CAUTION! Do not allow the propulsion motors to All drive axles on EV Ph2 HD trucks Always put the transmission in neutral spin while towing this truck to avoid contain diff lock hardware, even when and remove the axle half shafts before generating unsafe voltage.
  • Page 22 How to Jump-Start a Battery WARNING! CAUTION! DANGER! Lead acid batteries contain an acid that Improperly attaching the jumper cables can burn and gasses that can explode. or failing to follow these instructions Do not connect any components to the Ignoring safety procedures may result in correctly could seriously damage all the propulsion battery packs.
  • Page 23 5. Set the parking brakes. 11. Attach the other end of the WARNING! 6. Shift the transmission into neutral. negative cable on to a bare metal 7. If either vehicle is equipped with part on the truck with the dead When disconnecting the jumper cables, battery disconnects, ensure they battery.
  • Page 24 Recovering a Vehicle WARNING! WARNING! Never place chains or straps on or across any high voltage components or orange When jacking or lifting a vehicle, do not high voltage cables. Failure to comply place the jack or hoist on or within 12” with this warning could result in injury, of any high voltage components or death, or equipment damage.

  • Page 25: Controls

    Controls Y53-6158-1C1 (07/18/2022)
  • 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 1. This telltale illuminates when the Gauges in the Center Cluster Guide to the Battery Electric electric PTO (ePTO) is enabled. Truck 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 abnormal operating conditions such as extreme ambient temperatures or long downhill grades. Location: If the RBS telltale is activated, or the Physical Telltale (Position 8 on Cluster) high voltage battery pack is at a high Location: Color: Amber (Yellow) state of charge, the operator must rely Physical Telltale (Position 8 on Cluster)
  • Page 29 Position 1 on Cluster over, shutdown the truck, and call the Purpose: PACCAR Customer Center. This gauge helps drivers determine if their driving is economical (ECO) or resulting in regenerative braking, charging (CHG). Driving with the needle in the green ribbon region (CHG and ECO) will result in increased range.
  • Page 30 component power consumption is Battery Gauge (State of Charge) 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 functionality allowed at lower truck accelerator pedal demand occurs, the Heating and Air Conditioning speeds. Two switches exist for truck will be coasting with no braking Heating and Air Conditioning switches controlling the retarder levels. effort from the propulsion motors. have the same functions for both diesel and battery electric trucks.
  • Page 32 Fan Switch Since the truck uses an electric Upshift powertrain fan that turns on automatically, the fan override switch is no longer an option and will not be included. Downshift Aftertreatment Switches Since the truck uses a battery electric powertrain, there is no need of a Regen Aftertreatment Switch.

  • Page 33: Operation

    Operation Y53-6158-1C1 (07/18/2022)
  • Page 34 2. Ensure the wheel cap nuts are in Pre-Trip Inspection WARNING! place and torqued properly. Ensure the park brake is engaged and 3. Ensure all tire pressures match and the transmission is in neutral before Only visually inspect high voltage are in the recommended pressure performing any checks.
  • Page 35 Startup WARNING! WARNING! WARNING! 1. Remove the charger plug if necessary. Pull over if the digital Stop Lamp is present. Pull over if the digital Stop Lamp is present. Vehicle noise may be reduced in some 2. Turn the ignition key fully Continuing to discharge the battery pack Continuing to discharge the battery pack operation modes.
  • 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 port) and the charger screen (on the charger, not on the truck) to monitor the charging status.
  • Page 38 press the Charge Port LED/button to end Initiating Charging the charge. WARNING! If the charger plug has a button, you may need to press the charger plug button to disengage it. Ensure the park brake is engaged before connecting the truck to a vehicle charger.

  • Page 39: Maintenance

    Maintenance Y53-6158-1C1 (07/18/2022)
  • Page 40 o Ensure all clamps or zip ties Ensure the usual telltales are Daily Checks 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 Approximately 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 First 15,000 Miles Power Steering EMGARD FE 75W-90 2.5 quarts (2.4 L) Then 120,000 Miles Or Every Year Cab A/C...
  • 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 comply may result in personal CAUTION! injury, death, or equipment damage. Ask the body builder for guidance on WARNING! power washing any equipment added...
  • Page 44 Vehicle Storage Instructions Battery EV Storage Requirements Summary Duration Up to 7 days 8 to 30 Days Over 30 days* SOC (State of Charge) unplugged 40%-70%** Shaded/Covered Area Environment (Temperature Shaded/Covered Area Shaded/Covered Area (Avoid Direct Sunlight) controlled building recommended) Temperature Inside the Battery -35°C to 65°C 0°C to 40°C...
  • Page 45 P E T E R B I LT M OTO R S C O M PA N Y A PACCAR Company P.O. Box 90208 Denton, TX 76202 SCAN THIS QR CODE TO ACCESS ONLINE DRIVER RESOURCES. Do not remove this manual from the vehicle.