I just hooked a pair of Hella 500's and they will not work. I know I have the lamps, battery, ground and switch wires connected correctly to the relay; and the switch has the three wires connected to it correctly. I don't know if I have the hot wire from the switch to the fuse box connected right? I bought a fuse adapter that plugs in to a fuse spot, you splice the hot wire to the adapter wire, and you place a fuse in the adapter.

What am I doing wrong? When I tested the switch directly to the lights and the battery, the lights switched on/off with the switch.

I even tried a different relay.

mochoajr

 

Bad light switch in your dash maybe? I'm sure others will have some ideas later, but that's all I can think of now at the moment.

 

I used the ignition fuse, in the cab, and the lights work.

mochoajr

 

Check to be sure that the lamps and the switch are grounded properly. Everything else could be in order exept the ground.

 

I wired the hot wire from the switch to the in-cab ignition fuse. The engine would crank over, but not run. When I took the hot wire out and just put the fuse back in, the engine would work.

Anyone have any ideas? Or, how should I connect the hot wire from the switch?

Thanks, mochoajr.

 

You should have a hot leg from the battery to the relay(red)with a inline fuse. A ground from the battery to the relay(black).Green from the relay to the switch(hot leg). blue from the lamps to the relay. Green from the switch to either headlamp lowbeam for fogs, highbeam for driving lights or parking light for the ability to turn them on with high, low or parking lights.Thats it

 

I'm guessing that you dont have a wiring diagram. But the red to relay go'in the 30 spot, black to 85, blue to 87 and green to 86. Also the switch, top is ground middle is green from relay and bottom goes from the light source high, low, ect. Hope this helps

 

Marco, got your emails also.
I would not use the ignition fuse in the cab to run to your switch.

Did you read my write-up in the Tech section on wiring up off road lamps?
Before I installed my extra fuse box under the hood, I used the cigg lighter fuse I think for the switches power source.

Try using a fuse that is either hot with the key off if you want full control over the lamps, or use a fuse there that is only hot with the key on.

The reason I don't tap into any of the in cab fuses anymore is explained in my write-up.

I also have the Hella wiring diagram scanned in and linked in the write-up.

 

Thanks to everyone who responded.

Thanks Corey, I'll print your tech article and read it. Thank you very much for your help.

Marco.

 

Corey-

I read your write-up numerous times and I am about to install some hellas this weekend(500's). I want to be able to turn them on when ever the key is on, or preferably anytime that I want; not only when the high beams are on like the hella instructions say.
How do you tap into a fuse, like the cigg lighter one that you previously used before your extra fuse box install?

Is is a bad idea to run a wire from your battery(with a inline fuse), to the switch, and from the switch to the lights; all with the proper grounds? Or is is best to incorporate a relay like the directions instruct?

Thanks,
Chris

 

You should use a relay, that is what they are for.
Very easy to hook up after you study it for awhile.

To tap a fuse, all you do is pull the fuse out, and then stick your wire in there and muscle the fuse back in again.

It might take a few tries.
The ultimate setup though is to go with an external fusebox like I did, and not worry about tapping any fuses.

I have all three sets of lights on one fuse in the new fusebox.
The wires only need a small amount of current to engergize the relay with, and that is those wires jobs.

 

I just installed some several weeks ago, with bamachem's help, really a lot simpler to do than I first thought. There is a write-up of what I did on my website.
Hella 500 Fog Light Write-Up

 

Brian,

How did you get the wires through the grommet? It's pretty tight there.

mochoajr

 

Chris,

There is an adapter you can buy at Autozone or Pepboys. I don't know the name, but it looks like a slightly larger fuse with a wire coming out of the side. On top of the adapter there are two slots to insert two 5 or 10 amp fuses. The wire that comes out of the adapter, you splice to the green wire coming from the Hella light switch.

Just follow the instructions to the adapter. I used the ignition fuse that's in the in cab fuse box. As long as I have the key on, I can turn on the Hellas.

mochoajr

 

Try vaseline and brute force...that doesn't sound right...

 

....and some 'protection'??

 

Thanks Corey, Brian, and mochoajr

I appreciate the responces. I guess that I have some work cut out for me tomorrow. I'm planning on picking up one of those OEM fog light switches in the morning. I'll see about one of those fuse adapters as well.

Brian I read your write up also. Very good write up, very detailed and the pictures help a lot as well.

I appreciate the help. I'll keep ya'll posted on the outcome.

Thanks,
Chris