I mounted a set of Hella 500's behind the grille on my '08 SCrew 4x4. They look awesome and I got them mounted good and sturdy, but I'm having wiring issues. I followed the (lousy) Hella diagram that came with the lights, and immediately blew the included fuse. Got online and found about 10 other wiring diagrams for these lights, all a little different but for the most part the same (different grounding points, etc.) I am still having the problem, and have searched and searched online for any type of solutions and am coming up with nothing. I have replaced the relay, tried different grounding points, nothing. I keep blowing the fuse between the battery and the relay as soon as the switch for the Hella's is thrown. They will light up a split second and then the fuse goes. Put fuses in all the way up to 30amps and still the same thing. Does anybody have any ideas, or had any experience similar to this???
One thing I have not done is replace the aftermarket switch in the cab. Could that switch cause the fuse to blow?

 

Here's how I have them wired up:
Battery + to #30 pole on relay, with inline fuse between batt and relay
#87 pole on relay to hot lead on Hella lights (parallel)
Lights grounded to body (ground has been checked and is good)
Green wire from high beam hot to switch in cab
Switch in cab grounded (ground checked - good)
Yellow wire from switch in cab to #85 pole on relay
#86 pole on relay grounded in engine bay (ground is good)

The fuse between the batt and relay keeps blowing as soon as switch is thrown.
I can hear the relay clicking, plus I've replaced it, pretty sure it's not the relay