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Anyone replaced charge cord on 240V Voltec Charger?

5.1K views 14 replies 8 participants last post by  butch9286  
#1 ·
Has anyone replaced the charge cord on the 240V Voltec Level 2 Charger? My handle keeps pulling apart and it finally has failed permanently. I have by the looks of it a 25ft Calgreen charge cord that has 4 wires in in Black White Green and Blue, the original has 5 Wires Black Red Green Grey and Purple I think.

I have tried wiring the new 4 wire cord in and it doesn’t seem to want to charge for some reason , I wired green to green black to black white to red and the blue to grey/purple

hoping someone can help here so I don’t have to buy a entire new charge station
 
#2 ·
Not me, but my local Chevy dealer has. They have a Voltec EVSE mounted on a pole just outside the service department. When I went to pick up my Volt, they had it charging there. I noticed they had replaced the original cable and plug with one from a Duosida! Now correct me if I’m wrong, but those EVSE’s were made by Lear and had an LED flashlight built into the handle. There may be an extra wire or 2 in the cable for the LED that aren’t necessary for a regular plug.
 
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#4 ·
Yeah, only Lear EVSE’s had that feature. The one that came with my 2015 has it, and it’s a Lear unit.

So how many wires in the old cable vs. the new?
 
#5 ·
I replaced mine with a different brand (maybe Yazaki?) that I found on eBay. Took me a while to figure out that I just needed to ignore the LED wire that the original had. It works fine.
The original was poorly made. The wires were molded into the plastic/rubber casing and one was near the surface. It failed (open.) Couldn't be repaired, since I had to destroy the handle to get to the wires. Bad engineering.
 
#7 ·
I'm using a Duosida 240V portable EVSE that I "mounted" just inside my garage. It's plugged into a 240v 20 amp circuit. The cable comes out under the garage door. My Volt's Clipper Creek OEM EVSE is plugged into a 20 amp 120v circuit and "mounted" on the other side of the garage charging my wife's Clarity PHEV. These two EVSEs have 25 ft cables so they have good reach on my driveway. The Clarity's Honda EVSE (not sure the actual manufacturer) and a 40 ft 10x3 all weather extension cord are my portable kit.
 
#11 ·
It's definitely possible to use a 4-wire cord on the Voltec branded wall unit. I've done it. I just can't remember which of the 5 original wires is for the LED and can be eliminated. I think it was the grey with purple stripe. But you can probably get away with attaching the 3 fat wires and then playing Russian Roulette with the small signal wire until it works.
 
#12 ·