Splitvolt
Overheating Cable / Connector
Splitvolt EV charger cable or J1772 handle becomes excessively hot during charging.
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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
High resistance at connector pins, Worn or contaminated contacts, Undersized or damaged cable conductors, Loose crimp inside handle
How to Fix / Troubleshooting
Safety first: If you notice melting plastic, smoke, or burning smell, turn off the breaker immediately and do not use the charger.
- Monitor temperature: During a charge, periodically feel the cable and handle. Warm is normal; too hot to hold comfortably is not.
- Inspect connector: With power OFF, examine the J1772 pins for discoloration, pitting, or deformation. Replace the cable/handle assembly if damage is found.
- Check for kinks or crushing: Avoid tight bends or running the cable under doors or tires, which can damage conductors and increase heating.
- Reduce current: If your Splitvolt supports it, lower the charging current to reduce heating until the cable can be replaced.
- Replace affected parts: Overheated connectors should not be reused; install a new Splitvolt cable/handle assembly.
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Repair Difficulty
Medium
3/5
Required Part
EV Charging Cable Assembly
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