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Don't use higher voltage, though many PPC chargers actually list around 5.4v. That would be OK. Current on chargers is what the device can deliver, not what it does deliver. The current drawn is determined by the device. Typically car chargers have sufficient ummpf (the technical term for current capacity) to effectively charge PPCs while running. Normally the car adapters with a USB socket do too, as the difference is normally just the socket, allowing you to use a standard sync'n'charge USB cable.
Sounds like you said that it worked when you first got it. Is that right? Is the car charger specifically designed for PPCs? The iPAQ listed as supported? Seems that if it did work and now doesn't it might be broken. Yes, one failure mode can be reduced output capacity. PPCs do demand more charging current when on than when off, so if the charger is marginal, you could see what you see.
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