Has anyone had this happen on their Minnkota onboard charger? Fuse melted into the line? Can I splice a new fuse “box” into the line, or at I better off buying a new charger? If I need a new charger, what do y’all recommend?

You can fix it, but I wouldn’t trust it.

Looks more like corrosion from trapped moisture.

That lead goes to the cranking battery. The other two banks to the trolling motor batteries are working fine.Which three bank charger are you guys using that’s the most reliable?

Did you replace the fuse holder and try it?

Like mentioned it looks like corrosion.

I use two Dual Pro Professionals. I have a three bank for the cranking battery and trolling batteries. I use a single for an electronics battery that I added. One of them is 15 years old, or older, and works perfectly with constant use. The single is 3 years old.

I’ve been working in the 12v electronics business for 32 years. When fuse holders melt, and don’t pop the fuse, it IS due to corrosion on the contacts. A bad connection causes voltage drop. That results in amperage having to go up to supply the needed power. This, in turn, causes excessive heat. I see a lot of melted fuse holders in my line of work.

Clean connections, and proper wiring is the fix. In your case, proper wiring is already supplied.

Reason for not trusting this? It isn’t always 100% a bad connection that you can fix. Splicing in a new fuse holder is adding two more chances for failed connections.

Cut the fuse holder out and put a new one in its place. It uses a 30 amp AGX 32V automotive fuse.
Its an under $10 fix.

Had the same problem. Minn Kota sent me a whole new lead. Had to take the charger apart and replace it. Wasn't too bad.

Thats not heat damage, only corrosion. Cut and splice in new one using environmental splices.

You'd be fine cutting the wires and installing a new fuse box. Just make sure it's the same size fuse.

Exactly, when installing the Intereferemce isolator for Humminbird electronics you have to cut the lead in front of the fuse anyway.