Peterbilt 520EV User manual

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© 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. Please disregard any illustrations or descriptions relating to features or
equipment that 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. The information contained in this manual is
proprietary to PACCAR. Reproduction, in whole or in part, by any means is strictly prohibited without prior written authorization
from PACCAR Inc.

Y53-6158-1B1 (06/21)
520EV

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

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Y53-6158-1B1 (06/21)
Applies To 520EV
This manual is for the 520EV, a battery
electric vehicle. This truck does not have
an engine. The 520EV powertrain and
auxiliary components require different
operating procedures and service
intervals than the typical diesel powered
truck.
This supplemental operator’s manual
provides information that is not part of
the base 520 chassis. Please refer to the
base chassis operator’s manual for
information unrelated to battery electric
truck functions.

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Using this Manual
Please take time to become acquainted
with your vehicle by reading this
operator’s manual. Peterbilt strongly
recommends that you thoroughly read
and understand the manual before
operating the 520EV. This manual
contains useful information for the safe
and efficient operation of the 520EV. It
also provides some service information,
including safety checks and basic
preventative maintenance inspections.
After referencing this manual, please
return it to the glovebox for the next
vehicle user or new owner.
Your vehicle may lack certain features or
options mentioned in this manual.
Therefore, you should pay close
attention to the instructions that pertain
to just your vehicle. Additionally, if your
vehicle is equipped with special
equipment or options not discussed in
this manual, consult your dealer or the
manufacturer of the equipment. All
information contained in this manual is
based on the latest production
information available at the time of
publication. Peterbilt Motors Company
reserves the right to make changes at
any time without notice.
Safety Alerts
Please read and follow all of the safety
alerts contained in this manual. They are
there for your protection and
information. These alerts can help you
avoid injury to yourself and your
passengers. These instructions can also
help prevent costly damage to the
vehicle. Safety alerts are highlighted by
the safety alert symbols and signal
words such as “DANGER,” “WARNING,”
“CAUTION,” or “NOTE.” Do NOT ignore
any of these alerts.
Dangers
The safety message following this
symbol and signal word provides a
warning against operating procedures
that, if not avoided, will cause injury or
death. They could also cause equipment
or property damage. The alert will
identify the hazard, how to avoid it, and
the probable consequence of not
avoiding the hazard.
Warnings
The safety message following this
symbol and signal word provides a
warning against operating procedures
that, if not avoided, could cause injury
or death. They could also cause
NOTE
After you have read this manual, store
it in the glovebox for the next truck
operator or the next owner.

Y53-6158-1B1 (06/21)
equipment or property damage. The
alert will identify the hazard, how to
avoid it, and the probable consequence
of not avoiding the hazard.
Cautions
The safety message following this
symbol and signal word provides a
caution against operating procedures
that, if not avoided, could cause minor
or moderate injury and equipment or
property damage. The alert will identify
the hazard, how to avoid the hazard,
and the probable consequence of not
avoiding the hazard.
Notes
The message following this symbol and
the signal word provides important
information that is not safety related
but should be followed. The alert will
highlight information that may not be
obvious but is useful to your efficient
operation of the vehicle.
Illustrations
Some illustrations in this manual are
generic and do NOT exactly match the
powertrain or parts used in your
application. The illustrations can contain
symbols to indicate an action required
and an acceptable or unacceptable
condition. The illustrations show service
procedures. The procedure will be the
same for all applications, although the
illustration may differ.
General Safety Instructions
Important safety notices about
operating and servicing your vehicle are
included in this section.
California Proposition 65 Warning
Low voltage battery posts,
terminals, and related accessories
contain lead and lead compounds,
which are chemicals known to the
State of California to cause cancer
and reproductive harm. Wash
hands after handling.
Other chemicals in this vehicle are
also know to the State of California
to cause cancer, birth defects or
other reproductive harm.
Data Recorder
California Vehicle Code –Section 9951 –
Disclosure of Recording Device
Your vehicle may be equipped with one
or more recording devices commonly
referred to as “event data recorders”

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(EDR) or “sensing and diagnostic
modules” (SDM). If you are involved in
an accident, the device(s) may have the
ability to record vehicle data that
occurred just prior to and/or during the
accident. For additional information on
your rights associated with the use of
this data, contact:
The California Department of
Motor Vehicles –Licensing
Operations Division
http://www.dmPage 11v.ca.gov/
Environmental Protection Agency
(EPA)
Below is information on the use and
disposal of hazardous materials.
Some chemicals in the hydraulic oil,
transmission oil, axle oil, coolant,
propulsion battery packs, refrigerant,
refrigerant lube, lead acid batteries, etc.
may contaminate the environment if
spilled or improperly disposed of.
Contact your local government agency
for proper disposal guidelines.
A Special Word about Repairs
Before performing any repair, read and
understand all safety precautions and
warnings. The following is a list of
general safety precautions that must be
followed to provide personal safety.
Failure to follow these instructions may
cause injury or death. Special safety
precautions are included in the
procedures when they apply.
WARNING!
Do not attempt repair work without
the proper training, service manuals,
and tools. You could be injured, killed,
or make your vehicle unsafe. Only
conduct tasks that you are qualified to
perform.
WARNING!
Only allow qualified service
technicians to work on this vehicle.
Improper practices, carelessness, or
ignoring any warnings could cause
death, personal injury, and equipment
or property damage.
CAUTION!
The installation of electronic devices
on any of the vehicle Controller Area
Networks (CAN) or their associated
wiring is not permitted and could
adversely affect vehicle performance
and cause vehicle fault codes to be
recorded. These modifications could
also void the vehicle warranty.

Y53-6158-1B1 (06/21)
Even a well-maintained vehicle must be
operated within the range of its
mechanical capabilities, electrical
capabilities, and load rating limits. See
the Weight Ratings label on the driver’s
door edge.
Every new vehicle is designed to
conform to all Federal Motor Vehicle
Safety Standards that were applicable at
the time of manufacture. Even with
these safety features, continued safe
and reliable operation greatly depends
upon regular vehicle maintenance.
Follow the maintenance
recommendations found in the
Preventative Maintenance section. This
will help preserve your investment in
the 520EV.
Your dealer’s service center is the best
place to have your vehicle repaired.
Properly maintained high voltage
personal protective equipment is
required. If you are not a qualified
mechanic for the Peterbilt 520EV, leave
all repairs to an authorized service
facility. Authorized service facilities are
equipped to perform repairs safely and
correctly.
Additional Sources of Information
Major component suppliers also supply
operator’s manuals specific to their
products. Additional manuals and other
pieces of literature are included in the
glove box literature package.
Safe Vehicle Operation
Refer to the 520 Operator’s Manual for
more guidance on safe driving.
Vehicle Loading
Refer to the 520 Operator’s Manual for
guidance on loading the vehicle.
Battery Electric Truck Parts
Description
Air Compressor
The air compressor is driven by an
electric motor.
WARNING!
Vehicle noise may be reduced in some
operation modes. The vehicle
operator must remain aware of
nearby vehicles or pedestrians at all
times. Failure to comply may result in
death, injury, or property damage.
WARNING!
Modifying your vehicle can make it
unsafe. Some modifications can affect
your vehicle’s electrical system,
stability, or other important functions.
Before modifying your vehicle, check
with your dealer to ensure the
modification can be performed
properly. Improper modifications
could cause injury, death, or
equipment damage.

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Air Conditioning Compressor
The air conditioning compressor is also
driven by an electric motor.
Cab Heater
The cab heater uses energy from the
propulsion battery pack for the cab
heating. It heats up coolant that
circulates through a heater core for the
cab.
Charger
This truck is equipped with a DC fast
charger and has an optional AC charger.
The charger is located on the driver’s
side on the propulsion battery pack.
Chiller
The chiller is occasionally needed to cool
the propulsion battery pack when
ambient temperatures are not cool
enough for circulating coolant.
Coolant Pumps
Two coolant pumps are used to circulate
the coolant through several coolant
loops on the 520EV.
DC-DC Converter
The DC-DC converter is the battery
electric truck’s equivalent to a diesel
truck’s alternator. The DC-DC converter
uses energy from the propulsion battery
pack to power the low voltage
components such as controllers and
lights.
eAxle Differential
Each eAxle has a 3.91 differential ratio
with a 2:1 wheel end ratio, resulting in a
7.82 rear axle ratio.
eAxle Transmission
Each eAxle has a 2-speed or 3-speed
transmission.
Power Steering Pump
The power steering pump is driven by its
own motor.
Powertrain Fan
The powertrain fan is electric and has
little to no impact on the powertrain
capabilities. If the electric powertrain
fan is running frequently, it will slightly
decrease the truck’s range.
CAUTION!
Use a compatible charger when
charging the propulsion battery pack.
Using chargers that are not listed by
Meritor as compatible may negatively
affect the propulsion battery pack life.

Y53-6158-1B1 (06/21)
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.
WARNING!
The 520EV contains a sealed lithium-ion
high voltage battery. If the battery is
disposed of improperly, there is a risk of
severe burns and electric shock
resulting in serious injury or death.
CAUTION!
Do not store the battery pack in ambient
temperatures above 95 °F (35 °C).
Permanent damage to the propulsion
battery pack will occur.
CAUTION!
To prevent damage to the propulsion
battery pack:

Do not expose the vehicle to
extreme ambient temperatures for
extended periods.

Do not store the vehicle in
temperatures below -13 °F (-25 °C)
for more than seven days.

Do not leave the vehicle for more
than 14 days where the state of
charge gauge (Battery Gauge)
displays a zero or near zero state of
charge.
NOTE
If the outside temperature is -13 °F
(-25 °C) or colder, the propulsion battery
pack may freeze, and it cannot be
charged or provide power to run the
vehicle. Move the vehicle to a warmer
location for the propulsion battery pack
to thaw.

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Vehicle Layout

Y53-6158-1B1 (06/21)
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.

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Y53-6158-1B1 (06/21)
Emergency

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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 a 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. Their custom mapping
system can locate the nearest
Authorized dealers and Independent
Service Providers (ISPs) based on the
vehicle's location. In addition, the
customer center can dispatch services
for tires, trailers, fines and permits,
chains, towing, hazardous clean-up,
mechanical repairs and preventive
maintenance services. If they cannot
answer a specific question, they will
direct you to a representative who can.
First Responders Guide
First Responder instructions are
available through the QR below.
Download and print the documentation
for the Peterbilt 520EV with your
current model year. Routinely check the
NFPA site to ensure your first responder
materials are up-to-date.
First Responders Field Guide
QR Code (Scan with Phone
Camera to Navigate to URL)
Emergency Procedures
If an accident occurs, follow the below
steps:
1. If it is possible, put the truck in
park and remove the key from the
ignition.
2. If anyone is injured, call 911
immediately.
3. If the vehicle is on fire, do NOT try
to extinguish the fire. Per NFPA
guidelines, move at least 100 feet
upwind of the fire.
4. Provide First Responders with the
First Responders Field Guide or
point first responders to the First
Responders label with a QR code.
Towing
The 520EV can be transported on a
lowboy trailer with all 520EV wheels off
the ground. Alternatively, call the
PACCAR Customer Center for guidance