Zencar Connector Arcing / Poor Contact

Visible arcing, sparking, or burn marks at the vehicle connector when plugging in or during charging.

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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 loose connector pins, Contaminants on pins, Misalignment between connector and vehicle inlet, Overheating due to high resistance contact

How to Fix / Troubleshooting

Safety first: Stop using the charger immediately. Arcing can cause fire and damage the vehicle inlet.

  • Inspect connector: With power OFF and unplugged from the EV, examine the J1772/Type 2 connector for pitted, blackened, or deformed pins and melted plastic.
  • Check vehicle inlet: Inspect the EV's inlet for similar damage. If present, the vehicle may also require repair.
  • Do not attempt to file pins: Filing can remove plating and worsen arcing. Replace the entire output charging cable assembly if pins are damaged.
  • Verify secure connection: When using a new or undamaged connector, ensure it is fully inserted and latched before charging.
  • If arcing recurs: Have a technician verify correct contact pressure and alignment, and check for internal overheating in the connector head.
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Repair Difficulty

Medium 3/5

Required Part

Output Charging Cable Assembly
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