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Paccar Peterbilt 220EV 2024 Manual
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Paccar Peterbilt 220EV 2024 Manual

Paccar Peterbilt 220EV 2024 Manual

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Summary of Contents for Paccar Peterbilt 220EV 2024

  • Page 2 Please disregard any illustrations or descriptions relating to features or equipment which are not on this vehicle. PACCAR reserves the right to discontinue, change specifications, or change the design of its vehicles at any time without notice and without incurring any obligation.

  • Page 3: Table Of Contents

    Contents Introduction ______________________________________________________________________ 4 Electric Powertrain ________________________________________________________________ 4 Telematics _______________________________________________________________________ 6 Chapter 1 - Safety _________________________________________________________________ 7 Safety Alerts and Warnings _________________________________________________________ 7 Warnings and Safety Regulations ____________________________________________________ 7 Modification of the Vehicle ________________________________________________________ 7 Cooling System Fill Cap __________________________________________________________ 8 Oils and Lubricants ______________________________________________________________ 8 Maintenance Activities ___________________________________________________________ 8 Environment ___________________________________________________________________ 8...
  • Page 4 Regenerative Braking Retarder Telltale _____________________________________________ 20 Charging Telltale _______________________________________________________________ 21 Limited Performance Mode Telltale ________________________________________________ 21 Regenerative Braking System Telltale ______________________________________________ 21 DC-DC Converter Telltale ________________________________________________________ 22 PTO Enabled Telltale ___________________________________________________________ 22 Low Charge Level Telltale _______________________________________________________ 23 Charge Level Gauge ____________________________________________________________ 23 Power Output Gauge ___________________________________________________________ 24 Driver Feedback System ________________________________________________________ 24 Electrification Display ___________________________________________________________ 25...

  • Page 5: Introduction

    Introduction This vehicle is equipped with a 100% electric powertrain that was manufactured and installed by Dana. It is important to understand the operational characteristics and functions of this electric vehicle (EV). The supplemental manual provides information that is not part of the base OEM chassis.
  • Page 6 Caution: To prevent damage to the lithium-ion battery: • Do not use the lithium-ion battery for any other purpose. • Do not leave the vehicle in a zero or near zero state of charge for more than 14 days. Check the lithium-ion battery available charge gauge display prior to parking the vehicle for extended periods of time.

  • Page 7: Telematics

    PACCAR certified DEP dealers, PACCAR’s marketing partners, your fleet company (if your vehicle is a fleet vehicle), your rental company (if your vehicle is a rental vehicle), and third-party service providers such as cellular information systems and data management providers.

  • Page 8: Chapter 1 - Safety

    Chapter 1 - Safety Safety Alerts and Warnings Please read and follow all safety alerts in this manual. They are for your protection and information. The alerts can also help you avoid injury to yourself and your passengers. The alerts can also help prevent costly damage to the vehicle.

  • Page 9: Cooling System Fill Cap

    Failures and damages caused by improper CAN bus connections are not covered by PACCAR warranties and may result in equipment or property damage. Cooling System Fill Cap Warning: Do not remove the radiator fill cap while the powertrain is hot.

  • Page 10: High Voltage (Hv) System

    Caution: The HV battery pack requires no routine owner maintenance outside of battery balancing, visual inspections, and long-term storage. If the battery service icon illuminates, contact a PACCAR dealership and do not attempt to service the battery. Failure to comply may result in equipment or property damage.

  • Page 11: Welding

    LV Batteries The following messages apply to low voltage (LV) batteries. Warning: Always disconnect the battery negative (ground) lead before carrying out repairs or service on the electrical system. Failure to comply may result in death, personal injury, equipment, or property damage. Warning: Before attempting any work on the batteries or electrical system, remove all jewelry.

  • Page 12: Roadside Assistance

    Instead, contact your nearest battery electric vehicle servicing dealership. Roadside Assistance Call toll-free to talk to someone at the PACCAR Customer Center. 1-800-4Peterbilt (1-800-473-8372) The Customer Call Center is open 24 hours per day, 365 days per year, and is staffed with trained personnel (English and other languages if necessary), free of charge, to provide total roadside assistance.

  • Page 13: First Responder's Guide

    First Responder’s Guide First Responder instructions are available through the QR code or URL below. Download and print the documentation for the Peterbilt 220EV with your current model year. Routinely check the NFPA site to ensure your first responder materials are up to date. QR Code for First Responder Instructions (Scan with phone camera or use URL below) https://www.nfpa.org/Training-and-Events/By-topic/Alternative-Fuel-Vehicle-Safety-Training/Emergency-Response-Guides/Peterbilt...

  • Page 14: Towing Procedures

    Warning: Shut down the HV system before towing electric commercial vehicles for ANY distance. HV Shutdown should never be performed by anyone that has not been trained and certified. Failure to comply may result in death, personal injury, and equipment or property damage. Warning: Do not tow this vehicle after an accident if high-voltage components were damaged.
  • Page 15 6. Starting on the driver’s side, place a drip pan under the end of the drive axle wheel hub to catch the lubrication. 7. With an impact gun, remove any axle shaft nuts, washers, and tapered dowels (if used). 8. Remove the axle shaft from the drive axle housing. Note: Do not use a chisel or any other wedge device to loosen the shaft.
  • Page 16 3. Lower the right side. 4. Raise the left side of the axle 12 inches (0.3 meters) or more. Hold the axle in this position for one minute. 5. Lower the left side. 6. With the axle on a level surface, add the lubricant through the housing cover oil filler hole until the fluid is level with the bottom of the filler hole.

  • Page 17: Chapter 2 - Emergency

    Chapter 2 - Emergency Emergency Operation Warning: High voltage shutdown should only be performed by someone who is both trained and certified. Failure to comply may result in personal injury, death, equipment, or property damage. Warning: Because EV’s can move with little or no sound, conventional methods of determining if a vehicle can be moved under its own power cannot be relied upon.

  • Page 18: Fire Instructions

    The above image shows location of the First Responders Label. Fire Instructions Warning: Do not touch any fluid on the vehicle during a fire. Certain plastic seals may produce gases that can form a corrosive acid if combined with water. Failure to comply may result in personal injury, death, and equipment or property damage.

  • Page 19: Chapter 3 - Truck Operation

    Chapter 3 - Truck Operation Vehicle Display and Instruments This vehicle is equipped with a PACCAR instrument cluster behind the steering wheel and a battery electric truck display to the right of the steering wheel. Instrument Cluster This section explains the new telltale and gauge locations (relative to the previous diesel cluster). The following image shows the location of these telltales and gauges.

  • Page 20: Overheat Warning Light

    When the Coolant Overheats Turn on the hazard-warning flasher, immediately pull over to a safe place that does not impede traffic and place the truck in park. Key off the vehicle and contact the PACCAR Customer Center for direction: 1-800-4Peterbilt (1-800-473-8372). Stop Telltale...

  • Page 21: High Voltage Hazard Telltale

    High Voltage Hazard Procedure: 1. Pull over as soon as possible. 2. Remove the keys from the ignition. 3. Exit the truck. 4. Call the PACCAR Customer Center for guidance: 1-800-4Peterbilt (1-800-473-8372). Regenerative Braking Retarder Telltale Instrument Check: Yes Location: Cluster Color: Green Dial 1-877-777-5360 and then choose option 4 for Dana’s RTW warranty.

  • Page 22: Charging Telltale

    The regenerative braking retarder telltale will activate when regenerative braking is enabled. After every key cycle, the regenerative braking system will default to enabled. Warning: Drivers should disable regenerative braking under low traction road conditions (e.g., ice, rain, snow). Failure to comply may result in personal injury, death, equipment, or property damage.

  • Page 23: Dc-Dc Converter Telltale

    Instrument Check: Yes Location: Cluster Color: Yellow RBS stands for “Regenerative Braking System.” This telltale illuminates when the regenerative braking system is active and is severely derated or disabled. This can occur when the battery State of Charge (SOC) achieves or exceeds 95%, or due to abnormal operating conditions -- such as extreme ambient temperatures or long downhill grades.

  • Page 24: Low Charge Level Telltale

    Location: Cluster Color: Yellow The Power Take Off (PTO) telltale will illuminate if you have an electric PTO (option) on your truck and it is enabled. Low Charge Level Telltale Instrument Check: Yes Location: Cluster Color: Yellow The Low Charge Level telltale is located in the charge level gauge. This telltale will have a yellow illumination when the vehicle’s high voltage battery is close to entering Limited Performance Mode and needs to be recharged.

  • Page 25: Power Output Gauge

    Power Output Gauge Location: Cluster The Power Output gauge shows the power output from the HV battery pack. This includes auxiliary components (for example, cab climate control, powertrain fan, HV battery heater, HV battery chiller, lights, etc.). Gauge Values OFF: When the truck is not ready to drive, the gauge’s needle will stay at OFF. READY: When the truck has started up and ready to move, the needle will initially move to READY.

  • Page 26: Electrification Display

    This is a driver reward system for efficient driving. This vehicle does not use the DFS system, but the bar may still appear in the instrument cluster display. Electrification Display Three System State Modes (Vehicle state is always display in the top right of the display). OFF –...
  • Page 27 READY – The HV bus is ON, and the truck is fully operational. Warning: Do not assume the vehicle is off if the vehicle is silent. Failure to comply may result in death, personal injury, and equipment or property damage. Warning: Remain watchful for pedestrians.
  • Page 28 Auxiliary Power – The auxiliary power gauge monitors usage of other chassis components. The truck range loss due to auxiliary power usage is shown in miles per hour of truck operation. Energy Screen Button Auxiliary Power Gauge 27 | P a g e...

  • Page 29: Chapter 4 - Quick Start Guide

    Chapter 4 - Quick Start Guide Charging the High Voltage Battery Pack Warning: Never spray liquid at high pressure towards the charging port while charging. Failure to follow these instructions can result in serious personal injury or damage to the vehicle, charging equipment, or property. Caution: Do not store the battery pack above 104 °F (40 °C) for extended time periods.

  • Page 30: Charging Procedure

    Charging Procedure Warning: If the key is in the accessory/run position after the charge session ends, the vehicle cannot shut down. This will lead to the low voltage batteries discharging, which may result in lower charge than expected when operating the vehicle. Always remove the key from the ignition switch after the charge session ends.
  • Page 31 Type Sequence Potential cause(s) Action Charge plug not fully seated (OR) 5 White 1 Red Proximity pilot error 1 White 3 Red No Control Pilot detected 2 White 3 Red Control Pilot Error Continuous Red SLAC Failure 1 White 4 Red Charge inlet lock error 1 White 5 Red...

  • Page 32: Driving The Vehicle

    Action 1 Step 1: Disconnect the charging plug from the truck, ensure vehicle Key is in ‘OFF’ position, wait for at least one minute. Step 2: Look at charger, ensure it is ready for a new charge session. Step 3: Connect charge plug to vehicle charging port. Ensure charge plug is fully seated and 'locks' into place.
  • Page 33 After a double ‘chirp’ is heard, the display will show READY. With foot on brake, select a gear. D-N-R on the PACCAR gear selector. The gear will be show in the PACCAR cluster. Disengage parking brake and drive. 32 |...

  • Page 34: Turning The Vehicle Off

    Warning: Do not exceed the maximum vehicle speed (65 mph) while driving downhill. Failure to comply may result in death, personal injury, equipment, or property damage. Turning the Vehicle Off 1. With vehicle at a standstill, enable the park brake via parking brake knob. 2.
  • Page 35 Warning: Do not turn on the Driver Controlled Differential Lock (DCDL) when traveling on a road with an elevated grade. Failure to comply may result in a loss of vehicle stability, which could lead to death, injury, or equipment and property damage. The DCDL can be turned on or off only if the vehicle is standing still or moving at a constant, slow speed with level traction.

  • Page 36: Chapter 5 - Maintenance

    Caution: The HV battery pack requires no routine owner maintenance outside of battery balancing, visual inspections, and long-term storage. If the battery service icon illuminates, contact a PACCAR dealership and do not attempt to service the battery. Failure to comply may result in equipment or property damage.
  • Page 37 Warning: Only use approved air conditioning (A/C) oil as listed in the maintenance chart or on the vehicle’s A/C service information label. Use of the wrong oil may lead to malfunction of the high voltage isolation in electric A/C compressor that could cause personal injury, death, and equipment or property damage.

  • Page 38: Component Inspection Intervals

    Component Inspection Intervals Inspection Component Description Interval Type High Voltage Verify integrity of cables - look for Once a year or during regular Visual Cables signs of wear and tear. scheduled truck maintenance Warning: This inspection must be performed by a Peterbilt technician with a HV Cable Battery Electric Vehicle (BEV) Level...

  • Page 39: Cleaning The Vehicle

    Cleaning the Vehicle Warning: Do not pressure wash any part of this vehicle. Failure to comply may result in injury, death, or equipment damage. Warning: Perform the vehicle shutdown procedure before washing the truck. Failure to comply may result in personal injury, death, or equipment damage.

  • Page 40: Fluid Level Inspection

    Fluid Level Inspection Top off the cooling system when coolant is not full in the surge tanks for all three coolant systems. The powertrain surge tank and HV battery pack chiller surge tank are translucent, which allows the coolant level to be seen. The front-of-cab surge tank uses a fill level indicator to aid in monitoring fluid levels. Electric Powertrain Coolant Level Inspection 1.
  • Page 41 Electric Powertrain Coolant Top Off Surge Tank Fill Cap Coolant Level Sensor Cap Warning: Before performing any routine maintenance on the vehicle, place the ignition switch in the OFF position, remove the key, turn the low voltage battery disconnect ‘OFF’, and lock the disconnect in place. Follow the Dana high voltage decommissioning procedure before performing maintenance (see Towing...
  • Page 42 Caution: When adding fluid, be sure to use fluid of the same type. While many fluids have the same description and intended purpose, they should not be mixed due to incompatible additives. Mixing incompatible fluids may lead to equipment damage. Caution: Failure to follow this procedure and maintain proper coolant level can cause system failure, resulting in equipment damage.
  • Page 43 HV Battery Chiller Coolant Top Off Warning: Before performing any routine maintenance on the vehicle, place the ignition switch in the OFF position, remove the key, turn the low voltage battery disconnect ‘OFF’, and lock the disconnect in place. Follow the Dana high voltage decommissioning procedure before performing maintenance (see Towing...
  • Page 44 Caution: Do not overfill the cooling system. Excess coolant may overflow or result in loss of antifreeze and reduced corrosion protection. Failure to comply may result in equipment damage or property damage. Note: Do not use the pressure cap opening to fill the surge tank with fluid. Note: Maximum recommended ELC concentration is 60% ELC and 40% water by volume.
  • Page 45 Warning: Before performing any routine maintenance on the vehicle, place the ignition switch in the OFF position, remove the key, turn the low voltage battery disconnect ‘OFF’, and lock the disconnect in place. Follow the Dana high voltage decommissioning procedure before performing maintenance (see Towing Safety), and do not attempt any high voltage maintenance.

  • Page 46: Long Term Storage

    ensure the removal of air that may cause damage to the circulation pump. Note: Carefully read the safety instructions that comes with your vacuum tool. Long-Term Storage Battery EV Storage Requirements Summary Duration Less than 15 days 15 days or longer * SOC (State of 40 - 100% 100%**...

  • Page 47: Chapter 6 - Information

    Chapter 6 - Information Warranty Schedule This Battery Electric Powertrain Warranty Schedule applies only to original factory equipment and is subject to the terms and limitations in the attached Limited Warranty Agreement. Pursuant to the terms of the attached Limited Warranty Agreement, Peterbilt Motors Company will pay warranty claims for Warrantable Failures within the following maximum limits in time or mileage, whichever shall occur first.
  • Page 48 P E T E R B I L T M O T O R S C O M P A N Y A PACCAR Company P.O. Box 90208 Denton, Texas 76202 Do not remove the manual from vehicle. Before operating vehicle study the manual carefully.