Over the past few weeks my truck has been blowing the high beam fuse when they are on. I have 4 Hella 500's taped into the high beams that can be also turned off with a switch if they are not wanted with the high beams. I wired them according the the Hella wiring diagram and have been this way for well over a year with no issues.

The first time they blew out I had the Hella lights on as well and after it blew the running lights and fog lights stayed on. The second time was two nights ago coming down the interstate and my Hella's were not on and it did the same thing; running lights and fog lights stayed on.

I do not have the bambi mod done so I'm not sure why the fog lights stayed on. Not sure what the cause for this is, any help is appreciated

 

how big is the fuse? Whats the total power drawn by the lights? P=IV (figure out how much current youre drawing)

 

It's a 20A fuse. The extra lights weren't on the second time the fuse blew so I wouldn't suspect it to be drawing too much current.

 

U need to add a relay to a seperate feed circuit for the big guys and fuse that feed. I recommend a wireless relay.

 

check all your wiring, make sure none of your added wires are getting pinched or rubbing on metal surfaces. headlights can draw alot of amps, i would recommend putting your add on lights on a seperate fuse/relay switch maybe run a signal wire from your high beams to your new relay if you don't want your add on lights on with out your high beams on.

 

Each set of Hella's have there own in line fuse and relay as well (it was supplied with the lights). I'll have to go over all the wiring again and see if I missed something exposed.

 

how do you have the hella's wired? does the main power for the relay come from the high beam circuit or another 12v source? if its on the high beam circuit your still probably overloading the high beam fuse. make sure the main power for the relays come from either the battery or an empty hole from the fuse box that has a hot wire available. then wire the signal wire to your high beam cirucit if thats when you want the hella's to work

 

I would give their circuit its own signal as U can't be on the highway with all those lights a blazing/blinding oncoming/incoming. Also don't overload the ground circuit either. Give Mm their own ground.