Hey all,
I am in the process of installing some hella 500's onto the front of my 3rd gen and have run into a problem.

as soon as i plug in the fuse for the switch (see diagram) the inline fuse and the relay fuse both blow. I have tried 15-30A fuses with no luck. I have an OEM toyota fog switch.

Also useful to note: I have run the black power wires directly to the + battery and the lights do turn on.

here are the instructions i was following
http://www.4runners.org/writeups/hella500/index.html
and
https://www.yotatech.com/forums/f127...4runner-75274/

please let me know if you guys have any idea on what i did wrong! very frustrating to say the least.
EDIT: SWITCH THE BOTTOM TWO WIRES ON THE SWITCH!

 

sounds like your getting the wires wrong at the switch

 

Your red wire(12 volts) should go to term 30 on your relay. Your black wires from your lights should go to term 87 on your relay.Your green wire should stay on term 85 and you should ground term 86. This should work. The way you have it wired you are putting power directly to ground through the relay. Terminals 30 and 87 are the contacts that close to power the lights. Terminals 86 and 85 are the coil that close the contacts. Good luck, Pete

 

Hey Pete,
Thanks for the help... I have no more fuses blowing after switching the wires on the relay. However, my lights still do not turn on. The switch (illuminated) lights up and I can hear the relay click. Also, lights still light up if i connect the black wires directly to the terminal... any more ideas?

 

It sounds like you probably cooked the contacts in the relay. I would try another relay, should be available at any parts store. Make sure it is rated for at least the same amperage as the one you have. Let us know how you make out, Pete

 

Thanks Pete, for the help. I followed these two writeups as well:

http://www.4runners.org/writeups/hella500/index.html
and
https://www.yotatech.com/forums/f127/wiring-...4runner-75274/

With my setup the hella lights can switch on at anytime.

With the instructions from those writeups I kept blowing my inline fuse every time I tried to switch the lights on. So your recommendation to swap the ground wire and the double lights wire on the relay pins solved the issue.

My layout:

Relay Pin --> Wire
87 --> lights (2x black)
86 --> ground [- battery terminal] (blue)
30 --> 12v [+ battery terminal] (red w/ 15A inline fuse)
85 --> switch (yellow)


Green wire runs from my switch to an aux fuse box w/ 30A fuse. The aux fuse box runs to + battery terminal as well. No more blown fuses and lights work perfect.

Many thanks Pete!
-liz

 

Thread bump,
I know this is an old thread but now i have a question. Is the relay provided by Hella wired incorrectly with the 86 & 87 terminals backward?

I just got my Hella 500FF lights and hooked it all up and i'm blowing fuses but my relay and wiring came prewired from Hella so there is no individual wires to hook up to the relay just a male plug (relay) and a female plug (all the wires that go to the battery, switch, ground etc). So there is no guessing game but i'm getting the same results as others. Any clues? I'll post a picture shortly when i get the chance of the relay harness.

 

as i posted above this fix worked for me:

Relay Pin --> Wire (color)
87 --> lights (2x black)
86 --> ground [- battery terminal] (blue)
30 --> 12v [+ battery terminal] (red w/ 15A inline fuse)
85 --> switch (yellow)

my relay is a bosch replacement - but I believe the electrical stuff is all the same for these

i went through two packs of fuses before i finally got it right, if you keep blowing them with the 86 and 87 terminal wires switched to either location, check to make sure your wiring at the switch is not backwards too...speaking from experience

good luck!