MUSTART Overheating Connector / High Contact Resistance

Charger’s cable or J1772 handle becomes very hot to the touch during normal charging, even at rated 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 contaminated J1772 contacts, partially inserted connector, internal crimp failure in cable, undersized or damaged cable conductors

How to Fix / Troubleshooting

Safety warning: Overheated connectors are a fire risk. If the handle is too hot to hold comfortably, stop charging immediately.

  • Stop charging: Unplug the charger from the EV and wall (if portable) and allow everything to cool.
  • Inspect connector: Look for discoloration, melted plastic, or deformed pins on the MUSTART J1772 handle.
  • Clean gently: Use a dry brush or compressed air to remove debris from the connector. Do not use lubricants or contact sprays.
  • Reduce current: If your model allows, lower the current setting and monitor temperature closely on the next session.
  • Replace cable if damage found: Any visible melting or deformation means the J1772 cable assembly should be replaced.
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Repair Difficulty

Medium 3/5

Required Part

J1772 Charging Cable Assembly
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