ABB Overheating Connector / High Contact Resistance

Charger’s cable or connector becomes excessively hot during charging, sometimes with a plastic smell.

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Possible Causes

Worn or contaminated connector contacts, Loose crimp or termination in connector, Undersized or damaged cable conductors, Prolonged operation at maximum current in high ambient temperature

How to Fix / Troubleshooting

Fire risk: Stop using the charger immediately if you notice melting or burning.

  • Inspect connector: Look for discoloration, warping, or burn marks on the plug and vehicle inlet. Do not continue using a damaged connector.
  • Clean contacts: If only light contamination is present, clean the connector pins with approved electrical contact cleaner and a lint-free swab.
  • Reduce current: Temporarily lower the maximum charging current in the ABB settings to reduce heating.
  • Replace cable assembly: If there is any sign of melting or persistent overheating, replace the ABB tethered cable and connector assembly.
  • Check vehicle inlet: If the vehicle inlet is damaged or loose, have it inspected by the vehicle manufacturer’s service center.
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Repair Difficulty

Easy 2/5

Required Part

Tethered Charge Cable and Connector
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