EV charging cable maintenance

Most charger downtime starts with how the cable is handled. Keep runs short, avoid abrasion and crush, respect bend limits, clean and dry after use, and a lot of “mystery faults” disappear.   The length policy matters most: within China keep cable length at or below 5 m; for overseas sites keep it at or below 7.5 m. If you must exceed these limits, add proper protection and management so the cable doesn’t live on the ground.   1. Over-length runs without protection Stretching a lead beyond the site policy (≤5 m domestic, ≤7.5 m overseas) invites dragging, twisting, and vehicle rollovers. Match length to the bay you serve. Where longer reach is unavoidable, lift slack with reels, booms, or retractors and place protector ramps at every crossing.   2. Scraping on corners, gravel, and sharp edgesRubbing the jacket over wall corners, curb lips, or loose stone cuts the sheath and lets moisture in. Route away from abrasive surfaces, add corner guards or sleeves where contact can’t be avoided, and guide the run by hand rather than dragging.   3. Bare metal clamps on the jacketDirect clamping with metal parts chews the sheath as the cable moves. Wherever the cable is fixed or guided, add a rubber pad, grommet, or sleeve and tighten only enough to stop slip. Re-check after the first week; hardware settles.   4. Tight bends and added twistSmall radii near the connector boot crack the sheath and stress conductors; twisting to “free” a plug shifts load into pins and crimps. Keep curves gentle (several times the cable’s outer diameter), avoid tight coils under tension, release the latch, and pull straight using the grip.   5. Sun, oil, water, and chemicalsUV embrittles polymers; oils and solvents soften jackets; standing water seeds corrosion. Store in shade where possible, wipe off rain, snow, oil, or chemicals after use, and specify jackets rated for UV and contaminants where exposure is routine.   6. Jerky long-distance draggingStop-start pulls create snap loads at the strain relief and the connector head can hammer the jacket. Move at an even pace and cradle the head during relocations. If long moves are common, use a simple tote or holder so the head doesn’t bounce.   7. Vehicle or pallet traffic over the cableRepeated crush loads deform conductors and raise trip risk. Keep routes out of drive aisles; where crossing cannot be avoided, use low-profile protector ramps and mark a fixed placement zone so staff set them in the same spot every time.     Quick field checklist Item What to check Length & routing Within ≤5 m（CN）/≤7.5 m（overseas） or managed; no long runs across aisles Edges & surfaces No scraping on corners/gravel; sleeves or corner guards in place Clamps & guides Rubber pads/grommets used; no jacket pinch Bend radius Gentle curves; no tight coil at the boot; no twist Exposure No standing water/oil; shaded stow when possible Traffic crossing Protector ramps placed and secured; cable off wheel paths Cleanliness Contacts and housings clean/dry before stow Visual health No cuts, nicks, bulges, or split boots; tag out if unsure     Replace the cable immediately if you see Jacket breach deep enough to show inner layers or conductor outline Exposed shielding/conductor, or a split/loose strain-relief boot Persistent hot handle, odor, or discoloration under normal load Damaged latch, distorted shell, pitted/burnt pins Repeat faults traced to the same lead after clean/dry checks