Sun Country Highway High Resistance Connection in J1772 Handle or Cable

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

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Possible Causes

Worn or spread contacts in J1772 handle, Corroded pins, Undersized or damaged conductors in cable, Loose crimp connections inside handle

How to Fix / Troubleshooting

Safety first: Stop charging and allow the connector to cool before inspection.

  • Inspect handle contacts: Look for discoloration, pitting, or melting around the power pins. Any damage requires replacement of the handle/cable assembly.
  • Check cable for kinks: Avoid tight bends or coiling the cable tightly during use, which can concentrate heat.
  • Monitor temperature: During a test charge, periodically touch the cable (it may be warm but should not be too hot to hold). If it overheats, replace the cable assembly.
  • Verify current setting: Ensure the EVSE’s maximum current does not exceed the cable’s rated capacity.
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Repair Difficulty

Easy 2/5

Required Part

J1772 Output Cable and Handle Assembly
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