NHTSA ID Number: 10252336
Manufacturer Communication Number: SF681
TSB/Document Date: 2024-04-02
Summary
Field Service Campaign for eCascadia Software Package Update
2
02/02/2024
1. Pump
f548472
2. Hardline
Fig. 7, Disconnecting Hardline from Pump
Page 9
Daimler Truck
North America LLC
Field Service Campaign
March 2024
SF681 A-C
24.
Remove the mounting fasteners that attach the hardline to the 3/2 valve, then disconnect the hardline from
the 3/2 valve. See Fig. 8.
1
2
02/02/2024
f548473
1. 3/2 Valve
2. Hardline
Fig. 8, Disconnecting Hardline from 3/2 Valve
25.
Install the hardline on the 3/2 valve, and install the mounting fasteners.
26.
Install the hardline on the pump.
Page 10
Daimler Truck
North America LLC
Field Service Campaign
March 2024
SF681 A-C
27.
Install the vent bracket, and install the mounting fasteners. See Fig. 9.
1
3
2
02/02/2024
1. Pump
f548474
2. Hardline
3. Vent Bracket
Fig. 9, Connecting Hardline to Pump
28.
Gently move the high voltage cables back to their original position, then install the high voltage cable clamps.
29.
Connect the low voltage chassis harness to the main frontbox.
30.
Connect the wiring harness to the coolant pump.
31.
Connect the ground cables to the main frontbox, and tighten 115 lbf·in (1300 N·cm).
32.
Install the hardline over the high voltage battery
B1.
33.
Tighten all coolant line connections 62 lbf·in (700 N·cm).
Page 11
Daimler Truck
North America LLC
Field Service Campaign
March 2024
SF681 A-C
34.
Install the vent line bracket, and install the mounting fastener. See Fig. 10.
1
2
3
4
02/09/2024
f548486
1. Mounting Fastener
2. Vent Line Bracket
3. Vent Hose
4. Cable Tie
Fig. 10, Installation of Vent Line Bracket
35.
Remove the left-hand side radiator support and fasteners to get access to cut the vent line. See Fig. 11.
02/09/2024
Fig. 11, Left-Hand Side Radiator Support
Page 12
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Daimler Truck
North America LLC
Field Service Campaign
March 2024
SF681 A-C
36.
Cut the front portion of the vent line hose, and install the Y-fitting. See Fig. 12 and Fig. 13.
2
3
1
02/22/2024
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Fig. 12, Vent Line to Cut
02/02/2024
1. Y-Fitting
2. Hose Clamp
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3. Vent Hose
Fig. 13, Y-Fitting
Page 13
Daimler Truck
North America LLC
Field Service Campaign
March 2024
SF681 A-C
37.
Install and route the vent line. See Fig. 14.
38.
Install the frame clamps, and secure the vent line with a cable tie. See Fig. 14 and Fig. 15.
1
2
A
02/02/2024
f548477
A. Add an extra clamp in the indicated location.
1. Vent Line Clamps
2. Vent Line
Fig. 14, Vent Line Routing
Page 14
Daimler Truck
North America LLC
Field Service Campaign
March 2024
SF681 A-C
02/09/2024
f548487
Fig. 15, Location of Frame Clamp
39.
Install the left-hand side radiator support and fasteners. Tighten the three rear fasteners 35 lbf·ft (48 N·m)
and the front isolated fastener 59 lbf·ft (80 N·m).
40.
Clean any spilled coolant from the top of the battery.
41.
Install the ground cable support bracket.
42.
Transfer the high voltage connector protective caps from the old DC boxes to the new DC boxes.
43.
Install the DC boxes on the mounting bracket, and install the fasteners that attach the DC boxes to the
mounting bracket. Tighten the fasteners 115 lbf·in (1300 N·cm).
44.
Install the DC boxes and bracket on the vehicle.
45.
Install and tighten the mounting bracket fasteners.
46.
Connect the coolant lines to the DC boxes.
47.
Route the wiring harnesses back to the original positions.
48.
Connect the low voltage connectors to the DC boxes and on the front side of the ground bracket.
49.
Install the ground cable fasteners. Tighten the smaller nut and the DC box bolt 11 lbf·ft (15 N·m), and the
larger nut 35 lbf·ft (48 N·m).
IMPORTANT: Clean any dirt or debris from high voltage connectors before removing them. Failure to do so
could increase the chance of dirt getting into the connector during installation.
50.
To ensure the high voltage connectors are installed vertically during installation, use the tool
(DSNEMG022008) to connect the three high voltage connectors.
51.
Remove the alignment pin, and install the high voltage connector mounting fasteners.
52.
Install the high voltage cable clamps, and tighten the fasteners.
Page 15
Daimler Truck
North America LLC
Field Service Campaign
March 2024
SF681 A-C
53.
Tighten the high voltage connector fasteners 14 lbf·ft (19 N·m).
54.
Secure the low voltage harnesses and the ground cables with cable ties.
55.
Install the side impact protection. For instructions, see Section 31.03, Subject 100 of the eCascadia
Workshop Manual.
56.
Remove the block off plate of the dual port charger. See Fig. 16.
02/09/2024
f548488
Fig. 16, Location of the Block Off Plate
57.
Install the forward battery cover that is attached to the side impact protection assembly.
58.
Install the left-hand side battery deck plate. For instructions, see Section 31.05 of the eCascadia Workshop Manual.
59.
Commission the vehicle. For instructions, see Section 08.08 of the eCascadia Workshop Manual.
60.
Fill and bleed the battery cooling system. For instructions, see Section 20.01, Subject 160 of the eCascadia
Workshop Manual.
Page 16
Daimler Truck
North America LLC
Field Service Campaign
March 2024
SF681 A-C
SF681 B-C: Replacement of Direct Current Box (DCB) Module(s)
1.
Check the base label (Form WAR259) for a completion sticker for SF681 (Form WAR261), indicating this
work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm)
below the door latch. If a completion sticker is present, no work is needed. If a completion sticker is
not present, proceed to the next step.
2.
Park the vehicle on a level surface, place the vehicle in neutral, shut down the vehicle, and set the parking
brake. Chock the tires.
DANGER
Service and repair of the electric vehicle should only be performed by technicians that have completed
HV2 or HV3 Daimler Safety Training. Decommissioning and commissioning of the HV system should
only be performed by technicians that have completed HV3 Daimler Safety training. To prevent personal
injury or death, or damage to the electric system, do not attempt repairs yourself.
Decommission the vehicle and verify the high voltage system is shut down. Failure to follow these
steps could result in serious personal injury or death.
3.
Decommission the vehicle. For instructions, see Section 08.08 of the eCascadia Workshop Manual.
4.
Remove the left-hand side battery deck plate. See Fig. 17. For instructions, see Section 31.05 of the
eCascadia Workshop Manual.
5.
Remove the left-hand side battery protection cover that is attached to the side impact protection assembly.
See Fig. 17.
1
2
3
10/21/2021
1.
2.
3.
4.
4
f080357
Battery Protection Cover
Side Impact Protection Assembly
DC Box
Left-Hand Side Battery Deck Plate
Fig. 17, Removal of Battery Protection Cover
6.
Remove the side impact protection. For instructions, see Section 31.03, Subject 100 of the eCascadia
Workshop Manual.
7.
Clamp the coolant lines to the DC boxes.
Page 17
Daimler Truck
North America LLC
Field Service Campaign
March 2024
SF681 A-C
8.
Remove the high voltage cable clamps.
IMPORTANT: High voltage connectors need to be kept clean and clear of debris, fluids, and damage. A dirty or
damaged connector can cause problems for energy transfer within the cable or high voltage components and
can lead to high voltage system failures.
NOTE: To ensure the high voltage connectors are installed vertically during installation, use the tool
(DSNEMG022008) to connect the three high voltage connectors.
9.
Remove the high voltage connectors from the DC box(es).
10.
Remove the fasteners from the ground cables, then disconnect the ground cables.
11.
Disconnect the low voltage cable connectors from the DC box(es) and the front side of the ground bracket.
12.
Gently move the high voltage, low voltage, and ground cables out of the way.
13.
Transfer the high voltage connector protective caps from the new DC box(es) to the high voltage connections on the DC box(es) being removed.
14.
Disconnect the coolant lines from the DC box(es).
15.
16.
Remove the DC box mounting bracket fasteners. See Fig. 18.
Remove the DC box(es) and bracket from the vehicle.
02/02/2024
f548467
Fig. 18, DC Box Mounting Bracket Fasteners
Page 18
Daimler Truck
North America LLC
Field Service Campaign
March 2024
SF681 A-C
17.
Remove the DC box(es) from the mounting bracket. See Fig. 19.
1
2
3
02/02/2024
f548468
1. DC Boxes
2. Mounting Bracket
3. Mounting Fasteners
Fig. 19, Removal of DC Box
18.
Clean any spilled coolant from the top of the battery.
19.
Transfer the high voltage connector protective caps from the old DC box(es) to the new DC box(es).
20.
Install the DC box(es) on the mounting bracket, and install the fasteners that attach the DC box(es) to the
mounting bracket. Tighten the fasteners 115 lbf·in (1300 N·cm).
21.
Install the DC box(es) and bracket on the vehicle.
22.
Install and tighten the mounting bracket fasteners.
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TSB/Document ID: SF681
Replacement Service Bulletin Number:
MFR Communication Date: 2024-03-11
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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