DHC Wiring Kit for Pulse Max & Auxiliary Lights
— The Harness That Gets It Right
Dual 40A relays. 25A fuse protection. Copper conductors. Plug-and-play dual switch — no wire cutting, no dashboard drilling, no shortcuts.
Your Auxiliary Light Is Only as Good as Its Wiring
A ₹200 relay kit from a roadside shop will not run a 160W auxiliary light correctly — and here is why that matters.
You've spent ₹8,000–₹11,000 on a DHC Pulse Max, Pulse Pro, Aozoom W-Series, or FBL SPL auxiliary light. You've mounted it correctly. But then you wire it through an undersized relay with aluminium conductors and no proper fuse rating — and suddenly that 160W light is flickering, the relay is running hot, or the connector melts at the terminal.
Generic relay kits sold at ₹150–₹300 typically use CCA (copper-clad aluminium) wire, 30A or cheaper relays, and a single toggle with no beam separation. For a 60W fog bulb that works fine. For a dual-lens 100W–160W auxiliary projector pulling 12–14A at peak — it's a liability.
The DHC Wiring Kit for Pulse Max & All Auxiliary Lights is purpose-built for this exact load. Priced at ₹2,699 — roughly 25–33% of your auxiliary light's cost — it is the component that ensures your light actually performs at full spec, every time.
What's in the Kit — and Why Each Spec Matters
| Specification | Detail |
|---|---|
| Relay Rating | 2 × 40A — one per beam channel (low + high independent) |
| Fuse Rating | 25A inline fuse on main power lead |
| Conductor Material | Copper (not CCA / copper-clad aluminium) |
| Switch Type | Dual illuminated adhesive-mount switch |
| Beam Control | Independent low beam & high beam switching |
| Dashboard Modification | None — adhesive switch mount, no drilling |
| Vehicle Wiring Alteration | None required — trigger tap only |
| Price | ₹2,699 (tax included) |
| Dispatch | Same-day · 3–5 days Pan India delivery |
Why 40A and not 30A? The DHC Pulse Max pair draws approximately 13–14A at peak under full 160W load. A 30A relay runs at ~45–47% of its rated capacity — which sounds fine — but relay contacts heat up disproportionately near rated current under sustained automotive vibration. A 40A relay under the same 14A load stays cool, the contacts don't weld, and the relay lasts years instead of months.
Generic Kit vs DHC Wiring Kit
Here is what the difference actually looks like in practice.
Six Things This Harness Gets Right
Low beam and high beam each get a dedicated 40A relay. No shared load, no contact heating, full voltage delivered to each projector independently.
Fuse sits close to the battery on the main power lead — the correct placement. If anything faults downstream, the fuse breaks before your vehicle wiring or lights take damage.
Pure copper wire maintains voltage at the load end. CCA alternative wire heats up under sustained 12A+ draw — not acceptable for auxiliary lights running for 2–4 hours on a night drive.
Two separate switches — one for low beam, one for high beam. Illuminated so you can find them at night. Adhesive mount, no dashboard drilling needed.
Tap the existing headlight circuit for the trigger signal — no wire cutting, no vehicle wiring alteration. Factory wiring stays intact. Removal is clean and complete if needed.
Connector spec matches these brands directly. No adapter hunting, no guess work on pin-out. Plug in and the circuit is complete.
Which Auxiliary Lights This Kit Supports
Officially listed compatible models — plug-and-play with no modification.
Pulse Max 5" 3-Lens (160W/pair)
TH-01 / TH-02 / TH-03
SPL-2000 (100W Slim)
SPL-3000
Compatibility note: This harness is optimised and tested for the DHC, Aozoom, and FBL products listed above. If you're running a different brand, WhatsApp us on +91 97287 64403 with your auxiliary model name before buying — we'll confirm fitment in minutes.
How to Fit the DHC Wiring Kit
Professional installation is recommended. The plug-and-play design makes it DIY-friendly for those comfortable with basic automotive wiring.
-
1Battery power leadRoute the main positive lead from the battery. The 25A inline fuse holder goes on this lead as close to the battery terminal as possible — this is the first line of protection.
-
2Relay block placementMount the dual relay block in a dry, accessible location in the engine bay — away from heat sources and moving parts. Both relays are pre-wired in the harness.
-
3Trigger wire tapIdentify the existing low beam and high beam wires from your vehicle's headlight circuit. Tap these for the relay trigger signals — no cutting, just a proper tap connection. The relay does the heavy switching; your factory circuit carries only the trigger current.
-
4Auxiliary light connectionPlug the harness output connector directly into your DHC / Aozoom / FBL auxiliary light. Connectors match directly — plug in and it's done.
-
5Switch placementChoose your switch location — ideally below the steering column or on the lower dashboard panel. Peel the adhesive backing and press firmly. Both switches are illuminated, so they're easy to find at night. No drilling required.
-
6Test and verifyTurn on ignition. Test low beam switch — auxiliary low beam should activate. Test high beam switch — high beam activates independently. Verify fuse is intact. Check all connections for heat after a 10-minute run. Done.
Pro tip: Run the power cable through the firewall using an existing grommet, not a bare hole. Use a grommet if creating a new pass-through. Protect any cable run near the exhaust or engine block with braided sleeve. These steps prevent insulation wear and maintain reliability over years of use.
Pair This Kit With These Auxiliaries at CCS
DHC Pulse Max — ₹10,590
5-inch triple-lens, 160W/pair, built-in CANBUS, Spot + Spread beam pattern, White/Yellow or White/White. The Pulse Max is the primary match for this harness — same brand ecosystem, designed together. At ₹10,590 + ₹2,699 for this kit, you have a complete, properly-wired 160W auxiliary installation for under ₹14,000.
DHC Pulse Pro — ₹9,199
2.8-inch dual-cup, 100W, 6000K + 3000K dual colour, Tata-specific fitment (Nexon, Punch, Harrier, Safari). The harness handles Pulse Pro's 100W draw with 40A relay headroom to spare — long-term reliability guaranteed.
FBL SPL-2000 — ₹8,999
100W slim double-lens, 9,000LM, 35mm blue lens, built-in 12,000 RPM fan, DC 9–16V, White/Yellow or White/White. The SPL-2000 is officially listed compatible and pairs directly with this harness — no adapter needed.
Complete bundle: When you buy an auxiliary light + this wiring kit together, everything is spec-matched and connector-compatible. No separate relay sourcing, no fuse hunting. WhatsApp us on +91 97287 64403 to ask about bundle availability or in-store fitment at Naraingarh.
Common Questions
Some auxiliary lights include a basic single-relay harness; others ship without any wiring. If your light came with a harness, check its relay rating and conductor type. If it's a 30A single relay with CCA wire, this DHC kit is a meaningful upgrade — especially for 100W+ lights on extended night drives. If your light came with nothing, this kit is essential.
Yes. The switches are compact and adhesive-mounted — they work on any flat, clean surface. Most owners place them below the steering column, on the lower centre console, or on the side panel near the driver's knee. The illumination makes night-time operation easy regardless of where you mount them.
Possibly — the harness works with any auxiliary in the 60W–160W range with compatible connector type. However, it is spec'd and tested for DHC, Aozoom, and FBL. If your auxiliary is from another brand, send us the model name on WhatsApp (+91 97287 64403) and we'll confirm fitment before you order.
The fuse breaks the circuit — your auxiliary lights go off, nothing else on the vehicle is affected, and your harness and lights are protected from overload damage. Keep a spare 25A automotive blade fuse in your glovebox. If the fuse blows repeatedly, there is an underlying fault in the wiring or a short — get it checked before replacing again.
Recommended for best results, especially if you're not familiar with automotive relay circuits. The plug-and-play design makes it DIY-feasible, but correct relay placement, fuse proximity to the battery, and clean trigger wire taps make a real difference in long-term reliability. We can fit it at our store in Naraingarh — call or WhatsApp to book.
The harness itself is a relay-based power supply — it does not interfere with or modify CANBUS communication. The DHC Pulse Max already has built-in CANBUS suppression on the light side. If your auxiliary light has CANBUS suppression built in, this harness pairs with it correctly. If your vehicle throws error lights with auxiliaries, check the light's CANBUS spec first.
The harness your auxiliary light deserves — spec-matched, relay-protected, plug-and-play.