Schumacher High-Resistance Connection / Overheating Conductors

Charger or cable becomes excessively hot during normal charging, but no error code appears.

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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 terminal lugs inside charger, Undersized supply wiring, Worn J1772 connector contacts, Corroded vehicle inlet pins

How to Fix / Troubleshooting

Safety first: If any part of the charger or cable is too hot to touch comfortably, stop charging and turn OFF the breaker.

  • Check cable and handle: Look for discoloration or softening of the plastic near the handle. Replace the handle/cable assembly if any damage is found.
  • Inspect internal lugs (qualified only): With power OFF, open the charger and check that all line and load lugs are torqued to the manufacturer’s specifications.
  • Verify wire size: Have an electrician confirm that the branch circuit wire gauge matches the charger’s current rating and run length.
  • Reduce current (if adjustable): Temporarily lower the charger’s output current setting to reduce heating until permanent corrections are made.
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Repair Difficulty

Hard 4/5

Required Part

J1772 Charge Handle and Cable Assembly
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