DuroMax
Overheating Electrical Component
Unusual burning smell or melted plastic odor from generator enclosure
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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 high‑current connection, Overloaded breaker or contactor, Failing AVR or control board, Shorted wiring harness
How to Fix / Troubleshooting
Safety first: Immediately shut down the generator, open all breakers, and disconnect battery negative. Do not restart until the source is found.
- Visual inspection: Open the control panel and alternator end cover. Look for discolored, melted, or charred components and insulation.
- Tighten connections: Check all lugs on breakers, contactors, and terminal blocks. Tighten to specified torque.
- Replace damaged parts: Any melted connectors, breakers, or boards must be replaced with DuroMax‑approved parts.
- Check for shorts: Inspect harnesses for rubbing against sharp edges and repair or reroute as needed.
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Repair Difficulty
Hard
4/5
Required Part
Main Power Terminal Block
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