Primecom Intermittent Connection / Thermal Cutback

Charger intermittently stops charging without any 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 J1772 connector latch, Overheating at plug or receptacle, Weak relay coil dropping out under heat, Marginal pilot signal due to cable damage

How to Fix / Troubleshooting

Safety first: Intermittent faults can lead to arcing. Inspect all connections for heat damage.

  • 1. Check for heat: After a charging session, carefully feel (without touching metal prongs) the wall plug, receptacle, and J1772 handle. Excessive warmth indicates a poor connection.
  • 2. Inspect receptacle (plug-in models): Look for discoloration or looseness. Replace any worn or burned receptacle with a heavy-duty, properly rated unit.
  • 3. Secure latch: Ensure the J1772 latch fully engages. A loose connection can cause the vehicle to stop charging.
  • 4. Cable flex test: While charging, gently move the cable near the handle and charger. If charging stops, the cable conductors or pilot wire may be broken internally and the cable should be replaced.
  • 5. Professional diagnosis: If no external cause is found, the internal relay or control board may be overheating and dropping out; replacement may be required.
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Repair Difficulty

Medium 3/5

Required Part

J1772 Charge Cable and Handle Assembly
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