LEVC VN5 Instruction sheet

LEVC VN5
First Responder’s Manual
Date of publication: 11/2020

Table of contents
2A
2020-07-17
S023569
1  Introduction 3
1.1  Introduction......................................................................................................................................... 3
1.2  Important safety instructions............................................................................................................ 3
2  Systems overview 5
2.1  High Voltage components ................................................................................................................. 5
2.2  High Voltage battery........................................................................................................................... 5
2.3  Fuel system components .................................................................................................................. 7
2.4  Airbag system..................................................................................................................................... 7
3  Emergency Response Procedures 11
3.1  Initial response ................................................................................................................................... 11
3.2  Identify................................................................................................................................................. 11
3.3  Immobilise........................................................................................................................................... 12
3.4  Disable................................................................................................................................................. 13
3.5  Crash/Extrication................................................................................................................................ 17
3.6  Fire fighting......................................................................................................................................... 19
3.7  Water submersion .............................................................................................................................. 20
3.8  High Voltage battery fire damage...................................................................................................... 21
4  Towing/Jump Starting 22
4.1  Towing ................................................................................................................................................. 22
4.2  Recovering the vehicle ...................................................................................................................... 22
4.3  Unlocking with the detachable key blade ........................................................................................ 23
4.4  Jump starting the 12 volt battery...................................................................................................... 24
4.5  Tools .................................................................................................................................................... 26

Introduction 1
S023569 A
2020-07-17 3
Introduction
This guide is intended only for the use of trained and certified rescuers and first responders.
This guide assumes the reader has:
Full knowledge of how the safety systems operate.
Completed all of the appropriate training and certification necessary to safely work in, and
manage rescue situations.
Therefore, this guide provides only the specific information required to understand and safely
handle the vehicle in an emergency situation.
It describes how to identify the vehicleand provides the locations and descriptions of the High
Voltage, safety restraint and fuel system components.
This guide includes the High Voltage disabling procedure and any safety considerations specific
to the vehicle.
Failure to follow the recommended practices and procedures can result in serious injury or
death.
The High Voltage Battery is the main energy source. The vehicle has a petrol engine, which is
only used to charge the high voltage battery.
The images in this guide may differ slightly to the vehicle you are working on.
Important safety instructions
This document contains important warnings and instructions that must be followed when
working with the vehiclein an emergency situation.
WARNING
Always use the appropriate tools, and always wear the appropriate Personal
Protective Equipment (PPE) when you cut the vehicle. Failure to follow these
instructions can cause serious injury or death.
WARNING
Regardless of the disable procedure you use, always assume that all of the
High Voltage components are energized. Cutting, crushing, or touching High
Voltage components can result in serious injury or death.
WARNING
After deactivation, the high voltage circuit requires 5 minutes to de-energize.

1Introduction
4A
2020-07-17
S023569
WARNING
When there is fire involved, always consider the entire vehicle as energized
and Do Not Touch any part of the vehicle. Always wear full PPE, including
Self-Contained Breathing Apparatus (SCBA).
WARNING
Handling a submerged vehicle without the appropriate PPE can cause serious
injury or death.

Systems overview 2
S023569 A
2020-07-17 5
High Voltage components
1 Inverter - Electric Rear Axle Drive (ERAD)
2 On Board Charger (Primary)
3 Electric Rear Axle Drive (ERAD)
4 On Board Charger (Secondary) (Optional)
5 Junction box - combined charging system
6 High Voltage (HV) Battery
7 Combined Inverter
8 Crankshaft Integrated Starter Generator (CISG)
9 Combined Charging System (CCS) charge point
10 CHAdeMo charge point (optional)
11 Switch - Safety High Voltage Battery
High Voltage battery
The high voltage cables that connect all of the high voltage components are shown in the next
two images. The high voltage cables on the vehicle are orange.
The vehicle is fitted with a 400 volt lithium-ion battery. The high voltage battery attaches to the
vehicle, below the floor and behind the front subframe. Do not break the high voltage battery
when you lift from under the vehicle, or when you use rescue tools.

2Systems overview
6A
2020-07-17
S023569
High Voltage Battery Connections
1 High Voltage Battery safety switch (MSD)
2 High Voltage connection to the CHAdeMO point (optional)
3 High Voltage connection to the ERAD inverter
4 High Voltage connection to the on board charger 2 (optional)
5 High Voltage connection to the on board charger

Systems overview 2
S023569 A
2020-07-17 7
Fuel system components
Although the vehicle is a High Voltage electric vehicle, it uses a petrol engine to charge the High
Voltage Battery. All precautions taken with a petrol powered vehicle must be followed.
1 Roll over valve
2 Fuel tank
3 Fuel delivery module
4 Charcoal canister
5 Fuel tank isolation valve
6 High pressure fuel pump
7 Fuel filter
8 Fuel line pressure sensor
9 Canister purge solenoid
10 Fuel rail
11 High pressure fuel sensor
12 Fuel injector (x3)
Airbag system
The vehicle is equipped with an airbag system consisting of:
– Driver's airbag.
– Passenger's airbag.

2Systems overview
8A
2020-07-17
S023569
– Seat side airbags.
– Curtain airbags.
When the ignition mode is set to II (ON), the airbagwarning light will illuminate for a
system check and then go off. The airbagwarning light will stay illuminated if there is a
fault in the airbag system.
Driver's airbag
The driver's airbag is in the centre of the steering wheel and marked AIRBAG.

Systems overview 2
S023569 A
2020-07-17 9
Passenger's airbag
The passenger's airbagis in the centre of the dashboard and marked AIRBAG. In the event of a
collision, the passenger's airbag may inflate quickly to protect the head and chest of the
passenger.
Seat side airbags
The seat side airbag is located inside the backrest of the driver's and passenger's seatand
marked AIRBAG.

2Systems overview
10 A
2020-07-17
S023569
Curtain airbags
The curtain airbags are installed in the side of the roof lining.
There are two curtain airbags in the driver's cabin located above the driver's seat and the
passenger's seat.

Emergency Response Procedures 3
S023569 A
2020-07-17 11
Initial response
Use these procedures when you do work on this vehicle at an emergency scene
WARNING
Always assume the vehicle is some type of hybrid, electric or alternative
fuelled vehicle until proven otherwise.
1. Identify the vehicle as a High Voltage vehicle.
Identify
2. Isolate the vehicle to prevent any accidental movement that can cause danger to the first
responders or any crash victims.
Follow the instructions on how to immobilise the vehicle.
Immobilise
3. Disable the vehicle. This makes the High Voltage system safe at the scene of the incident.
Disable
Identify
All vehicles manufactured by the LEVC (LEVC) are High Voltage electric vehicles. LEVC
vehicles can be identified as shown below.

3Emergency Response Procedures
12 A
2020-07-17
S023569
Immobilise
The vehicle's petrol engine only runs in certain operation modes and will stop when not needed.
There will be times when the vehicle appears to be off because there is no engine noise.
Do not assume the vehicle is immobilised just because you do not hear engine noise.
When the vehicle is in certain operation modes, the vehicle has the ability to move almost
silently using the electric rear axle drive.
First responders must only approach the vehicle from the sides and stay away from the front
and the rear as these are potential paths of travel.
To immobilise the vehicle complete the following steps:

Emergency Response Procedures 3
S023569 A
2020-07-17 13
To Immobilise the vehicle
1. Chock the wheels.
2. Pull the parking brake switch up to engage the parking brake.
Disable
To disable the vehicle you must disable the 12 Volt and the High Voltage batteries.
1. Set the ignition switch to OFF.
With the ignition in either I (ACC) or II (ON) turn the rotary switch START/STOP clockwise
and release it.

3Emergency Response Procedures
14 A
2020-07-17
S023569
2. Remove the access panel from the right side of the load space to access the 12 volt battery.
3. Loosen the fastener on the battery monitor sensor.
Remove the battery ground cable from the ground terminal of the 12 volt battery.
Make sure that it is not possible for the ground cable to return to its original position and
make contact with the 12 volt battery.

Emergency Response Procedures 3
S023569 A
2020-07-17 15
4. Remove the tray from the centre console.

3Emergency Response Procedures
16 A
2020-07-17
S023569
5. Remove the access hatch.
6. WARNING
You must wait a minimum of 5 minutes before you continue to disable the
High Voltage Battery. If you do not wait, injury or death can occur.
WARNING
You must wear rubber gloves of Class 0 or better for the next 2 steps.
Release the tab on the isolation switch (MSD). Pull the lever to the maximum up position to
release the isolation switch.

Emergency Response Procedures 3
S023569 A
2020-07-17 17
7. Remove the isolation switch from the vehicle.
Crash/Extrication
"Do not cut" locations
WARNING
Do not cut the orange High Voltage cables. If you cut these cables it can cause
injury or death.
WARNING
Do not cut in any of the locations shown.

3Emergency Response Procedures
18 A
2020-07-17
S023569
Do not cut here
There are specific locations on the vehicle that you must not cut the vehicle. The locations are
shown in the images.
1 Airbag location
2 Airbag location
3 All High Voltage cables are orange
4 Fuel lines
5 High Voltage Battery

Emergency Response Procedures 3
S023569 A
2020-07-17 19
Fire fighting
Use typical vehicle fire-fighting procedures to extinguish small fires that do not involve the High
Voltage battery.
Do not make contact with any High Voltage components during any overhaul procedures.
Always use insulated tools during overhaul procedures.
Always perform an adequate knock down to minimise any vapour before entering a hot zone.
Only use large amounts of water to cool the High Voltage battery if it catches fire, is exposed to
high heat, or is bent, twisted, cracked, or breached in any way.
Do not try to extinguish a fire on the High Voltage system with a small amount of water. Always
establish or request an additional water supply.
In the event that a vehicle connected to charging station is involved in a fire, treat the incident
as an energized electrical fire and shut down the electrical circuit that supplies the charging
station before applying water. Extinguishers classified for Class C energized electrical
applications can also be utilised.
High Voltage battery fires can take up to 24 hours to extinguish.
Protect the vehicle and the High Voltage battery from any exposures and consider allowing the
battery to burn.
Use a thermal imaging camera to make sure that the High Voltage battery is completely cooled
before leaving the incident.
The High Voltage Battery must be monitored for at least one hour after it is found to be
completely cooled. Any smoke or steam coming from the High Voltage Battery area indicates
that the High Voltage Battery is still heating.
Do not release the vehicle to second responders until no heat is detected in the High Voltage
battery for a minimum of one hour.
Always advise second responders that there is a risk the High Voltage battery can catch fire
again.
After the vehicle has been involved in submersion, fire, or a collision that may have
compromised the condition of the High Voltage battery, store the vehicle in an open area at least
50 ft (15 m) from any exposure.

3Emergency Response Procedures
20 A
2020-07-17
S023569
To Open the Bonnet
1. Pull the bonnet release lever located inside the vehicle on the left side below the dashboard.
2. To release the bonnet safety catch push the lever rearward and lift the bonnet.
Water submersion
General procedures
If submerged or partially submerged in water, electric vehicles are specifically designed to pose
no risk of electrical shock from simply touching the vehicle. Additionally, their electrical systems
are designed to not energize the surrounding water.
Response procedure