Charger reports pilot signal fault; vehicle does not recognize charger; app shows EVSE communication error.

Note: The pilot signal is the low-voltage communication line between the EV and charger. Damage here prevents charging.

• Step 1 – Inspect connector:
  • Examine the J1772 plug for bent, recessed, or corroded pins.
  • Clean light corrosion with electrical contact cleaner and a soft brush.
• Step 2 – Check cable strain:
  • Look for kinks or sharp bends near the handle and where the cable enters the charger.
  • If the cable has been pulled or crushed, internal pilot conductor damage is likely.
• Step 3 – Continuity test (qualified):
  • With power OFF and the charger opened, disconnect the cable assembly from the control board.
  • Use a multimeter to check continuity of the pilot conductor from the board connector to the J1772 pilot pin.
  • If open or shorted to other conductors, replace the output cable & J1772 connector assembly.
• Step 4 – Board-level fault:
  • If the cable tests good, the pilot driver or sensing circuit on the main control board may be defective.
  • Replace the control board through an authorized service provider.