JuiceBox
Overheating of Cable or Internal Connections
Charger or cable becomes excessively hot during normal charging; plastic may feel soft or discolored.
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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
Loose input or output terminals, Undersized branch circuit wiring, Damaged or high-resistance J1772 connector, Failing main power contactor with pitted contacts
How to Fix / Troubleshooting
Safety first: Overheating is a fire hazard. Turn off power at the breaker and stop using the charger until the cause is identified and corrected.
- Inspect J1772 handle: Look for discoloration, melted plastic, or deformation around the pins. If present, replace the J1772 charge cable assembly.
- Check input wiring (power OFF): Open the unit and inspect the input terminal block and contactor lugs. Tighten any loose screws and look for signs of arcing or heat damage. Replace any burned terminal blocks or contactors.
- Verify circuit sizing: Confirm that the breaker and wiring gauge match the JuiceBox's maximum current. If the circuit is undersized, have an electrician upgrade it.
- Reduce current setting: Temporarily lower the maximum current in the app to reduce heating until permanent repairs are made.
- Do not ignore recurring heat: If overheating continues after tightening and inspection, replace the suspect components and consider having a professional evaluate the installation.
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Repair Difficulty
Hard
4/5
Required Part
J1772 Charge Cable Assembly
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