Hella 500 install question

J

jeeper1

New member
Ok guys,

I am in the garage installing some hella 500 on the runner that came from my old jeep.

I have a question about the wiring diagram and what I need. I have connected everything, lights are grounded, switch is grounded, power cable is connected and the thing doesnt want to fire up. I think I am missing something here with the aux fuse. On the write up on 4runners.org, the instructions state I need to hook up a 15 amp fuse to the aux fuse box. I cant seem to find my aux fuse box. Can someone help me if you know where it is and also what else I need to do to turn these bad boys on?

Thanks

:roadkill:
 
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you dont have to go to the aux fuse box, you can just put an inline fuse in the power wire before the switch and that will do the same thing. the only reason people go to the aux fuse box is so it "looks" factory. i bought my own aux fuse box to run all my aftermarket electrical items, and it looks nice and clean i just put it on the back of the fire wall with one main power wire 8awg and it the splits to 6 separate fuse-able outputs. but if you are only going to ad the hella lights then just use an inline fuse, the closer to the battery the better.
 
OK Thanks kid!

On the hellas, there is a fuse on the power line. So if I add the inline fuse is it going on the yellow line to the switch?
 
ok so you have a power line running from a power sorce (lets say the battery) to the switch, then from the switch to the lights. the lights them selfs have a ground, and the switch has a ground. correct? -you need the fuse to ideally be in between the power source and the switch. there is no need for a second fuse.

what is your power source?

are you sure the fuse you are using is good?

what is the switch rated at? if its less than the draw of the lights you might burn out the switch

are you using a relay? if so dose it work?

are you sure the bulbs arent burnt out?
 
Sounds like the situation I was in.

You need a wire running from your battery (if you want them to come anytime) to the switch with a fuse in line. The switch needs to be grounded and then you need a wire going from the switch to the lights.

Are you using the switch that came with the Hellas?
 
Kid- power source is the battery, fuse is good, switch is a universal 12v rocker, Im guessing that the relay is the box that all the wires are connected through. If so yes. Dont know if the bulbs are burnt out. =(

So, here is the diagram. try to follow.

Relay box has 85,86,87 and 30 that you hook up the power which is red, the black which is for the lights that have their own ground, and a yellow line for the source and a blue for the ground. Thats what it states on the hella site and on 4runners.org writeup.

For the inline fuse, my question is do I connect it to the yellow source, which is supposed to go from the relay to the switch or do I jump from the red power line that connects to the battery to the yellow source line that connects to the switch.

the red power line has a fuse in it already that is still good.
 
ok then dont add another fuse, that wont do a thing. have you made sure that the wires are hooked up correctly to the switch?

is the relay working(yes that black box is your relay), dose it make a clicking sound when you flip the switch?
 
make sure you run the hi beam line to the +power other wise it wont turn on, i agree in the hella switch they suck
 
Ok, so I plugged all up without the inline fuse box and it blew the fuse on the red power line. Then I plugged in the inline fuse box with a 15 amp and a fresh new fuse in the red power line and it blew it again.

The relay switch works and makes a clicking noise when I turn on the switch. Also the switch still works as it lights up when in the on position.

I need to know what to do to keep the fuse in the power line from blowing. We were using 30A fuse for the power line and a 15amp fuse for the inline fuse box.
 
why do you have 2 fuses? there is no need. just the one fuse is all you need, but thats not your problem, it sounds to me like you might have some wiring crossed at the switch, or in the relay something might be crossed, dubble check the wiring diagram. next step would be take apart the lights them self and check the wires in the housings they might be touching in there causing a short.

again just one fuse -and it goes in the line from the power source to the switch. no need for any more fuses
 
Ok so I took off the fuse in the power line and ran with the 15amp in the inline fuse box. I also checked all the connections and no lines are crossed. The bulbs are good in the lights and still no go. The grounds are all metal to metal contacts as I dremeled the surface. What else could it be?
 
jeeper1 said:
Ok so I took off the fuse in the power line and ran with the 15amp in the inline fuse box. I also checked all the connections and no lines are crossed. The bulbs are good in the lights and still no go. The grounds are all metal to metal contacts as I dremeled the surface. What else could it be?
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you know when i did mine i was so frustrated, i end up taking the whole thing inside my house and wired it up using another battery, sometimes you just gotta see where everything goes to get how it works
 
I know what you mean. I will have to try again on thursday. I dont get why it keeps burning my fuse. Everything works (switch lights up, relay clicks off and on, grounds are clean, bulbs are good) I just dont know what else it could be. I will post pics of what I did and how it was ran when I get inside to hook up the camera.
 
jeeper1 said:
I know what you mean. I will have to try again on thursday. I dont get why it keeps burning my fuse. Everything works (switch lights up, relay clicks off and on, grounds are clean, bulbs are good) I just dont know what else it could be. I will post pics of what I did and how it was ran when I get inside to hook up the camera.
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same thing happened to me so i just went with a bigger fuse, its been couple pf weeks and so good so far
 
t4r4life said:
same thing happened to me so i just went with a bigger fuse, its been couple pf weeks and so good so far
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What size fuse did you originally have in there and what did you move up to? I asked the guys at autozone and they were no help. I asked them if I can move up in fuse size and he didnt know. It had a 30a in there and was wanting to go to 40 or 50. What do you think?
 
if you are blowing a 30 amp fuse you have something wrong, i have a set of 130w piaas on my 4runner and im only running a 20 amp fuse and have no issues. im sure you hellas arent even 100w so you should be fine with a 15 amp fuse.
 
the kid said:
if you are blowing a 30 amp fuse you have something wrong, i have a set of 130w piaas on my 4runner and im only running a 20 amp fuse and have no issues. im sure you hellas arent even 100w so you should be fine with a 15 amp fuse.
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I went through 5 30amp fuses, we stuck a 15amp fuse in and it didnt blow. What could I check. Should I re-do all my connections? I added/redid a few female/male blade connectors. I'm stuck man, everything worked except the lights... :redbrick:
 
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