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Peterbilt 520ev 2024 Manual
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Peterbilt 520ev 2024 Manual

Peterbilt 520ev 2024 Manual

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Summary of Contents for Peterbilt 520ev 2024

  • Page 2 © 2024 PACCAR Inc. - All Rights Reserved This manual illustrates and describes the operation of features or equipment which may be either standard or optional on this vehicle. This manual may also include a description of features and equipment which are no longer available or were not ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which are not on this vehicle.
  • Page 3 520EV...

  • Page 5: Table Of Contents

    Contents Safety ..........................................6 Emergency ........................................16 Controls ........................................... 22 Operation ........................................32 Maintenance ........................................40 Information ........................................50...

  • Page 7: Safety

    Safety Y53-6158-1D1 (09/2024)
  • Page 8 SAFETY Applies To 520EV This is the operator’s manual for the This supplemental operator’s manual Please refer to the Model 520 Model 520EV, a battery electric vehicle. provides information on electric vehicle operator’s manual included with this Because this truck does not have an components, operations, and safety truck for information on components, internal combustion engine, the 520EV...

  • Page 9: Using This Manual

    520EV. It production information available at the also provides some service information, time of publication. Peterbilt Motors including safety checks and basic The safety message following this Company reserves the right to make preventative maintenance inspections.

  • Page 10: General Safety Instructions

    SAFETY Warnings that, if not avoided, could cause powertrain or parts used in your equipment or property damage. The application. The illustrations can alert will identify the hazard, how to contain symbols to indicate an action avoid the hazard, and the probable required and an acceptable or consequence of not avoiding the unacceptable condition.

  • Page 11: Data Recorder

    SAFETY and reproductive harm. Wash your rights associated with the use of A Special Word about Repairs hands after handling. this data, contact: Before performing any repair, read and • Other chemicals in this vehicle understand all safety precautions and •...
  • Page 12 SAFETY Even a well-maintained vehicle must be Every new vehicle is designed to WARNING! operated within the range of its conform to all Federal Motor Vehicle mechanical capabilities, electrical Safety Standards that were applicable Only allow qualified service capabilities, and load rating limits. See at the time of manufacture.
  • Page 13 SAFETY Authorized service facilities are Refer to the 520 Operator’s Manual for circulates through a heater core for the equipped to perform repairs safely and more guidance on safe driving. cab. correctly. Charger Vehicle Loading Additional Sources of This truck is equipped with a DC fast Refer to the 520 Operator’s Manual for Information charger and has an optional AC...
  • Page 14 SAFETY Chiller eAxle Differential Propulsion Battery Packs The chiller maintains the optimal Each eAxle is equipped with a There are several high voltage battery operation temperature differential gear reduction and a wheel propulsion battery packs on this truck. threshold by circulating chilled coolant end reduction.
  • Page 15 SAFETY Vehicle Layout Y53-6158-1D1 (09/2024)
  • Page 16 SAFETY Additional PCAS Components (PCAS: Power Electronics and Controls Subsystem) DISTRIBUTION SYSTEM...

  • Page 17: Emergency

    Emergency Y53-6158-1D1 (09/2024)

  • Page 18: Roadside Assistance

    Download and print the documentation The Customer Call Center is open 24 for the Peterbilt 520EV with your 1. If possible, park the truck and hours per day, 365 days per year, and is current model year. Routinely check...
  • Page 19 EMERGENCY When jacking the front end of a How to Jack an Electric Vehicle Towing vehicle, place the jack at the center of WARNING! the steer axle and then lift the vehicle. When jacking the back end of a vehicle, Do not tow this truck after an place the jack at the center of the rear accident if high voltage components...
  • Page 20 EMERGENCY If it is not possible to tow off the CAUTION! ground, the vehicle may be towed with all wheels on the ground using the Always put the transmission in following steps. neutral and remove the axle half shafts before towing. Failure to Wheels-on-the-Ground Towing comply may result in equipment or 1.
  • Page 21 EMERGENCY WARNING! NOTE WARNING! Absorbent Glass Mat (AGM) batteries The maximum on-vehicle charge rate Never place chains or straps on or contain lead acid, which can burn a for LV batteries is 10 amps. across electric cables person on contact, and explosive components.

  • Page 22: Fuse Replacement

    EMERGENCY Follow the steps in the first responders field guide for recovering a vehicle from a precarious position. Fuse Replacement Follow the steps in the 520 Operators Manual for replacing fuses. Refer to Additional PCAS Components for the location of the low voltage fuses for the battery electric truck components.

  • Page 23: Controls

    Controls Y53-6158-1D1 (09/2024)
  • Page 24 CONTROLS Vehicle Cluster 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, but otherwise remains the same.
  • Page 25 CONTROLS This telltale illuminates when Gauges in the Center Cluster Telltales the electric PTO (ePTO) is Ready to Move enabled. This telltale flashes when there is an ePTO error. External Plug Connect Location: 8 (Physical Telltale) Color: Green Purpose: This telltale illuminates when Location Descriptions: Location: 8 (Physical Telltale) the truck is ready to move.
  • Page 26 CONTROLS Stop Powertrain speed is reduced, and soon after, the WARNING! vehicle will completely shut off. Ensure the park brake is engaged NOTE before connecting the truck to a Location: 2 (Digital Telltale) vehicle charger. Failure to engage the Color: Red This telltale is a standard indication of park brake before connecting the Purpose: This telltale illuminates when...
  • Page 27 Regenerative Braking System Telltale and Stop Telltale are both High Voltage Hazard deactivated. WARNING! Location: 8 (Physical Telltale) Location: 8 (Physical Telltale) Color: Amber (Yellow) The Regenerative Braking System Color: Red Purpose: The RBS telltale illuminates (RBS) is limited in its ability to slow Purpose: This telltale illuminates when when the propulsion battery is at a high the vehicle as the propulsion battery...

  • Page 28: Heating And Air Conditioning

    CONTROLS Location: 1 Location: 3 Purpose: This gauge helps drivers Purpose: This gauge shows the power determine if their driving is economical consumed by auxiliary components. (ECO) or resulting in regenerative Auxiliary component power braking, charging (CHG). Driving with consumption is considered any power the needle in the green ribbon region that is not consumed by the propulsion (CHG and ECO) will result in increased...

  • Page 29: Dash Switches

    CONTROLS Since this truck is powered by a battery when the accelerator pedal is released When regenerative braking is on, the electric powertrain, it does not and the vehicle is moving. In battery green indicator will turn on. The telltale generate enough waste heat to power electric vehicles, regenerative braking has three dots that indicate the level of...
  • Page 30 CONTROLS See the following regenerative braking Driver Controlled Differential Lock NOTE switch level settings: (DCDL) Switch This switch activates the Driver When the regenerative braking Level Retarder Behavior Controlled Differential Lock (DCDL) switch is OFF and 0% accelerator located on the front and rear axles. The pedal demand occurs, the truck will No Regenerative Braking lock maximizes vehicle traction and...

  • Page 31: Gear Selector

    CONTROLS If the truck is losing traction, release The right-hand stalk can be rotated to WARNING! the accelerator and ensure the truck enter Drive, Neutral, or Reverse (see returns to stable traction levels before diagram below). Do not turn on the Driver Controlled turning on the DCDL.
  • Page 32 CONTROLS WARNING! Do not exit the vehicle without first making sure the parking brake is engaged. The gear change lock does not stop the operator from releasing the parking brake before they exit the vehicle, which could result in the vehicle moving during the charge session.

  • Page 33: Operation

    Operation Y53-6158-1D1 (09/2024)

  • Page 34: Pre-Trip Inspection

    OPERATION Truck Exterior PCAS Inspection (Located Under Cab) Pre-Trip Inspection 1. Check for low hanging cables Engage the park brake and put the WARNING! below the truck, especially transmission in neutral before high-voltage cables. Have an performing any checks. Do not attempt to check the coolant authorized technician examine level when it is still hot.
  • Page 35 OPERATION are all secure, intact, and free 6. Put the truck in drive. WARNING! of chafing. 7. The truck will be ready to Verify all three of the coolant move when the green Ready Turn the regenerative braking switch reservoirs are properly filled. to Move telltale is illuminated.
  • Page 36 OPERATION WARNING! NOTE Vehicle noise may be reduced in Stay within the green region of the some operation modes. The vehicle power output gauge to maximize operator must remain aware of truck range. nearby vehicles or pedestrians at all Shutdown Push to Release Park Brake times.
  • Page 37 OPERATION 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’s interface to monitor the charging status.

  • Page 38: Charging Errors

    OPERATION 1. Use the vehicle-side stop Initiating Charging NOTE button to request a stop WARNING! charge. For optimal performance and range, 2. Verify the charger says “not frequently charge the high voltage charging.” Ensure the park brake is engaged batteries to 100% state of charge, 3.

  • Page 39: Idle Shutdown

    OPERATION Idle Shutdown CAUTION! CAUTION! This truck comes equipped with an automatic shutdown. If the truck is left If a shutdown occurs, the truck will Do not use the emergency cut-off on idle for longer than 45 minutes, the slowly drain the low-voltage battery. button except during an emergency.
  • Page 40 OPERATION...

  • Page 41: Maintenance

    Maintenance Y53-6158-1D1 (09/2024)

  • Page 42: Daily Checks

    MAINTENANCE of the orange high voltage Chassis and Cab Exterior Daily Checks cables) (See 520 Operator’s Manual) The driver should perform these checks Check for signs of of the vehicle daily, at a minimum. chafing or rubbing. Note and replace any damaged labels. Ensure all clamps or zip ties holding the Cab Interior...

  • Page 43: Maintenance Schedule

    MAINTENANCE Maintenance Schedule WARNING! WARNING! DANGER! Key off the truck and wait until all Only use approved air conditioning radiators are cool before checking (A/C) oil as listed in the maintenance Restrict high voltage system the coolant levels. Personal injury chart or on the vehicle’s A/C service maintenance to qualified personnel could occur if this warning is not...
  • Page 44 MAINTENANCE CAUTION! CAUTION! NOTE Do not mix different brands or types Do not perform welding procedures Since the automatic transmission of lubricants. Drain or remove old on the truck. Welding could damage fluid (ATF) is used by the transmission lubricants from the unit before the heat-treated rails, the high and wheel end assemblies, the ATF refilling it with the specified lubricant...
  • Page 45 MAINTENANCE Service Interval System Type of fluid Capacities 1.25 gallons (4.7L) Cab Heater 10.25 gallons (38.8L) Radiator TRP Extended Life Coolant 50/50 2 Years Propulsion To Centerline of Reservoir Sight Glass Battery Pack (ESS) 3.5 lbs. R134a for Dual Steer Configurations R134a Cab A/C 2.9 lbs.
  • Page 46 MAINTENANCE Component Inspection WARNING! WARNING! Intervals If any issues involving the high- DO NOT attempt to diagnose or WARNING! voltage electrical system correct vehicle issues. Please contact discovered, DO NOT drive the or take your vehicle to an authorized DO NOT touch or attempt to remove vehicle.
  • Page 47 Inspection Type Interval HV Cable WARNING! Connectors Do not attempt this inspection unless you are a Peterbilt Mechanical Once every two years technician with a Battery Electric Vehicle (BEV) Level Three certification. Failure to comply will result in death, injury, or property damage.
  • Page 48 MAINTENANCE Component Description Inspection Type Interval Coolant In/Out Once a year or during regular Verify tubes for coolant leaks at entry and exit points. Visual (Motor) scheduled truck maintenance Ground Location Once a year or during regular Ensure ground is securely fastened. Visual (Inverter) scheduled truck maintenance...

  • Page 49: Cleaning The Vehicle

    MAINTENANCE Cleaning the Vehicle WARNING! CAUTION! WARNING! Do not wash the truck while it is Do not get any harnesses, cables, or charging. Do not wash the charge coolant routes wet. Failure to comply Do not pressure wash any part of this port, especially not while the truck is may result in equipment or property vehicle.

  • Page 50: Vehicle Storage Instructions

    SOC (State of Charge) 40%-100% 100%** potentially unwarrantable repairs. Environment Well ventilated Refer your local Peterbilt dealership for the latest Storage Ambient Temperature Must stay within -31°F to 131°F (-35°C to 55°C) maintenance In-Service Parking Brake Engaged procedures. Low Voltage (LV)

  • Page 51: Information

    Information Y53-6158-1C1 (09/2024)
  • Page 52 INFORMATION Once the vehicle starts the battery Battery Monitoring System balancing process, try to avoid stopping The vehicle is equipped with passive the BMS. If the vehicle must be battery balancing through the Battery operated, press the “stop charge” Monitoring System (BMS). The Energy button on the vehicle to stop the BMS.

  • Page 53: Warranty Schedule

    NOTE Pursuant to the terms of the attached Limited Warranty agreement, Peterbilt The BMS system may be active for Truck Company will pay warranty days at a time since the vehicle will claims for Warrantable Failures within...
  • Page 54 INFORMATION Vehicle System Months Miles Battery Electric Powertrain System [All other components not listed below] This coverage applies to the electric powertrain system, except for additional coverage 100,000 and warranty exclusions. eAxle 300,000 Motor/Transmission/Carrier 300,000 ePowertrain eAccessory Systems Air Compressor and Motor Power Steering Hydraulic Pump and Motor 300,000 HVAC Compressor and Motor...
  • Page 55 Denton, Texas 76202 Do not remove the manual from vehicle. Before operating vehicle study the manual carefully. Read and understand all warnings, cautions and notes. Need help? Give us a call 24 hours a day Y53-6158-1D1 Printed in the U.S.A. 09/24 1.800.4.PETERBILT...