AMPROAD Overheating Connection / Thermal Damage

Charger or connector emits a burning smell or shows signs of melted plastic around the plug or cable entry.

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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 power terminal inside charger, Worn or pitted J1772 pins, Undersized or loose supply wiring, Prolonged operation above rated current

How to Fix / Troubleshooting

Safety: Immediately stop using the charger. Turn OFF the breaker and do not re-energize until the cause is corrected. Fire risk is present.

  • 1. Inspect connector:
    • Check the J1772 handle for melted plastic, discoloration, or deformed pins.
    • If any damage is present, replace the AMPROAD cable & handle assembly.
  • 2. Inspect internal terminals:
    • With power OFF, open the charger and examine the input and output terminal blocks for heat damage.
    • Tighten all terminals and replace any burnt lugs or wires.
  • 3. Verify circuit rating:
    • Ensure the breaker and wiring gauge are appropriate for the charger’s maximum current.
  • 4. Reduce current setting:
    • After repairs, set a lower maximum current in the AMPROAD app to reduce stress on connections.
  • 5. Monitor closely: During the first few sessions after repair, periodically feel the connector and enclosure (they should be warm at most, not hot) and watch for any smell.
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Repair Difficulty

Hard 4/5

Required Part

AMPROAD J1772 Charge Cable & Handle Assembly
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