What main fuses? Fuses in the car electrical system? If so, your amp is too powerful to run through the cars electrical system, you should get a heavy guage wore ran straight from the battery, with its own dedicated fuse placed in-line, ad close to the battery as possible. Wait, is this a bass guitar combo??? Open it up, if there's wax coming from the power supply, thats prolly the culprit. Check for any obviously blown resistors or any short circuits. But most likely, its not gonna be user-servicable.
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Your amp is overheating as your speakers all combined are 680 watts, double your max output on your amp. Ideally you need a 1000 watt amp to do the job and for perfect sound as you should never have your amp up to max as it is more likely to blow quicker. The 2000 watt amp your are speaking of will do the job perfect, but you need to keep the gain down around 50% as you could blow your speakers. But yeah all together you are right, the 2000 watt amp will stay cool as doesnt have to work nowhere near as hard as the one you have currently.
Generally, this indicates that there's at least one shorted output transistor.
Disconnect all speaker wires from the 'amplifier's speaker terminals' and disconnect RCA/signal cables from the amp. If it powers up normally, the speakers/wiring need to be checked. If it still blows the fuses, the amp almost certainly has shorted output transistors and will need to be repaired.
I'd recommend using two 10 amp fuses. The amp will power up with 10 amp fuses if there is no problem. If there is a problem, there's less of a chance of doing more damage by using the 10 amp fuses.
can you use headphones? if so do they sound normal. probably have bad filter caps. 2200uf caps big ones, go bad and lose their capacitance and cant process the low end notes, sounds like a motorboat or ******* out. speaker may have issues as well. get the caps from mouser.com and careful of stored voltage on the capacitors it is deadly....... those caps are less than 2 bucks each.
The reason your blowing fuses is the amp needs at the least a 150 amp fuse on the wire that runs to your bat. There are fuse blocks that you can put 4 40amp fuse and theres the high dollor ones that you can put all the way to 200amp. When you trun up your amp its drawing to much current for the little 40 amp fuse that you have and will blow it everytime. I recomend Running a 4 gage wire to bat and ground with same. Get you a 150 or above amp fuse from a car audio shop somewhere. anyway sounds like from what you decribed, theres nothing wrong with your amp just the wires and fuse are not big enouf to handle the current that your amp pulls.
When any amp blows fuses, this indicates that something is drawing too much current. The most common cause are components in the output stage and driver stages that have become defective.
On the amp that is blowing the fuse with the volume being turned up, this means that the output stage is partially working. The short or over-draw of current must be in the output stage, or what is loading it. It is possible in this case that a crossover in a speaker unit is defective, and is drawing too much current. I have seen this with especially sub-woofer crossovers, and the driver itself. Subs pull a lot of current because of the amount of drive power required to have very strong bass sounds. Other than that, this still does not rule out the possibility of the problem being defective components in the amplifier.
If I were a guessing man, I'd guess that you had your amp hooked up in a bridged configuration. And also that you connected your two speakers in parallel (plus to plus and minus to minus). And if I were to further guess, I'd guess that you have a blown amp now because of what I mentioned above. Sounds like you need to spend some quality time with your favorite electronic repair shop. Good luck.