Bus Bar Safety Covers

This topic provides information on replacing bus bar safety covers.

Required Tools and Materials

T25 security screwdriver

8 mm socket

T20 security screwdriver

    

Before You Begin

  1. Power off the charging station.

  2. Lift charging cable connector off the holster.

  3. Determine if the Power Link 1000 has preassembled covers or unassembled components, remove them as necessary.

  4. Open the upper and/or lower door.

AFTER REPLACING A SAFETY COVER, REVERSE THE ABOVE STEPS TO COMPLETE THE SERVICE.

Replace DC Smart Cable Bus Bar Safety Cover

To replace the DC smart cable bus bar safety cover, complete the following steps:

  1. Loosen the M4 screws (x2) (use T20 Torx screwdriver). Do not remove completely.

    While reinstalling torque the screws to 1.7 Nm (15 in-lb).

    Loosen the two M4 screws using T20 Torx screwdriver, but do not remove completely. While reinstalling torque the screws to 1.7 Nm or 15 ln-lb

  2. Slightly slide the cover up to disengage the keyholes and remove it.

REVERSE THE ABOVE STEPS TO REINSTALL THE COVER.

Replace L Shaped Bus Bar Safety Cover

To replace the L shaped bus bar safety cover, complete the following steps:

  1. Loosen the M5 nuts (x3) (use 8 mm socket). Do not remove completely.

    While reinstalling torque the screws to 2.8 Nm (25 in-lb).

    Loosen the three M5 nuts using 8 mm socket. Do not remove completely. While reinstalling torque the screws to 2.8 Nm or 25 ln-lb

  2. Slightly slide the cover up to disengage the keyholes and remove it.

REVERSE THE ABOVE STEPS TO REINSTALL THE COVER.

Replace Upper Bus Bar Safety Cover

To replace the upper bus bar safety cover, complete the following steps:

  1. Disconnect the Ethernet cable from the Ethernet surge suppressor.

    Disconnect the Ethernet cable from the Ethernet surge suppressor.

  2. Loosen the M4 screws (x2) (use T20 security screwdriver). Do not remove completely.

    While reinstalling torque the screws to 1.7 Nm (15 in-lb).

    Loosen the two M4 screws using T20 security screwdriver. Do not remove completely. While reinstalling torque the screws to 1.7 Nm or 15 in-lb

  3. Remove the cover.

    Remove the cover.

REVERSE THE ABOVE STEPS TO REINSTALL THE COVER.

Replace Lower Bus Bar Safety Cover

To replace the lower bus bar safety cover, complete the following steps:

Remove

  1. Loosen the M5 screws (x3) (use T25 security screwdriver) on the right side.

    Loosen the three M5 screws using T25 security screwdriver on the right side.

  2. Tilt out and slide the cover out of the slots on the left side.

    Tilt out and slide the cover out of the slots on the left side.

Reinstall

  1. Slide in the panel behind the slots on the left.

    Slide in the panel behind the slots on the left.

  2. Install screws (x3) (use T25 security screwdriver) on the right side. Torque to 2.8 Nm (25 in-lb).

    Install three screws using T25 security screwdriver on the right side. Torque to 2.8 Nm or 25 in-lb.