Charger displays E02 and refuses to start; vehicle reports charging station error; relay click may be heard briefly then drops out.

Safety first: Turn OFF the charger’s dedicated breaker and verify no LEDs are lit. Use a non‑contact voltage tester at the charger input before opening the enclosure.

• Listen for relay operation: With the cover on, turn the breaker ON and start a charge session. If you hear a loud click followed by E02, the control board is detecting abnormal relay behavior.
• Visual inspection (power OFF): Remove the front cover. Locate the main power contactor/relay block (usually a multi‑pole contactor labeled with current rating). Check for discoloration, melted plastic, or burn marks.
• Manual contactor test (advanced): With power OFF and wires still connected, gently move the contactor armature (if accessible) to feel for mechanical sticking. A welded or sticky contactor should be replaced, not repaired.
• Check coil connections: Ensure the low‑voltage control wires to the contactor coil are firmly seated. Loose spade terminals can cause intermittent E02.
• Do NOT bypass safety: Never attempt to bypass or jumper the contactor to force charging; this defeats safety interlocks and can cause fire or shock.

If the contactor shows any signs of overheating or mechanical damage, replace the entire contactor assembly with the Volvo‑specified part. If the contactor appears fine but E02 persists, the main control board relay driver may be defective and should be replaced by a qualified technician.