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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