LEVC VN5 2021 Conversion Manual Download Page 73

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Chassis

PA1

2020-05-12

S023074

Brake System

General

WARNING

Do not make changes to the brake system.

WARNING

Do not obstruct air flow in or out of the brake discs.

WARNING

The installation of additional exterior trim or wheel covers must not restrict

airflow to the braking system. Restrictions in air flow will cause the brakes to

overheat.

The brakes and Electronic Stability Control (ESC) system are certified to the requirements of

ECE R13H and ECE R140.

The brake system must be fully functional when you complete the conversion.

YOU MUST TEST THE:

– Foot brake

– Parking brake

– Brake warning light

If you must remove any brake system components for access refer to the workshop manual for

the correct procedure.

Summary of Contents for VN5 2021

Page 1: ...LEVC VN5 Conversion Manual Date of publication 07 2020...

Page 2: ...ons 13 1 14 Load Distribution 14 2 Body and Paint 19 2 1 Body 19 2 2 Drill Zones 20 2 3 Racking Systems 26 2 4 Load space 27 2 5 Load Space Panels 28 2 6 Body Closures 29 2 7 Interior Trim 31 2 8 Seat...

Page 3: ...16 Lane Departure Warning 56 3 17 Handles Locks Latches and Entry Systems 57 3 18 Fuses and Relays 58 3 19 Antennas 66 3 20 Electrical Connectors and Connections 67 3 21 Ground Connections 68 3 22 Win...

Page 4: ...gal approvals and application for re certification may be necessary Modifications to the vehicle which do not meet the guideline standards in this publication may severely impact vehicle performance s...

Page 5: ...l must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods tools or components WARNINGS CAUTIONS and NOTES are used throughout this...

Page 6: ...hicles components and separate technical units put on the market provide a high level of safety and environmental protection This will help to ensure that all vehicles are not damaged by the fitting o...

Page 7: ...rpose principles inherent in the original product Care Points Do not exceed the gross vehicle mass The position of the center of gravity is changed when masses are added or removed from the vehicle Th...

Page 8: ...s provided by law The Converter or equipment manufacturer is liable for the Operational reliability and road worthiness of the vehicle to its original intent Operational reliability and road worthines...

Page 9: ...fitted to the vehicle if they are tested and do not affect the operation of the vehicle There are no special provisions or conditions for installations or use For EMC on Blue Light conversions with r...

Page 10: ...d in the development process of new components and vehicles A Dismantling and De Pollution manual is available from LEVC which provides more information on this NOTE For additional information or tech...

Page 11: ...se Vibration and Harshness NVH Noise levels must not be deteriorated by the conversion Exterior noise Make sure any powertrain exterior related NVH is not affected by the conversion The exterior noise...

Page 12: ...position and lifted off of the glass Increase normal tire pressure by 0 5 bar Keep the parking brake disengaged during storage Switch the electronic parking brake off before disconnecting the 12 volt...

Page 13: ...gh voltage battery are discharged then the two batteries must be charged The 12 volt battery must have a minimum state of charge before the high voltage battery can be charged The 12 volt battery shou...

Page 14: ...ery charge recharge if necessary Check the HV battery charge level in the driver s display if it is below 70 charge to 80 Check the tyre condition Perform these checks every 3 months Check the interio...

Page 15: ...s may influence the steering characteristics handling behavior and the brake performance It is important to check that the centre of gravity position has not moved beyond acceptable limits once extra...

Page 16: ...n a horizontal position Then the front wheels are to be raised to three different heights and weights and measurements taken again each time NOTE The higher the front of the vehicle is lifted the more...

Page 17: ...05 12 S023074 Centre of Gravity Height Calculation Measurements Required Measurements Taken 1st 2nd 3rd Wheelbase WB mm Front Axle Weight mV kg Rear Axle Weight mH kg Total Mass mG mV mH kg Inclined...

Page 18: ...f Gravity Height Z mm Values Horizontal Centre of Gravity CoG height from the ground Z Wheelbase WB Front axle weight mV Rear axle weight mH Total vehicle weight mG Radius of the tyre rtyre Values Inc...

Page 19: ...n 18 PA1 2020 05 12 S023074 Centre of Gravity Longitudinal Position The longitudinal position of the Centre of Gravity can be found by weighing the vehicle at it s wheels in a horizontal position usin...

Page 20: ...asteners installed through the floor side or roof must be sealed to prevent water ingress Use an LEVC approved sealant Welding CAUTION Do not weld the vehicle structure The aluminum structure is rivet...

Page 21: ...The images show the locations of the wiring and other components that are not visible on the surface It is the converters responsibility to check that holes drilled and fasteners installed do not cau...

Page 22: ...e from the load space compartment Load space floor Under the load space floor there are High Voltage HV components coolant hoses the fuel system and 12V electrical components It is not recommended to...

Page 23: ...3074 A Floor vent can be installed in the location shown Drill a hole in the centre of the round area 1 If additional floor vents are necessary contact LEVC NOTE For additional information or technica...

Page 24: ...installed behind the door rail cover 4 12V wiring harness attached to the B pillar in front of the load space bulkhead 5 Left rear wheel arch Do not drill into this panel The fuel tank filler pipe is...

Page 25: ...n Number VIN 3 Do not drill into the inner wheel arch 4 Load Space Rear Doors 1 Latch 2 Centre High Mounted Stop Light CHMSL 3 Interior door release lever 4 12V wiring harness 5 Door control module 6...

Page 26: ...e mechanism 5 12V wiring harness 6 Release cable NOTE The doors shown are for a right hand drive model with two sliding doors On other variants components 3 and 6 can be installed on the right side do...

Page 27: ...an be fastened to the floor covering This system removes the need to drill into the aluminum floor structure refer to Load space page 27 for more information Frames must be rigid structures attached t...

Page 28: ...can then attach additional components to the floor covering If you use this method you do not need to drill into the aluminium floor structure Tie Downs Floor Fasteners The vehicle has eight M10 femal...

Page 29: ...motion sensor is switched off in vehicles supplied by LEVC without a bulkhead panel A bulkhead panel should be installed to protect the passengers from objects in the load space In some countries a bu...

Page 30: ...o not modify the seal flanges or surfaces Security Anti Theft and Locking System CAUTION To avoid malfunction of the vehicles security systems contact LEVC before you attempt to add additional securit...

Page 31: ...2 Body and Paint 30 PA1 2020 05 12 S023074 1 The top of the area aligns with the line in the door panel 2 300 mm 3 400 mm 1 410 mm 2 350 mm 3 225 mm 4 235 mm 5 535 mm 6 605 mm...

Page 32: ...e smooth edges Panels must be pre drilled to align with existing fastener locations The recommended thickness for plywood panels is 4 3 mm The recommended thickness for a plywood floor covering is 10...

Page 33: ...Do not install components that prevent access to the remote key reader The operator must have access to put the key in position 2 if there is a fault Seats WARNING Do not modify the seats WARNING Do n...

Page 34: ...nsor 1 camera radar unit 2 and the Vehicle Identification Number VIN 3 Obstructions to the sensors will prevent the function of the Autonomous Emergency Braking AEB system automatic headlights and wip...

Page 35: ...ore you drill into the vehicle you must examine the Drill Zones page 20 document This will help you to avoid damage to other components NOTE For additional information or technical support contact Aft...

Page 36: ...Body and Paint 2 S023074 PA1 2020 05 12 35...

Page 37: ...of the backrest 5 Seat belt pre tensioners attached to the outboard side of the seat base Do not attach equipment or accessories to the areas shown in orange below See Drill Zones page 20 for more inf...

Page 38: ...ems Seat Belts If you must remove the seat belts or disconnect them from the seats refer to the correct procedure in the workshop manual Seat Belt Warning The instrument panel shows a warning light an...

Page 39: ...the base of the light or vent A base plate increases the surface area used by fasteners to attach to the light or vent to the roof this prevents damage to the roof Roof Racks The vehicle is equipped w...

Page 40: ...dge of the material NOTE For additional information or technical support contact Aftersales LEVC com Under Body Protection The wheel arch liners and under trays supplied with the vehicle must be insta...

Page 41: ...the fasteners There are holes in the vehicle structure used when the vehicle is made These holes are not to be used as mounting points Equipment Attached to the Rear Bumper WARNING The vehicle must no...

Page 42: ...ystem Overview 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...

Page 43: ...The installation obeys local regulations WARNING You must disconnect the 12 Volt and the High Voltage battery before you do work on the vehicle Refer to the correct procedure in the workshop manual CA...

Page 44: ...re is a risk defective connections or fire caused by electrical overload All connections to the vehicles wiring harness must be insulated Connections in the engine bay or under the vehicle must be wat...

Page 45: ...doors the point of entry in the door must be lower than the hole in the door pillar This will prevent water water ingress into the vehicle Joints in the Wiring Harness If you must join wires use heat...

Page 46: ...nce WARNING Do not install wiring near the vehicles wiring harness for the ABS and traction control systems Electromagnetic interference can cause these systems to malfunction LEVC are not responsible...

Page 47: ...ach system is chosen depending on the accuracy and reliability requirements of the system Network types used on the vehicle include Flexray CAN LIN MOST and APIX2 Each network type communicates with o...

Page 48: ...Flexray network at 500 kbit s CAN is divided into six networks Domain Network Domain Master Chassis CAN Vehicle Dynamics Domain Master VDDM Propulsion CAN Vehicle Dynamics Domain Master VDDM Safety C...

Page 49: ...perating conditions with images of up to 720p resolution ASDM Active Safety Domain Master ACCM Air Condition Control Module ACM Alternator Control Module AUD Audio Module BBS Battery Backed up Sounder...

Page 50: ...and Antenna Module OBC On Board Charger OHC Overhead Console PAC Park Assist Camera PAM Parking Assist Module PDM Passenger Door Module PSCM Power Steering Control Module RLSM Rain and Light Sensor Mo...

Page 51: ...vehicle to do a Jump start Do not connect a battery charger directly to the 12V battery terminals in the vehicle Refer to the operators manual for the correct procedure The vehicle does not have a bel...

Page 52: ...ease the electrical output of the vehicle If the conversion requires the installation of additional electrical equipment you must make sure The conversion obeys local regulations The operators use of...

Page 53: ...p start Do not connect a battery charger directly to the 12V battery terminals in the vehicle Refer to the operators manual for the correct procedure CAUTION Do not obstruct or remove the 12V battery...

Page 54: ...from discharging the 12V battery Climate Control System WARNING Do not make changes to the climate control system The vehicle has air conditioning and a climate control system The air conditioning com...

Page 55: ...w emission zones For additional information refer to the operators manual or the workshop manual NOTE For additional information or technical support contact Aftersales LEVC com Information and Entert...

Page 56: ...wiring harness Do not install components that will obstruct the operators view or access to the instrument cluster touch screen display or buttons For information about the instrument panel displays...

Page 57: ...The vehicle has an exterior sound module to warn pedestrians when it moves at low speeds Do not connect additional lights or audible warning devices directly to the reversing lamp You must connect to...

Page 58: ...conversion use the correct procedure in the workshop manual NOTE For additional information or technical support contact Aftersales LEVC com Central Locking and Remote Key less Entry For information...

Page 59: ...necessary You must record the specification and location of the fuses and give this information to the operator Relays CAUTION Do not change the specification of the factory installed relays Only ins...

Page 60: ...erator module Micro 5 BF 06 High voltage coolant heater Air conditioning control module HVAC cooling shut off valve Chiller shut off valve Micro 5 BF 07 Battery cooling shut off valve Battery heating...

Page 61: ...4 12 volt socket front Micro 15 BF 25 Micro 5 BF 26 Micro 5 BF 27 Micro BF 28 LH headlamp unit Micro 15 BF 29 RH headlamp unit Micro 15 BF 30 Micro BF 31 Heated windscreen Left MCase shunt BF 32 Heate...

Page 62: ...ry restraint system Micro 5 BF 53 LH headlamp unit Micro 15 BF 54 Accelerator pedal sensor Micro 5 AF 55 Electronic gear selector module Micro 5 AF 56 Engine control module Micro 5 AF 57 Micro AF 58 M...

Page 63: ...ply 1 Power supply 2 Micro 20 AF 70 Spark plug 1 ignition coil 1 Spark plug 2 ignition coil 2 Spark plug 3 ignition coil 3 Micro 15 AF 71 MCase AF 72 MCase AF 73 MCase AF 74 Vacuum pump control unit M...

Page 64: ...Micro CF 14 Micro CF 15 Micro CF 16 Micro CF 17 Micro CF 18 Climate control module Micro 10 CF 19 Steering wheel lock Micro 7 5 CF 20 Diagnostic socket OBD II Micro 10 CF 21 Centre display Micro 5 CF...

Page 65: ...Case 40 CF 38 HVAC blower module rear MCase 40 CF 39 Multiband antenna module Micro 5 CF 40 Micro CF 41 Micro CF 42 Micro CF 43 Pump electronic module Micro 15 CF 44 PSR relay CPSR relay Micro 5 CF 45...

Page 66: ...e Amp Rating DF 01 MCase DF 02 MCase DF 03 MCase DF 04 MCase DF 05 MCase DF 06 MCase DF 07 MCase DF 08 MCase DF 09 MCase DF 10 MCase DF 11 MCase DF 12 MCase DF 13I ignition relay Micro 5 DF 14 Micro D...

Page 67: ...33 Micro DF 34 Micro DF 35 Micro DF 36 Micro DF 37 MCase Antennas Additional antennas can cause electrical interference If you install RF transmitters in the conversion you must do a test to make sur...

Page 68: ...ets you connect additional electrical equipment to the vehicles wiring harness The after market in line connector is attached to the floor on the opposite side of the vehicle to the drivers seat If th...

Page 69: ...round points in wet areas Do not attach ground connections to doors The hinges and rails do not give a good path to ground Do not install ground connections near the fuel tank or fuel pipes Do not att...

Page 70: ...minals This type of nut has a large surface area and a deformed female thread that locks to male threaded components Do not install more than two ring terminals on one stud The highest current draw te...

Page 71: ...the leaf spring and rear lower control arms requires special tools Do not remove the leaf spring or lower control arms unless you have the correct workshop manual procedure and the special tools CAUTI...

Page 72: ...ystem TPMS The vehicle is equipped with TPMS The system uses the wheel speed sensors to check for changes in the diameter of the tyres No sensors are attached to the wheels If the TPMS warning light i...

Page 73: ...airflow to the braking system Restrictions in air flow will cause the brakes to overheat The brakes and Electronic Stability Control ESC system are certified to the requirements of ECE R13H and ECE R1...

Page 74: ...hoses The hoses must have clearance to other components to allow the movement of the suspension and steering Parking Brake The parking brake is operated by an electronic motor on each rear brake cali...

Page 75: ...Aftersales LEVC com Cooling System General WARNING Do not make changes to the cooling system If you need to remove cooling system components for access during the conversion refer to the correct proce...

Page 76: ...CISG NOTE For additional information or technical support contact Aftersales LEVC com Exhaust System Exhaust system modifications CAUTION Changes to the exhaust system must be tested Changes must com...

Page 77: ...module from inside the vehicle The fuel tank must be removed to access the fuel delivery module For more information on the fuel and evaporative emissions systems refer to the workshop manual NOTE For...

Page 78: ...Powertrain 5 S023074 PA1 2020 05 12 77...

Page 79: ...e Pixel APIX2 page 46 B Battery guard page 52 Battery Monitoring System BMS page 52 Beacon page 38 Blue light page 8 Bluetooth page 55 Body page 20 Body mounting page 39 Body structure page 19 Brake S...

Page 80: ...rmation Module DIM page 46 53 55 Driver s seat page 32 E E heater page 74 Electrical page 20 42 Electrical Conversions page 50 Electromagnetic Compatibility EMC page 8 66 Electronic Engine Controls pa...

Page 81: ...20 Interior lights page 56 Interior trim page 31 J Jacking page 9 Joining wiring page 42 K Keep out zones page 33 53 55 Key page 57 L Lane departure warning page 56 Leaf spring page 70 Legal page 4 LE...

Page 82: ...31 33 Passenger s seat page 32 Performance page 8 Precautionary drill zones page 20 33 Pre tensioner page 33 Protection page 39 R Rack page 38 Racking page 26 Radio frequency page 8 Raising the vehic...

Page 83: ...pproval page 4 Tyre Pressure Monitoring System TPMS page 70 Tyres page 70 U Underbody page 39 V Vehicle duty page 8 Vehicle lifecycle page 8 Vehicle lift page 10 Vehicle storage page 11 Vehicle transp...

Page 84: ...Index S023074 PA1 2020 05 12 83...

Page 85: ......

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