Sun Country Highway Severe Overheating / Component Failure

Charger emits a burning smell or visible smoke during operation.

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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

Shorted component on control board, Severely loose or arcing terminal, Melted contactor contacts, Internal wiring insulation failure

How to Fix / Troubleshooting

Safety first: Immediately turn off the breaker and do not use the charger until inspected. Smoke indicates a serious hazard.

  • Do not re-energize: Leave the charger off until a qualified technician has opened and inspected it.
  • Inspect internally: Once safe, open the enclosure and look for charred components, melted plastic, or burned wiring.
  • Replace damaged parts: Replace any burned contactor, terminal block, wiring, or control board with Sun Country Highway-approved parts.
  • Investigate root cause: Determine whether the failure was due to overcurrent, loose connections, or environmental factors, and correct those before returning to service.
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Repair Difficulty

Professional Required 5/5

Required Part

Main Control Board
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