Tech Articles

The trucking industry has been longing for maintenance-free trucks for many years, and it seems like we may have finally come close to achieving that goal with battery-electric trucks. These electric marvels have significantly fewer moving parts by 30-40% which reduces maintenance necessary. 

Unlike their diesel counterparts, electric motors have only one moving part, eliminating the hundreds of intricate components found in diesel engines and transmissions. This translates into fewer fluid changes, less greasing, and a lot fewer potential issues with electric trucks.

Ameya Jathar, Senior Director for Platform Engineering at Meritor, emphasizes the design intent for electric vehicle components like motors, inverters, and cables to last the vehicle's entire lifespan with only periodic inspections. While specific service intervals are yet to be finalized, it's clear that electric trucks are engineered for minimal maintenance.

However, some adjustments are needed. Components such as air compressors, power steering pumps, and coolant pumps will no longer be belt-driven by diesel engines, necessitating new maintenance protocols. The maintenance and inspection routines established by the original equipment manufacturer (OEM) will still apply to various chassis components.

For electric vehicles, the majority of periodic maintenance resembles that of internal combustion vehicles, with the addition of inspections for new components:

• Battery: Inspect for damaged or loose connections.
• Motor and inverter: Check for oil leakage and loose connections.
• Controllers: Inspect for loose connections and corrosion.
• High-voltage cables and wiring connectors: Look for damage, corrosion, and loose connections.
• Tires: Examine for excessive wear due to higher torque.
• Manual service disconnect (MSD): Verify integrity and effectiveness in de-energizing the system.
• E-axles: If equipped, inspect for oil leaks.

One notable advantage of electric trucks is a substantial reduction in brake maintenance due to regenerative braking handling most of the work. Some cooling fluid changes for batteries and controllers may be necessary, but precise intervals are still being determined.

Batteries themselves are expected to require minimal physical maintenance but will need periodic condition inspections. To maintain the balance of individual cells within the battery pack, an algorithm in the charging software can detect imbalances and initiate corrective processes during charging. This process, if followed correctly, can significantly reduce the need for manual intervention.

Unlike natural gas or hydrogen, transitioning to battery-electric trucks won't demand major shop modifications. However, technicians will need specialized insulated tools and possibly lifting equipment for handling batteries. Adding a charger to the shop for maintaining battery state-of-charge might also be necessary.

Technician training is crucial for working on battery-electric trucks. Maintenance for drivetrains and controllers will shift toward software and diagnostics, making it a smoother transition for experienced Class A technicians familiar with diesel systems. Specialized training for high-voltage components will be necessary, akin to what electric utility linemen receive.

Safety will be paramount, requiring techs to learn safety and emergency procedures for high-voltage systems. Training will likely be platform-specific, as vocational tech schools are yet to offer standardized programs for high-voltage battery electric systems.

Fleets may also consider first aid and firefighting training related to electrical injuries and fires. Understanding battery chemistries will prevent potential safety hazards, ensuring technicians can service electric trucks effectively without putting themselves at risk.

With the advent of electric trucks and their unique technologies, it's clear that maintenance and service procedures will need to be adapted and updated to ensure safe and effective maintenance practices.