Replace the DC Contact

To replace the DC contacts and front cover on a Phoenix Liquid Cooled Cable (LCCClosed Liquid Cooled Cable) CCS1 assembly, perform the following steps. These instructions apply only to assemblies identified by the approved Express Plus SKUs listed below.

List of SKUs

Part Number

Description
99-007905-02-FT EXPP-PL202X1BC-FTA
99-007910-01 EXPP-PL2011BC-6A1S1-MB
99-007910-02 EXPP-PL2011BC-6A1S1
99-007910-02-FH EXPP-PL2011BC-6A1S1-FHWA-A
99-007910-02-FT EXPP-PL2011BC-6A1S1-FTA-A
99-007911-01 EXPP-PL202X1BC-6A1S1-6A1S1-MB
99-007911-02 EXPP-PL202X1BC-6A1S1-6A1S1
99-007911-02-FH EXPP-PL202X1BC-6A1S1-6A1S1-FHWA
99-007911-02-FT EXPP-PL202X1BC-6A1S1-6A1S1-FTA-A
99-007911-03 EXPP-PL202X1BC-6A1S1-6A1S1-A
99-007916-02 EXPP-PL202X1BC-6A1S1
99-007916-02-FH EXPP-PL202X1BC-6A1S1-FHWA-A
99-007925-01 EXPP-PL202X1DC-6A6S1-6A6S1-A

Required Tools and Materials

Tools and Materials

Torque adjustable screwdriver with 1/4‑inch hex bit holder (10–19 in-lb range)

Orange and white icon that represents a tool or action.

T5 Torx bit

Inspect the Box for Contents

The replacement kit for DC Contact and Front Cover includes:

  1. DC Contacts (x2)

  2. S2 T20 Screw Bit

  3. DC Contact Screw Washers (x2)

  4. M4X10-5TX short screws (x5) (Included in applicable kits only)

  5. Front Cover (Included in applicable kits only)

Before you begin

  1. Power Off.

  2. Remove the charging cable connectors from the holster.

Replace the DC Contact

  1. Using the T5 screwdriver, remove the five M4x10‑5TX screws securing the front cover.

    A typical LCCClosed Liquid Cooled Cable CCS1 DC-connector profile is shown for reference.

  2. Remove the front cover and set it aside.

  3. Using the S2 T20 screwdriver, remove the two DC contact screws and their washers.

    Do not reuse the removed screws or washers.

  4. Install the two new DC contacts with the new screws and washers.

    Ensure the washer is placed between the screw and the DC contact.

  5. Torque the screws (x2) to 2.2 Nm (19 in‑lb).

  6. Using the T5 screwdriver, install the five M4x10‑5TX screws to secure the front cover.

    If available, use the new front cover and new screws.

  7. Torque the screws (x5) to 1.2 Nm (10 in‑lb).

  8. Place charging cable connectors into the holsters.