Zencar
Overheating Plastic Components
Charger’s front panel or connector has a burnt plastic smell even if it still operates.
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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 connection at terminals, Overheated connector pins, Undersized or loose wiring, Prolonged operation at maximum current in hot environment
How to Fix / Troubleshooting
Safety first: A burnt smell indicates overheating. Turn off power and stop using the charger until inspected.
- Inspect connector: Check the J1772/Type 2 connector for discoloration, softening, or deformation of plastic around the pins.
- Check internal terminals: With power OFF, inspect and tighten all high-current terminals. Look for darkened copper or melted insulation.
- Reduce current: After repairs, consider lowering the maximum current setting to reduce thermal stress, especially in hot climates.
- Replace damaged parts: Any melted or deformed connector or terminal block should be replaced (e.g., output charging cable assembly, input terminal block).
- If smell returns: Have a technician evaluate the main power contactor and power path for hidden damage.
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Repair Difficulty
Medium
3/5
Required Part
Output Charging Cable Assembly
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