Megear Localized Overheating at Connector or Cable

Charger cable or J1772 handle feels unusually warm or hot during charging.

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Possible Causes

Worn or loose J1772 contacts, Undersized or damaged conductors in cable, Poor crimp or solder joint inside handle, Continuous operation at maximum current with marginal connections

How to Fix / Troubleshooting

Safety first: Stop charging and allow the cable to cool if it becomes very hot. Overheated connectors can fail catastrophically.

  • 1. Inspect J1772 contacts:
    • Look for discoloration, pitting, or deformation of the metal contacts.
    • If contacts are damaged, replace the cable assembly.
  • 2. Check strain relief:
    • Ensure the cable is not sharply bent at the handle or charger end.
  • 3. Reduce current:
    • If your Megear model or vehicle allows, lower the charging current setting.
  • 4. Replace cable if in doubt:
    • Any sign of melting, burning smell, or soft spots in the cable jacket means the cable should be replaced immediately.

Do not continue using a cable that overheats; it is a fire risk.

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Repair Difficulty

Easy 2/5

Required Part

Megear J1772 Charge Cable Assembly
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