Bosch
Overheating Connector / High Contact Resistance
Bosch EV charger cable or handle becomes unusually hot to the touch during charging.
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Worn J1772 contacts in handle, Contaminated or corroded pins, Undersized or damaged cable conductors, Loose crimp connections inside handle
How to Fix / Troubleshooting
Safety first: If the handle or cable is too hot to hold comfortably, stop charging immediately and turn OFF the breaker.
- Inspect connector: With power OFF, look for discoloration, pitting, or melting on the J1772 pins and plastic around them.
- Check cable routing: Ensure the cable is not coiled tightly or covered by insulating materials while charging, which can trap heat.
- Reduce current (if configurable): Temporarily lower the maximum current setting in the Bosch app or installer menu and see if heating is reduced.
- Replace cable assembly: Persistent overheating or visible damage indicates the Bosch J1772 cable/handle assembly must be replaced. Do not continue using an overheated connector.
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Repair Difficulty
Medium
3/5
Required Part
Bosch J1772 Charge Cable and Handle Assembly
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