Walli Overheating Connector / High Contact Resistance

Walli charger is charging, but the cable and connector become excessively hot to the touch.

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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 deformed Type 2 connector contacts, Contamination on connector pins, Undersized or damaged Walli cable, Loose crimp connections inside connector head

How to Fix / Troubleshooting

Safety first: Stop charging immediately if the connector is too hot to hold. Risk of melting and fire.

Steps:

  • Allow to cool: Unplug the connector from the vehicle and let it cool completely.
  • Inspect visually: Look for discoloration, melted plastic, or pitting on the connector pins. Any visible damage means the connector must be replaced.
  • Clean contacts: If no damage is visible, gently clean the pins with a dry, lint‑free cloth. Do not use abrasives or liquids.
  • Check cable rating: Confirm that the Walli cable is rated for the maximum current configured in the charger.
  • Replace connector/cable: If overheating recurs, replace the Walli Type 2 connector or entire cable assembly. Continued use of an overheated connector is unsafe.
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Repair Difficulty

Medium 3/5

Required Part

Walli Type 2 cable assembly
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