Charging Cable (LCC and Non-LCC)

This section provides instructions for replacing the charging cable in the Power Link 2000.

Service instructions are given for both liquid cooled cables (LCC Liquid Cooled Cable) and non-LCC Liquid Cooled Cable.

Liquid cooled cable (LCC Liquid Cooled Cable)	Non-LCC Liquid Cooled Cable

Required Tools and Materials

	Stepladder	v	T20 Torx screwdriver
	T25 Security screwdriver		Hex socket set (10 mm for ground and HV DC High Voltage Direct Current wire lug nuts, and 7 mm for LCC Liquid Cooled Cable coolant hose retaining clips)
	Clean rags (only for LCC Liquid Cooled Cable)		ChargePoint coolant (only for LCC Liquid Cooled Cable)
	Funnel (only for LCC Liquid Cooled Cable to pour in coolant)

Before You Begin

Before servicing the component, complete the following steps:

1. Power off.

2. Remove these:

   1. Top cap

   2. Front lower cover

   3. Front upper cover

3. Open both the upper and lower doors.

   The lower door only needs to be opened when servicing an LCC Liquid Cooled Cable cable. It does not need to be opened for servicing a non-LCC Liquid Cooled Cable cable.

4. Determine which charging cable (left or right) you want to replace.

5. Remove these:

   1. Cable cap

   2. Side panel (do not remove this if replacing a non-LCC Liquid Cooled Cable cable)

   3. Charging cable bus bar safety cover

   4. DC power path bus bar safety cover

After replacing the components, reverse the above steps to complete the service.

Replace the Charging Cable

To replace the charging cable, complete all steps given below.

Release the cable

1. Loosen the tetherball screw (if present).

   

   Torque to 2.8 Nm (25 in-lb).

2. Hold the tetherball and gently push it up to unlatch the spring. The spring tab flips downward.

   

3. Hold down the spring tab.

   

4. Remove tetherball from the tether pin to release the cable.

   Place the cable on a padded surface to avoid scratches on the cable's surface.

   

   Align the spring with flat notch on the tether pin and gently push the tetherball onto the pin to suspend the cable as shown in the image below.

   

Replace the cable

1. Disconnect the wires and cables of a charging cable that you are replacing.

   The illustrated cable connections on the left side and right side are for the left side and right side charging cables, respectively.

   1. Press the latch and pull the connectors to disconnect the cables (x2; P238-23, and P317-2-06 or P317-1-06).

   2. Remove the lug nuts (x4, per red and black HV DC High Voltage Direct Current wires; and x1, per green ground wires).

   Non-LCC Liquid Cooled Cable wire and cable connections

   LCC Liquid Cooled Cable wire and cable connections

   
   
   

   • Connect red HV DC High Voltage Direct Current wires to positive (+) and black HV DC High Voltage Direct Current wires to negative (-) pole.

   • Torque all lug nuts to 5.6 Nm (50 in-lb).

   • Find the label on each cable to plug its connector back into its correct receptacle connector.

   • To reconnect, plug in. The connector latch must snap onto the receptacle with a click sound to ensure that the connection is secure.

2. (Skip this step for non-LCC Liquid Cooled Cable) Press the latch and pull the connector to disconnect the hoses (x3, per charging cable).

   While disconnecting, use a clean rag to catch and wipe off any coolant residue on the connectors.

   

   
   
   

   • To reconnect, plug in. The connector latch must snap onto the receptacle with a click sound to ensure that the connection is secure.

   • Top up or refill coolant.

3. (Skip this step for non-LCC Liquid Cooled Cable) Remove the hex nuts (x2, per charging cable) to detach the coolant hose retaining clips.

   

   Torque these nuts to 1.7 Nm (15 in-lb).

4. Loosen the screws (x4, per charging cable).

   

   Torque these screws to 4.5 Nm (40 in-lb).

5. Remove cable assembly from studs (a) (x2) and route all wires out of the Power Link 2000.

   

   • Route only the positive (red) and negative (black) HV DC High Voltage Direct Current wires through the Ferrite ring (b). Route the other wires below the Ferrite ring.

   • Ensure no small cables get pinched between the charging cable assembly enclosure and the frame when installing.

Reverse the above steps to reinstall with replacement FRU Field Replaceable Unit.