AMPROAD Intermittent Connection / Thermal Cutback

Charger intermittently stops charging mid-session with no error code; charging resumes if unplugged and replugged.

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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

Loose output cable connections inside charger, Overheating at terminal block, Failing temperature sensor causing premature cutback, Weak contact in J1772 handle pins

How to Fix / Troubleshooting

Safety: Intermittent faults can indicate overheating. Turn OFF the breaker and allow the unit to cool before opening.

  • 1. Observe pattern:
    • Note whether the stop occurs at high current or after a certain time; this suggests thermal issues.
  • 2. Inspect internal terminals:
    • With power OFF, open the charger and check all power terminals for discoloration or signs of heat.
    • Tighten any loose screws to the specified torque.
  • 3. Check cable strain relief:
    • Ensure the cable gland is tight and the cable is not pulling on internal connections.
  • 4. Inspect handle pins:
    • Look for pitting or discoloration on the J1772 power pins.
    • If pins are worn or loose, replace the cable & handle assembly.
  • 5. Monitor temperature: If the charger has a temperature readout in the app, monitor it during a test charge. Persistent early cutback may indicate a faulty temperature sensor on the power board, requiring board replacement.
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Repair Difficulty

Medium 3/5

Required Part

AMPROAD Output Terminal Block / J1772 Cable Assembly
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