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Unread 02-19-2010, 03:07 PM   #1
YJhobby
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1993 YJ Wrangler 
 
Join Date: Oct 2009
Location: Lexington, KY
Posts: 507
Offroad Lights wiring writeup, Brights dimmable

Okay, for starters I bought my Jeep YJ with windshield mounted KC's installed, but not working. Approximately 5min of troubleshooting lead me to realize the wires were chaffed through and shorted out. This lead me to rewiring the whole mess. As I was looking at the PO's wiring job I became very disgusted to find that he had pulled the power for the lights from the clock circuit by jamming the stripped wire into the fuse end: not good for offroad lights.

Thats when I started looking into wiring schematics and planning out my method of doing it right. To start with you need to know the power output of your lights. Mine were 2 @ 100W but I calculated at 130W cause I might upgrade at some point. Next you need to decide how you want to control your lights. I wanted the ability to shut off my offroad lights along with my brights for the times I am out in the sticks without other drivers to worry about. This requires splicing into the dimmer wiring. I also wanted to turn my lights on independently of the headlights for whatever the reason may be. Below is my schematic I ended up making to guide me.

260W of power gave me a single 10AWG power wire feeding the 30A relay I bought at RadioShack. I posted a picture of the type of relay I used at the bottom.

The rest of my wiring was 14AWG mainly because I think its best to go a little heavy on the wire and fuse it appropriately, and its what I had on hand already. These wire sizes are from my own calculations given the facts taht I am powering two lights from one relay with no single wire being longer than 6ft. Wire length is important to think about when planning electrical installations, just like current and voltage are important. I used a 25A fuse at the battery to limit the max amps my lights could pull, and it is lower than the rating of the wire and the relay for good wiring practices. The "hot" side of my in-cab switch has a 3 amp fuse at the battery, which is well below the power rating for the switch I bought and the wiring I used. Remember that the switch only powers the relay, which requires very little current.

I chose a 3-way toggle switch with a center "off" to turn my relay on. One side of the "on" comes directly from the battery, and the other comes from the high-beams hot wire (its only hot when the high beams are on). I used a multimeter to determine which wire to splice into right by the dimmer switch on the steering wheel.

Be careful about an installation such as this because if you accidentally leave the offroad lights on with the Jeep off, you'll drain your battery quickly.

auxillary-lights-wiring.jpg   30a-relay.jpg  
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~Steve~

[QUOTE=SnowdogMarc] YJ's don't get stuck....they get temporarily impeeded in their forward progress.[/QUOTE]



I'm patiently waiting for the "foot-in-mouth" moment to end... but since I've posted, its not today

Last edited by YJhobby; 02-19-2010 at 03:17 PM.. Reason: spelling
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Unread 02-19-2010, 03:14 PM   #2
prd_cdn
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Hmmm.. nice diagram !! Good work on the trouble shooting.. sounds like PO wasn't as confident.
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Unread 02-20-2010, 08:23 AM   #3
YJhobby
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Location: Lexington, KY
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I hope it helps others who want to wire their own lights, but are unsure of how to begin. As long as safe wiring practices are used, along with a good dose of common sense, this is really very easy.
__________________
~Steve~

[QUOTE=SnowdogMarc] YJ's don't get stuck....they get temporarily impeeded in their forward progress.[/QUOTE]



I'm patiently waiting for the "foot-in-mouth" moment to end... but since I've posted, its not today
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Unread 02-25-2010, 10:16 AM   #4
JEEP_GREEN_4DR
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2009 JK Wrangler 
 
Join Date: Dec 2009
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Sweet!

This is exactly what I was looking for. Wiring up 3x100W on my bumper and another 2x100W on windshield mounts from scratch. I want to run these on two separate circuits/switches, so it was really helpful to see this diagrammed.

Edit: using 10AWG throughout - Just in case!

Last edited by JEEP_GREEN_4DR; 02-25-2010 at 10:28 AM..
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Unread 02-26-2010, 09:54 AM   #5
YJhobby
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1993 YJ Wrangler 
 
Join Date: Oct 2009
Location: Lexington, KY
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Quote:
Originally Posted by JEEP_GREEN_4DR View Post
This is exactly what I was looking for. Wiring up 3x100W on my bumper and another 2x100W on windshield mounts from scratch. I want to run these on two separate circuits/switches, so it was really helpful to see this diagrammed.

Edit: using 10AWG throughout - Just in case!
Good plan on 10AWG... definately think about multiple relays and power wires from your battery since you've got a total of 5 lights. Also your main power from the battery should be bigger too, depending on the length of wire and total power to the lights. Just do the math.
__________________
~Steve~

[QUOTE=SnowdogMarc] YJ's don't get stuck....they get temporarily impeeded in their forward progress.[/QUOTE]



I'm patiently waiting for the "foot-in-mouth" moment to end... but since I've posted, its not today
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Unread 02-26-2010, 10:25 AM   #6
JEEP_GREEN_4DR
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2009 JK Wrangler 
 
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Quote:
Originally Posted by YJhobby View Post
Good plan on 10AWG... definately think about multiple relays and power wires from your battery since you've got a total of 5 lights. Also your main power from the battery should be bigger too, depending on the length of wire and total power to the lights. Just do the math.
Yup. I'm doing 2 independent circuits, each properly fused to the amount of draw for the lights on that circuit. The 2x100W on the windshield will have their own fuse/relay/switch rated @ 20A on a 30A relay and for the 3 on the bumper, I'll do the same thing fuse rated @ 25A and a 30A relay.
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Unread 12-09-2010, 09:27 PM   #7
Sofla1984
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1993 YJ Wrangler 
 
Join Date: Oct 2010
Location: big pine key, fl
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nice diagram!

I just rewired 6 Kc's, four forward and two side facing roof mounted. I searched everywhere for a diagram like this. I ended up having to contact KC to get one. The previous owner was a wiring systems worst nightmare!
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