Heidelberg Connector Overheating / High Contact Resistance

Charging cable gets unusually warm during charging, especially near the plug or strain relief, but no error code is shown.

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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 loosened contacts in Type 2 plug, Undersized or damaged tethered cable, Loose terminal screws inside charger, Corroded pins increasing resistance

How to Fix / Troubleshooting

Safety first: Overheating can lead to fire. If the plug or cable is too hot to touch, stop charging immediately and isolate power.

  • 1. Stop charging:
    • End the charging session via vehicle or charger controls.
    • Unplug the connector and allow it to cool.
  • 2. Inspect for damage:
    • Look for discoloration, melting, or deformation on the plug, socket, and cable.
  • 3. Check internal terminals:
    • With power off, open the charger and inspect the output terminals and contactor connections.
    • Retighten any loose screws to specified torque.
  • 4. Reduce current temporarily:
    • If your Heidelberg model allows, lower the maximum charging current in settings and monitor temperature.
  • 5. Replace worn components:
    • If contacts are visibly damaged or overheating persists, replace the tethered cable assembly or Type 2 plug with Heidelberg‑approved parts.
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Repair Difficulty

Medium 3/5

Required Part

Tethered Charging Cable
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