help, keep blowing fuse on dual battery install

[Jc12]

Hey guys, i just got everything finished up on my dual battery setup using the t-max kit. I did things exactly (triple checked) as shown in this write up

T-Max Dual Battery Install | IH8MUD Forum

and everytime i connect the power wire (on either battery) i blow the 200 amp inline fuse going from the battery's positive terminal to the solenoid. I cannot for the life of me see what is causing this and i need my truck back on the road as soon as possible! i can take photos if necessary, the only thing i can think of is i have the connections on the solenoid crossed. I have triple checked the wiring but i did flip the solenoid upside down (fitment issues) so i reversed everything they showed on the paper instructions as they had it right side up.

What might cause connecting either battery to blow the fuse? i initially installed the positive terminals first then when i went to connect my first ground the fuse blew. Second time i connected positive first then as soon as i connected the ground it blew.

thanks guys

 

[e46inperrycounty]

Post pics as it will help and check all wires for rub through. If you sliced the casing on a bracket it will be a dead short and blow fuses instantly. DO NOT run without a fuse and DO NOT hook it up without a rise to see what gets hot or smokes... inspect all the wires for cuts in the casing, be sure that hots are hooked to hot terminals and grounds are grounded properly. A loose ground can blow fuses as well. I currently have 4 batteries in my 3rd gen.

 

[Jc12]

i just ran through it again and the terminal connected from my battery's positive wire was just touching against the solenoid's case/body as well as the post that you connect it to. It looks a little burned on the metal.. i am guessing all hot wires going to the solenoid should only contact the post and not the body of the solenoid.

 

[RAD4Runner]

i just ran through it again and the terminal connected from my battery's positive wire was just touching against the solenoid's case/body as well as the post that you connect it to. It looks a little burned on the metal.. i am guessing all hot wires going to the solenoid should only contact the post and not the body of the solenoid.

Glad you found it.

NO guessing; As good electrical safety rule:
ALL hot wires should not contact any metal object or conductive metal objects except for the terminals they are meant to be connected to. If likely to wear out insulation from vibration/rubbing against metal surface, reinforce insulation.
Consider all large exposed metallic parts to have continuity to ground. ALL hot metal/conductive objects should be covered/insulated as much as possible. Example is "B" post of alternator. There may not be any ground likely to touch it, but wait until a wrench falls on it.