You’re about to save me Mayfield Marine. I also bought the same connector from Amazon to fix a plug that fell apart after 7+ years. I started on my own and got stuck at how to the wires get transferred over to the new plug. Your video explains that in more detail than I need but that shows you know what you’re doing even if this is for “entertainment” purpose. You’re a very smart Marine!
@@brandonjmayfield I’m curious are you an electrician these days or just a knowledgeable guy? Your editing of the video is well done given its not a fun subject. Are you planning on more videos?
@@victorlukito EE by schooling, always been a DIY. Best lesson I ever had was at 14 when a shift lever in my dirt bike's transmission broke. Looked like way too much for me to tackle, and I could not afford to pay for the repair. Local mechanic said "What's the worst that can happen? You get it apart and can't get it back together, put all the parts in a box and bring it to me." That was enough for me to attempt and successfully fix it myself.
Thanks for the kind words. I now have Honda Clarity plug-in hybrid, and I'll try to get the time to do a personal comparison between them at some point.
Thanks Ed, great to be able to provide something to the community. I've gotten much useful guidance from RUclips over the years, this was my opportunity to contribute.
i love the diy aspect of this, and its amazing to be able make repairs in the field to get you going. I LOVE THAT..... however....... you can buy one of these chargers for $160 soooooo
160$ must be a shitty charger. the OEM charger is like 400$. that part on ali-express is 60$ with shipping. either you're both doing the planet a service and saving yourself some cash
10:58 The wire gauge appears too thin explains why someone had reported the wires on fire and a recall was issued, if I remembered correctly. If you take it in they'll only force the computer to slow charge - an extra inconvenience. I recommend that people upgrade their wires or charge only at 8-Amps or less.
Hi David, interesting I had not heard there were any overheating problems. Can't recall just now if I mentioned this in the video, but since I am on the same circuit as a garage refrigerator I always charge at 8 amps. I'll get a dedicated line at some point.
Thank you for the video! What I'm struggling to understand is - where is the circuitry in this connector/handle (specifically R6 150) which I'd need to remove to build an extension cord?
Hi Michael, There are a number of problems with this, I would give it some serious thought. Keep in mind David's comment about overheating. Increasing the wire length will increase the total resistance and could result in overheating. You would want to make sure you have the proper wire gauge. You can find tables on the internet that show the voltage drops for different wire sizes and lengths, I would keep the voltage drop to 0.5% or less! The wire itself is not going to be easy to find, because in addition to the 3 AC wires you need the two low voltage signal wires. It needs to be flexible and have an insulating jacket that is oil and gas resistant. It should be reasonably resistant to sunlight and ozone and even more so if you use it outdoors frequently. I would look around for more videos on disassembling the EVSE and the car plug. The GM car plug circuitry is encapsulated in silicone rubber or something similar and extremely difficult to take apart. Perhaps a heat gun would help. I threw my original plug away as I was replacing it. Good luck
Someone recently cut off my j1772 adapter off the charging cord and some sort of vandalism oh, I have my new adapter but I got to say I'm still kind lost after watching this video as how to get it replaced.
HI Firstly great video and thank you. Now for a question. Could you not crimp an extra 20 gauge wire in with the ground and leave the ground wire whole? I am sure there are reasons you would not do this but asking for a friend. :)
It's been a while, but as I recall I was mostly worried that the rubber gasket that is meant to keep out any moisture might not do its job with two wires in the hole. I suppose you could put a little RTV in there. Having said that, the pins are very hard to crimp which makes it hard to keep the wire fully inserted while crimping. A hydraulic crimper might help.
Hi Yolie, I assume you mean the thumb latch on the plug that connects it to the car's socket. While it is possible to get to the mechanism itself, There are no replacement parts available from any source I know of. GM only sells the complete unit and the actual manufacturer of the unit, which is not GM, is prohibited from selling parts for it by their contract as I understand it. You can try reaching out to TusconEV , who I mention in the text section below the video. It is possible they can help you out. I have only these two suggestions that may work or that may give you other ideas if you are adventurous enough to try. The first is to find someone who has the ability to make a replacement latch of a suitable material, perhaps someone with a 3D printer or even someone who works with fiberglass reinforced resins like boat hulls are made from. If you know someone in that business, or have a sailor friend who does their own work they may be willing to help you out. Some cold beers on a hot afternoon open many doors. The second is to repair the existing part, but it only works in certain cases where there is a clean break leaving enough material on both sides of the break to work with. If this is the little hook part of the latch it will probably not work and it is likely that part is lost anyhow. I once did something similar by drilling a very carefully aligned small hole in both pieces; I then inserted a very stiff wire/round stock in both sides, gluing the two pieces and the wire together with epoxy. It worked and was very strong, I thought it might be a temporary repair and turned out to be permanent. The wire should be stiff enough to support the entire working load of operation. There is a movement afoot, mostly in Europe at this point I think, to institute rules requiring manufacturers to produce products that are repairable rather than disposable. I am a big fan of this sort of thing. It enables those that are so inclined, supports cottage industries, and is the right environmental choice. We should be making things to last and be repairable, even if initial costs are higher, in my opinion. Good Luck!
You forgot a very important step... the way you've assembled it the whole black pin holder can be pulled out. Your forgot to screw the black plug holder into the black plug housing... Very Dangerous!
You have good eyes! Actually I did screw the pin holder down, right around 11:29 but those frames apparently wound up on the cutting room floor. As I recall, when you are doing this it would be hard to miss, as the pins pull out fairly easily without it. But I am glad you point this out for anyone reading and doing this repair., thank you.
Thanks, replaced the exact same plug with the exact same as yours. 2014 Fiat500e charger. Bought the new plug from China for 26 dollar.
Excellent video! Our charger plug at work broke and I bought this exact same connector on Amazon. This was super helpful.
I'm glad to hear this was a help to you! Thank you for the feedback.
You’re about to save me Mayfield Marine. I also bought the same connector from Amazon to fix a plug that fell apart after 7+ years. I started on my own and got stuck at how to the wires get transferred over to the new plug. Your video explains that in more detail than I need but that shows you know what you’re doing even if this is for “entertainment” purpose. You’re a very smart Marine!
Hi Victor, I very much appreciate the kind words and hope your repair went successfully.
@@brandonjmayfield I’m curious are you an electrician these days or just a knowledgeable guy? Your editing of the video is well done given its not a fun subject. Are you planning on more videos?
@@victorlukito EE by schooling, always been a DIY. Best lesson I ever had was at 14 when a shift lever in my dirt bike's transmission broke. Looked like way too much for me to tackle, and I could not afford to pay for the repair. Local mechanic said "What's the worst that can happen? You get it apart and can't get it back together, put all the parts in a box and bring it to me." That was enough for me to attempt and successfully fix it myself.
Well done. Thanks for the detailed walk through and explanation.
Great video. Loved the materials overview at the end. Thanks for making this.
Thanks for watching, glad you liked it!
Great video and good explanation of the diagram
This was very helpful to watch! Thanks for sharing!
God job. The connector of my teacher's cart is damaged, 148 ohms and 0.473 ohms.
Thank you very much! Fellow Volt owner and hobby RUclipsr, you did a great job on this video. Keep up the good work. From Chicago IL Jay
Thanks for the kind words. I now have Honda Clarity plug-in hybrid, and I'll try to get the time to do a personal comparison between them at some point.
Great video! Thank you
Thanks Ed, great to be able to provide something to the community. I've gotten much useful guidance from RUclips over the years, this was my opportunity to contribute.
i love the diy aspect of this, and its amazing to be able make repairs in the field to get you going. I LOVE THAT..... however....... you can buy one of these chargers for $160 soooooo
160$ must be a shitty charger. the OEM charger is like 400$. that part on ali-express is 60$ with shipping. either you're both doing the planet a service and saving yourself some cash
Yeah I've seen those on Amazon. If you get one let us know your experience with it. I was thinking of trying one in level II.
You saved me, thank you
Great video, thank you so much for sharing it.
10:58 The wire gauge appears too thin explains why someone had reported the wires on fire and a recall was issued, if I remembered correctly. If you take it in they'll only force the computer to slow charge - an extra inconvenience. I recommend that people upgrade their wires or charge only at 8-Amps or less.
Hi David, interesting I had not heard there were any overheating problems. Can't recall just now if I mentioned this in the video, but since I am on the same circuit as a garage refrigerator I always charge at 8 amps. I'll get a dedicated line at some point.
Thank you for the video! What I'm struggling to understand is - where is the circuitry in this connector/handle (specifically R6 150) which I'd need to remove to build an extension cord?
Hi Michael,
There are a number of problems with this, I would give it some serious thought.
Keep in mind David's comment about overheating. Increasing the wire length will increase the total resistance and could result in overheating. You would want to make sure you have the proper wire gauge. You can find tables on the internet that show the voltage drops for different wire sizes and lengths, I would keep the voltage drop to 0.5% or less!
The wire itself is not going to be easy to find, because in addition to the 3 AC wires you need the two low voltage signal wires. It needs to be flexible and have an insulating jacket that is oil and gas resistant. It should be reasonably resistant to sunlight and ozone and even more so if you use it outdoors frequently.
I would look around for more videos on disassembling the EVSE and the car plug. The GM car plug circuitry is encapsulated in silicone rubber or something similar and extremely difficult to take apart. Perhaps a heat gun would help. I threw my original plug away as I was replacing it.
Good luck
How would you negotiate connecting this to an array of solar panels to DC direct charge you bolt?
I'm reading 50 - 350 KW. Huge array. As an example 50 KW / 500 V = 100 A. For the low end of level 3.
Great video. Thanks. I am trying to find a latch connector for the j1772. Do you know of anywhere they may be obtained?
Sorry Steve, I do not. You might reach out to TusconEV (see above) and see if they have or can get what you need.
Someone recently cut off my j1772 adapter off the charging cord and some sort of vandalism oh, I have my new adapter but I got to say I'm still kind lost after watching this video as how to get it replaced.
HI
Firstly great video and thank you. Now for a question. Could you not crimp an extra 20 gauge wire in with the ground and leave the ground wire whole? I am sure there are reasons you would not do this but asking for a friend. :)
It's been a while, but as I recall I was mostly worried that the rubber gasket that is meant to keep out any moisture might not do its job with two wires in the hole. I suppose you could put a little RTV in there. Having said that, the pins are very hard to crimp which makes it hard to keep the wire fully inserted while crimping. A hydraulic crimper might help.
How do I replace the latch on the charger to lock the battery in?
Hi Yolie,
I assume you mean the thumb latch on the plug that connects it to the car's socket.
While it is possible to get to the mechanism itself, There are no replacement parts available from any source I know of. GM only sells the complete unit and the actual manufacturer of the unit, which is not GM, is prohibited from selling parts for it by their contract as I understand it.
You can try reaching out to TusconEV , who I mention in the text section below the video. It is possible they can help you out.
I have only these two suggestions that may work or that may give you other ideas if you are adventurous enough to try.
The first is to find someone who has the ability to make a replacement latch of a suitable material, perhaps someone with a 3D printer or even someone who works with fiberglass reinforced resins like boat hulls are made from. If you know someone in that business, or have a sailor friend who does their own work they may be willing to help you out. Some cold beers on a hot afternoon open many doors.
The second is to repair the existing part, but it only works in certain cases where there is a clean break leaving enough material on both sides of the break to work with. If this is the little hook part of the latch it will probably not work and it is likely that part is lost anyhow. I once did something similar by drilling a very carefully aligned small hole in both pieces; I then inserted a very stiff wire/round stock in both sides, gluing the two pieces and the wire together with epoxy. It worked and was very strong, I thought it might be a temporary repair and turned out to be permanent. The wire should be stiff enough to support the entire working load of operation.
There is a movement afoot, mostly in Europe at this point I think, to institute rules requiring manufacturers to produce products that are repairable rather than disposable. I am a big fan of this sort of thing. It enables those that are so inclined, supports cottage industries, and is the right environmental choice. We should be making things to last and be repairable, even if initial costs are higher, in my opinion.
Good Luck!
You forgot a very important step... the way you've assembled it the whole black pin holder can be pulled out. Your forgot to screw the black plug holder into the black plug housing... Very Dangerous!
You have good eyes! Actually I did screw the pin holder down, right around 11:29 but those frames apparently wound up on the cutting room floor. As I recall, when you are doing this it would be hard to miss, as the pins pull out fairly easily without it. But I am glad you point this out for anyone reading and doing this repair., thank you.
Looks like the plug is $99 now, up from $88 at that time. The plug is from China, the only source I was able to find.
Ebay currently has one for $64 so the price is fluctuating.
Amazon link is broken now. :(
@@emmettturner9452 Yeah, THAT surprises me not at all. :-)
check ali-express