The91XJ

I just installed some hella lights on the XJ. They run off a 40 amp relay. The problem i'm having is the fuse is getting really hot on the wire that runs from the relay to the battery. I know for sure it's hooked up correctly, and i used all the wiring from hella, so i assume its the right gauge wire and size of fuse. I'm really stumped on why the fuse is getting so hot!! Any input would be much appreciated thanks!

SeriousOffroad

check for proper wiring:

Guest09

THAT,,, is an absolutely awesome diagram. I am going to print that bugger out and tape to the wall in my shop...

The91XJ

Thanks for the diagram, but it is properly wired. It would be pretty hard to screw it up will Hella's pre terminated relay and wire harness lol. I think i may have got wrong fuse between the battery and relay. There's no way its a 20 amp, its really small. I have installed this same kit 2 other times and haven't had any problems . Please keep the suggestions coming!

mark's91-XJ

its the load that heats up the wire. wrong gauge wire or wrong gauge relay. if the fuse was to small it would blow.

cherokee90

why do you guys wire every thing so complicated ? cant you just run a hot wire with a fuse to a switch to the lights then your ground?


i know the diagram is crappy lol

mark's91-XJ

cause the load will melt most switches and cheap fuse sockets

cherokee90

never had that prob.

Macky

check those grounds! dont just assume they are good because they work, grounds cause weird unexplainable things grind the paint away heck even some sand paper just make sure those grounds a 100% contact no resistance

bassackwards

bad ground is what im thinking unless you have a bad crimp in one of your connectors

CRoading

It is so important that everything is wired properly to avoid further power complications...

The91XJ

I have the relay grounded to the negative battery terminal... that should be fine right?

phillyxj570

I have a set of hellas on my bumper and on my fenders and both sets came with 15amp fuses. when i first got them all wired up and flipped the switch to turn them on both fuses blew. I upgraded to 30amp fuses and haven't had a problem with them since and its going on 3 months since i put the 30 amps in and i haven't had one blow out on me

You would be better grounding the relay on your firewall. I have mine grounded on the bolts for the hood hinge

mcssls

if your ground isn't very good it will heat up the load drawing wires also

The91XJ

Yeah i was thinking maybe Hella gave me a bad fuse or something. It seems like upgrading to a larger fuse defeats the purpose of having one though. Maybe I'll upgrade to 20's and see how that goes. Thanks for your input