HELP! Broken plug on my Hymotion kit.

Can't you just buy and replace the plug?

Hymotion may have gone the way of the Allosaurus, but the plug should be standard.
DIY or have a wrench do it for you.

It should be pretty easy, or am I missing something about the Hymotion plug?

 

Take a picture and post it. It has to be a COTS (commercial off the shelf) item.
I'm thinking that it's a bolt-on replacement.

If you're living right, you won't even have to break out a soldering iron.
It should just be some bolts and screws.

 

As it was said before; in your case, better get the help of a "wrench" with some electrical background.

 

For instance:

HUBBELL HBL61CM64BK AC Inlet NEMA 5-15 Male Black Marine - Amazon.com

But without a picture of your current plug, it's hard to help you.

 

Uh.....they have the internet and FedEx in the frozen North.....right?

1. Find something close.
MARINCO Inlet at West Marine

2. Order it delivered.

3. Break out a screwdriver set and do a lift and lay on the wires.

4. Bask in the warm glow of your accomplishment.

 

There is a very knowledgeable EV tech on the forum that goes by the screenname ericbecky here on PriusChat. I would bet he could get you going in the right direction or maybe even sell you one. If you do a search on his screenname and find a post of his, all of his contact information is in his signature line.

I had the same thing happen to my Hymotion plug, but fortunately it happened before the bankruptcy. They ended up sending me a new unit, which consisted of the receptacle pictured, plus about a foot of insulated wires that had to be connected/spliced to the pack. I took it to a Toyota dealer that used to do Hymotion installs and they fixed it in a few hours. The Hymotion pack seemed to charge fine with the broken ground, though, until the repair was made.

 

The electrical outlet seem to be riveted-in the bumper, nothing that a drill bit can't solve......
Eric can be easily reach troughh his website

 

Good luck with the project. I had my Hymotion Conversion done just two years ago, right before some rebates expired. Because I had read here on PC about others having this same problem, I have always been very careful to pull the extension cord straight out & push it straight in. Apparently, that ground terminal on the Guest unit is pretty fragile. Here's a couple of things that might help prevent this in the future. About four times a year I coat the three terminals a Synthetic Grease, (Super Lube). It makes plugging & unplugging smooth and easy. I also put a switch where the extension cord plugs into the wall, and keep it OFF when connecting or disconnecting the cord. I didn't like seeing a Spark when I did the plugging / unplugging. Others have mentioned that using two small a wire gauge can cause excess heat at the connection. I am using a 14/3 AWG 15 foot cord. If I needed a longer cord, I would probably go with a 12/3 AWG. Again, Good Luck!

 

Great Job!

 

Sorry I didn't see this thread earlier. You can order a cord repair kit from Sybesmas Electronics in Holland MI. They were the warranty service center for Hymotion and now have the largest inventory of Hymotion parts anywhere.

www.sybesmas.com

This is probably the most common failure mode with Hymotion packs. A good way to prevent this is to use dielectric grease on the plug and any cords used to plug the car in. This lubricates the pins, preventing large amounts of pulling and pushing force from being applied to the pins of the plug when making or breaking the connection.

Glad to see you were able to make the repair on your own. Hopefully this info will help others who may have the same issue.