dstock
Explorer
My ARB compressor's white plastic connector also melted. I believe the prongs became corroded, raising the resistance and increasing the voltage drop as well as generating heat.
I went with the Anderson 45A connector a while back and have had no problems.
Interesting, the relay went bad a couple months ago but I checked everything and thought it was just the relay. It wasn't until I went to unplug it that I realized something was up because you couldn't tell just by looking at it connected.