Wiring Mess, keeps blowing the same fuse

[C110GTR]

I just bought a car and it keeps blowing the same fuse when ever I put the headlights on.

There's a 40 amp 5 pin relay
Pin 86 - Earth
Pin 87 - Thermo Fan 12v
Pin 85 - Kill Switch OFF position
Pin 87a - 2nd Rear Thermo Fan
Pin 30 - has 2 connectors (split) 1st wire goes to one side of the fuse
2nd wire goes to the Kill Switch ON position

Now 2nd part
It has a solenoid R2D2 look-alike that distributes the power (power distributor)

Left Big Terminal - 12v to alternator, also a wire that connect to the other side of the fuse from the relay above (pin 30)
Right Big Terminal - Starter Motor
Left Front Small Terminal - Ignition Coil

12v from the Battery goes straight to the Alternator and a big wire from the alternator to the Left Big Terminal of the Solenoid


Should the thermo fan have its own relay, then not sure if the solenoid needs a relay for the kill switch.

Thanks in advance

[JZK25]

Thermo relay is manually switched in car by your description. Not sure why you have an 87a terminal feeding a fan, that is a changeover relay. You should have a relay with two 87 terminals. You don't say which fuse blows.

The solenoid sounds like a high current relay switched from ignition, possibly to connnect a boot mounted battery to the rest of the car. The small relay is just taking power from the high current r2d2.

[C110GTR]

I've installed two relays now one each thermo fan, currently switched manually by a toggle switch.
The battery is mounted at the back tray of the ute.
And yes the solenoid is activated by another toggle switch to give power for the whole car.
Now the fuse that keeps blowing is the fuse that connects from the left big terminal (same terminal that connects to the battery and alternator) and to the relay for the front thermo fan.
I've tried 40 and 30 amps and at 1st it blew when I put the headlights but this afternoon the fuse blew when I switch the key to ON after switching the toggle switch to turn the solenoid on (R2D2) lol
The fuse for the rear thermo did not blow.
All these when the thermo switch is still on OFF position.

[Dave75]

A Kill Switch normally has a #2 battery cable on both sides, not a normal 16/18 g wire.

Battery + to Kill Switch. Kill Switch to solonoid to Alternator.

You don't have relays on Kill Swtches.

[C110GTR]

Then it's just a manual switch
What do I need to stop blowing fuse whenever I turn the ignition to ON?

[Dave75]

Depends on whether you are using a 2 Pole or a 6 Pole Kill Switch.

The 2 Pole switch simply cuts the battery feed, the 6 Pole Switch [which has a 4 pin relay] cuts power to the coil/s & includes a resistor.

The main +ve battery feed is up to 100 amps,no wonder you are blowing fuses.

Main feed from battery/alternator should have its own high amp fuse...100 amp or a bit higher...to cover what the Alternator puts out.

A bit impossible to comment without a schematic drawing of the circuit.

[C110GTR]

heres a quick diagram except now theres two relay one for each fan

[Dave75]

I think what I recognise as a "Kill Switch" is entirely different to what you appear to call a Kill Switch. Your diagram only indicates a simple low amperage Toggle Switch.
Pin #85 looks wrong... you have 12v +ve from #30 to the switch & power from pin#85 also to the switch.

The toggle switch should be wired from #85 only, not #30. Pin #30 is the power inlet to the relay. #85 is power out to one side of the toggle switch ,other side of switch to the fan/s.

Delete the wire from pin #30 to the fan switch.

[myliberty]

What you smokin' homie?

[myliberty]

hint, most thermo switches switch from open to ground.

Yours is probably fried from copping 30A+ bursts.

Put the switch and the thermo switch on the earth side and double pin 30 straight round to pin 85.

[C110GTR]

I want what the previous owner was smoking as he made a freakin mess wiring this shit
Will try that now Dave
What do I do with that wire that taking off from pin 30? Where should the other wire coming from the switch should be connected?
Thanks

[myliberty]

12v to pin 30, 12v to pin 85.

pin 86 to thermo switch (which grounds when hot) and toggle switch (other side of toggle switch to ground)

[C110GTR]

How do I test if my thermo fan opens to earth and not 12v?
It's a Davies Craig item

[myliberty]

does it have one wire attached to it? they usually earth through the body to the engine block

if it's two wire, then you still attach it as described with another wire to earth.

[Dave75]

I intended to go out to the shed & have a look at the mini wiring but 3 degrees & a good breeze put me off.
His "Kill switch ",which he doesn't have , got me a bit rattled as well ...sorry about that

[myliberty]

PS. run 12v from coil positive to pin 85 if you want the fans to only be active with ign.

the way above will run fans regardless of ign position.

[C110GTR]

The fans got 2 wires 1 goes to earth
And the other wire currently goes to pin 87

[C110GTR]

So still have constant 12v to pin 30
12v from coil to pin 85
Earth to pin 86
Pin 87 to the fan

Now do I still keep two relays 1 each

[myliberty]

In between earth and 86 you put your toggle switch and thermo switch in parallel.

A single 30a or higher rated relay is more than enough for 2 thermo fans

[JZK25]

If Thermo switch goes to ground the fuse will blow. Thermo switch could be NC too. Either way, that's a retarded method of wiring a simple fan.
Davies Craig fan relay wiring is also shit, they assume switching with positive which is not the way to do it.

[myliberty]

Fuck you pal.

[C110GTR]

I've followed wht you said and the car won't power up
The toggle switch has markings off 20A then ON 12V
The switch with OFF pin wire goes to the positve side of the ignition coil

[myliberty]

Nigger wat?

your shit is an abomination. Where the fuck are you, I'll come fix it. It's pissing me off.

[myliberty]

2 times

[C110GTR]

Carina heights
I'm willing to pay!
I wanna kill the previous owner

[C110GTR]

That toggle switch that the PO turns on so you have power for the entire car, took that off and it's got some markings on the back of it. Two terminals
OFF below it states 20A - this wire goes to the +ve of the coil
ON below it states 12v - this wire goes to the pin 30 of the relay

I tried taking the relay out to eliminate the issue.
Wired the 12v wire from the switch straight to the 12v solenoid with 40 amp fuse and this gave me power to the car then turned it off and put it back on again and it blew the fuse.

[myliberty]

riiight. I assumed the other way, that your coil was switched elsewhere and that toggle was just a fan override.

can sort it out after work on Monday(My office is 5 minutes away at east brisbane), need to pick up my tools from JZK.

[C110GTR]

Should I install a 40 amp breaker from the solenoid to the 12v side of the toggle switch? Why does it blow the fuse straight away?
If you were to sort it out what would you do?
The PO owner even cut the starter wire from the ignition switch/barrel and installed a momentary toggle switch to start the car.
So we can rule out the relay the fans causing the fuse to blow as I've taken that out just to test.

[myliberty]

need to see it.

[C110GTR]

Paid a pro to do it
Now my wallets lighter
Installed a DPDT relay
Power wire from the solenoid was earthing