EvoCharge
Overheating Connector / High-Resistance Joint
Charger cable or J1772 handle becomes very hot during charging, even at normal current.
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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 or loose J1772 contact pins, Corroded connector contacts, Undersized or damaged output cable, Loose crimp inside handle
How to Fix / Troubleshooting
Safety first: Stop charging immediately if you notice excessive heat or burning smell. Allow components to cool before handling.
- 1. Visual inspection: Check the J1772 handle for discoloration, melted plastic, or deformation. Inspect the cable near the handle for soft spots or bulges.
- 2. Clean contacts: If no severe damage is visible, clean the connector pins with electrical contact cleaner and a soft brush. Do not use abrasive tools.
- 3. Check vehicle inlet: Inspect the vehicle’s charge port for dirt or bent pins that could cause poor contact.
- 4. Reduce current (if configurable): Temporarily lower the EvoCharge maximum current setting and observe if heating is reduced.
- 5. Replace cable/handle assembly: If overheating persists or any damage is visible, replace the entire EvoCharge J1772 cable and handle assembly. Internal crimps and contacts are not field-serviceable.
Continued use of an overheating connector is a fire hazard and can damage the vehicle inlet.
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Repair Difficulty
Medium
3/5
Required Part
J1772 Charge Handle and Cable Assembly
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