The pump is dead, long live the pump!

[Poconos]

Got a question...what wiring is melting? Sounds like the line going to the pump and not the pump windings themselves because you said hubby fixed it the first time and I doubt he rewound the motor. If that is the case, something is really wrong, like way undersized wire. As Watermom said the pump is way too big for that pool and you don't mention what size filter you have. Pool stores typically want to sell big pumps and small filters which is the opposite of what you need. Could be a small filter is just making the pump work harder. What was your pressure gauge reading when the system was working? That's also an important piece of info. If the pressure was high that means increased current draw and if you do have undersized wiring then the voltage at the pump is low and that would increase the heating of the motor. That's why some motors heat up and die in prolonged brownout situations. I still suspect way undersized feed wire.
Let's see where we go from here.
Al
Edit: Just re-read the posts...saw your signature. Don't know about that particular filter but from the diameter looks like a 200 pound filter. Too small for that pump but shouldn't be causing this kind of a problem.