1987 DS charging receptacle fuse is too hot

mountainman1982 · 06-10-2013, 06:09 PM

Ive replaced all wires, connections, fuse, solenoids, micro switches, and I've cleaned prongs and female connections on charging receptacle and the charger cord. I'm pleased to announce that she's as good as new! Thanks for all the help and advice!

mountainman1982 · 08-13-2013, 09:10 AM

Ok, so the charging receptacle fuse is up to its old tricks again. Last night I plugged in the charger and nothing happened...I lifted the seat and instantly I saw the clear plastic window that covers the fuse had melted and the fuse was burnt through... also the wire that runs from the fuse to the FW/R switch was burnt through. Any help here would be great.

galloway · 08-13-2013, 10:12 AM

I would go down to the hardware store and get some dielectric grease... Put it on the prongs of the plug. I have a camper and my plug was getting hot when I would go to different camp grounds... Talking to my uncle-in-law that is a retired electrician, if you don't have a good connection it will cause heat. When you put the dielectric grease on the prongs it will help bridge the contact and keep things cool by helping dissipate the heat. It is non conductive so you can be pretty liberal with the stuff. It is an 02 block also, so it will help with keeping things from getting corrosion.

08-13-2013, 10:33 AM

hummm ... 2 months good then it does it again

... a thought that hit me when you said the one wire was burnt through could an animal have chewed on it ?

i guess all you can do is replace wire and fuse then monitor voltage through wires to see if it is correct

simple man · 08-13-2013, 10:37 AM

What amperage does the charger show when charging? It should start at 20amps or so and taper down to 3 - 5amps after several hours. If the charge rate stays high, you have a battery problem and the extra current will melt the fuse housing over time.

mountainman1982 · 08-13-2013, 11:34 AM

After taking a better look at it this morning, I replaced the wire that runs from the fuse to the f/r switch and the wire that runs from the fuse to the charging receptacle. I replaced the fuse with an extra that I bought when this was happening before and plugged it in. Right now its charging at just above 20 Amps and both of those two wires I replaced are very hot. I felt of every other wire and those are the only two that are hot.

mountainman1982 · 08-13-2013, 02:05 PM

Just checked on it and the charger is reading 15 Amperes and those two wires are still warm but not nearly as hot as they were when I first plugged her in.

simple man · 08-13-2013, 08:25 PM

Make sure that the wiring you replaced is an equal or larger gauge than the original! If not, it will get hot!

06-10-2013, 06:09 PM	#11
mountainman1982 Not Yet Wild Join Date: May 2013 Posts: 10	Re: 1987 DS charging receptacle fuse is too hot Ive replaced all wires, connections, fuse, solenoids, micro switches, and I've cleaned prongs and female connections on charging receptacle and the charger cord. I'm pleased to announce that she's as good as new! Thanks for all the help and advice!

08-13-2013, 09:10 AM	#12
mountainman1982 Not Yet Wild Join Date: May 2013 Posts: 10	Re: 1987 DS charging receptacle fuse is too hot Ok, so the charging receptacle fuse is up to its old tricks again. Last night I plugged in the charger and nothing happened...I lifted the seat and instantly I saw the clear plastic window that covers the fuse had melted and the fuse was burnt through... also the wire that runs from the fuse to the FW/R switch was burnt through. Any help here would be great.

08-13-2013, 10:12 AM	#13
galloway Gone Wild Join Date: Jul 2009 Location: Knoxville, TN Posts: 495	Re: 1987 DS charging receptacle fuse is too hot I would go down to the hardware store and get some dielectric grease... Put it on the prongs of the plug. I have a camper and my plug was getting hot when I would go to different camp grounds... Talking to my uncle-in-law that is a retired electrician, if you don't have a good connection it will cause heat. When you put the dielectric grease on the prongs it will help bridge the contact and keep things cool by helping dissipate the heat. It is non conductive so you can be pretty liberal with the stuff. It is an 02 block also, so it will help with keeping things from getting corrosion.

08-13-2013, 10:33 AM	#14
crash test dummy Guest Posts: n/a	Re: 1987 DS charging receptacle fuse is too hot hummm ... 2 months good then it does it again ... a thought that hit me when you said the one wire was burnt through could an animal have chewed on it ? i guess all you can do is replace wire and fuse then monitor voltage through wires to see if it is correct
crash test dummy Guest Posts: n/a

08-13-2013, 10:37 AM	#15
simple man Gone Wild Join Date: Aug 2011 Location: Bunnell, Florida Posts: 2,408	Re: 1987 DS charging receptacle fuse is too hot What amperage does the charger show when charging? It should start at 20amps or so and taper down to 3 - 5amps after several hours. If the charge rate stays high, you have a battery problem and the extra current will melt the fuse housing over time.

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08-13-2013, 11:34 AM	#16
mountainman1982 Not Yet Wild Join Date: May 2013 Posts: 10	Re: 1987 DS charging receptacle fuse is too hot After taking a better look at it this morning, I replaced the wire that runs from the fuse to the f/r switch and the wire that runs from the fuse to the charging receptacle. I replaced the fuse with an extra that I bought when this was happening before and plugged it in. Right now its charging at just above 20 Amps and both of those two wires I replaced are very hot. I felt of every other wire and those are the only two that are hot.

08-13-2013, 02:05 PM	#17
mountainman1982 Not Yet Wild Join Date: May 2013 Posts: 10	Re: 1987 DS charging receptacle fuse is too hot Just checked on it and the charger is reading 15 Amperes and those two wires are still warm but not nearly as hot as they were when I first plugged her in.

08-13-2013, 08:25 PM	#18
simple man Gone Wild Join Date: Aug 2011 Location: Bunnell, Florida Posts: 2,408	Re: 1987 DS charging receptacle fuse is too hot Make sure that the wiring you replaced is an equal or larger gauge than the original! If not, it will get hot!

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