Electrify America Mechanical Cable Damage / Insulation Failure

Charger cable is physically damaged – cuts, deep abrasions, or exposed conductors visible.

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Possible Causes

Vehicle driven over cable, Cable pinched in garage door, UV or chemical degradation of jacket, Animal chewing

How to Fix / Troubleshooting

Safety first: Do not use the charger if any conductor is exposed or the cable jacket is compromised.

  • Step 1 – De‑energize: Turn off the breaker before handling the damaged cable.
  • Step 2 – Inspect extent of damage: Determine whether damage is localized or extends along a long section of the cable.
  • Step 3 – Do not tape over: Do not attempt to repair the cable with tape or generic heat‑shrink; this is unsafe for EV charging currents.
  • Step 4 – Replace cable assembly: Order and install a replacement Electrify America cable and handle assembly. Ensure proper strain relief and torque at the termination point.
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Repair Difficulty

Easy 2/5

Required Part

Charge Cable and Handle Assembly
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