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V.0.01 03/19/18
Charge Wire Fuse Kit Instructions
FK080 80 Amps
FK125 125 Amps
FK200 200 Amps
These instructions will help you install your Alternator Charge Wire Fuse Kit. Please read completely before
attempting to install.
The FK Series fuse kits are designed to be installed inline in the alternator charge wire. We recommend that this
wire always be fused. Each fuse kit includes an inline fuse housing, two fuses, and the crimp terminals required
for adding the necessary ring terminals to the charge wire where the fuse is inserted. The choice of alternator
charge wire and fuse kit depends upon the alternator installed:
ALTERNATOR
OUTPUT
CHARGE WIRE
FUSE KIT
63 Amps
10AWG
FK080
100 Amps
10AWG
FK125
177 Amps
8AWG
FK200
Installation:
Before you get started always disconnect your battery.
1.
It is easiest to install the fuse kit while installing the charge wire. When routing the charge wire from the
alternator to the battery connection at the starter solenoid, choose a location for the fuse that is easily
accessible and will not interfere with other components. The fuse holder does not need to be attached to
the engine or chassis apart from the electrical connection to the charge wire. The fuse holder is
electrically insulated when properly installed, but a small amount of the ring terminals are exposed where
they enter the fuse housing, so make sure there is nothing else can contact the terminals there.
2.
Cut the charge wire at the chosen fuse location, and strip each of the cut ends approximately ½”.
3.
Find the two #10 ring terminals in the fuse kit and crimp them onto the charge wire here. Note: While
common crimping tools are designed to crimp 10 AWG terminals, many are not made to accommodate the
8 AWG terminals that are in the FK200 fuse kit. Attempting to use such a tool to install the FK200 fuse
kit may not deliver sufficient force to adequately crimp the terminals, or may damage the nylon insulating
sleeves.
4.
Separate the two halves of the inline fuse housing, remove the nuts from the studs, and place one of the
fuses over the studs. Save the other fuse as a spare.
5.
Put the #10 ring terminals over the studs on top of the fuse tabs, and replace the nuts. Torque the nuts to
44 inch-pounds (3.5 foot-pounds or 5 Nm).
6.
Snap the other half of the inline fuse housing over the assembled fuse. Confirm that the cover is securely
snapped in place.
7.
Continue installing the charge wire.
