Melted relay panel + post toasty
 

Started to smell something funny right before my truck died. Diagnosed and found no power to my fuel pump. While troubleshooting, found the positive post had started melting the plastic and got the post hot enough to discolor the metal. Also see the fuse isn’t popped just burnt. Trying to figure it out but getting stumped. Car electrical is not my strong suite lol. What am I missing here?

10g wire coming off my alternator is feeding the panel. Did have my ground to the cab but changed that out to chassis now. 1st fuel pump always runs, 2nd fuel pump kicks on at 3psi boost or 75% TPS, trans cooler kicks on via a Derale temp sensor switch. Bought a replacement panel and will be here tomorrow.

Any help is appreciated. Thanks in advance everyone.

Re: Melted relay panel + post toasty
 

just keep in mind there is no such thing as too many grounds, and since the cab sits on rubber bushings, ground to frame and ground the cab, also ground the core support, as far as crazy stuff with the electronic fuel pump you could run a ground straight to the battery negative terminal to be super sure it is grounded properly, too many times I see guys grounding their fuel pump to a thickly powder coated frame, lol

Re: Melted relay panel + post toasty
 

Do you have the correct fuse size? Do you have the fuse close to the power source or close to the pump? Any damage to the wire? Which post is burn-pump or alternator?

My first guess is that your fuse isnt sized right.

Re: Melted relay panel + post toasty
 

Thanks guys for the help. I was able to determine I suck at math and that electrical is not my strong suit. I ran a 10g power feed to the panel but the problem was the amperage. To much amps for the size power wire. Replaced my fuse panel and upgraded power and ground to 4g and everything is happy again. Also ran power straight to battery.