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Unread 05-28-2013, 08:58 PM   #1
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Default 1987 DS charging receptacle fuse is too hot

I have a 1987 Ds and the 80 amp fuse that connects to the charging receptacle heats up so much that it melts the flux and the little plastic window covering. I burnt through one and this is the second fuse I've put in.
This is my first cart and I'm new to this forum, I would appreciate any help I can get on this.
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Unread 05-28-2013, 09:23 PM   #2
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Default Re: 1987 DS charging receptacle fuse is too hot

wow !!! it's not blowing the fuse ? ... resistance = heat ... arcing = heat
clean prongs and inside receptacle ... emery cloth and emery board
check to see if its a tight fit
receptacle may be bad
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Unread 05-28-2013, 10:11 PM   #3
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Default Re: 1987 DS charging receptacle fuse is too hot

Heat means a poor connection at the fuse.
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Unread 05-28-2013, 10:45 PM   #4
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Default Re: 1987 DS charging receptacle fuse is too hot

ok the new fuse came with a couple split washers and some nuts to tighten all the connections down. Should I get rid of the split washers and just use the nuts to the connections, and tighten the piss out of them?
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Unread 05-28-2013, 11:00 PM   #5
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Default Re: 1987 DS charging receptacle fuse is too hot

i would not... they help it not to rattle loose causing problems
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Unread 05-28-2013, 11:49 PM   #6
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Default Re: 1987 DS charging receptacle fuse is too hot

I tightened everything down good, and kept the split washers on. the fuse broke free from the flux. Tomorrow im going to try to soldering it back onto the bolt head. Any other advice before I give it this shot?
If this doesnt work out im gonna take it into a cart place and see what they can do for me there i guess.
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Unread 05-29-2013, 09:50 PM   #7
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Default Re: 1987 DS charging receptacle fuse is too hot

I re-soldered the fuse today, so far so good. slight warmth in the wires when its charging and when I put the plastic window back on heat builds up under it. Ive left it off and I cant feel any heat around the fuse itself when its charging.
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Unread 06-03-2013, 02:33 PM   #8
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Default Re: 1987 DS charging receptacle fuse is too hot

The fuse is still heating up. I am out of ideas to fix it... I'm ordering a few new fuses and I'm going to start replacing wires and connections until it stops melting through them. Any ideas out there for me?
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Unread 06-03-2013, 02:44 PM   #9
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Default Re: 1987 DS charging receptacle fuse is too hot

dumb question but is charger the right voltage ? 36v ?
again i'd check the receptacle and plug

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Unread 06-03-2013, 04:22 PM   #10
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Default Re: 1987 DS charging receptacle fuse is too hot

I've cleaned the prongs and inside the receptacle. I thought about replacing the receptacle also when I do the wires. The charger is a Lestronic II Model 7850
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