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Old 01-05-2013, 01:59 PM   #1
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KC HiLites fuse keeps blowing

So I received these lights for Christmas (thanks honey!)

KC HiLiTES 151 - KC HiLites 6" Apollo Pro Series 100 Watt Driving Lamp System with Stone Guards in Black - Quadratec

I installed them on my Besttop highrock bumper guard and ran the wiring exactly as the instructions says. I have the brown ground wire attached to a factory ground post on the driver side and the black ground attached to a ground post on the passenger side.

The issue I have is that the minute I connect the white load wire, it sparks and blows the fuse. I check to make sure there were no frayed wires, can anyone offer advice?

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Old 01-05-2013, 02:12 PM   #2
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Originally Posted by bluesman88 View Post
So I received these lights for Christmas (thanks honey!)

KC HiLiTES 151 - KC HiLites 6" Apollo Pro Series 100 Watt Driving Lamp System with Stone Guards in Black - Quadratec

I installed them on my Besttop highrock bumper guard and ran the wiring exactly as the instructions says. I have the brown ground wire attached to a factory ground post on the driver side and the black ground attached to a ground post on the passenger side.

The issue I have is that the minute I connect the white load wire, it sparks and blows the fuse. I check to make sure there were no frayed wires, can anyone offer advice?
What size fuse?

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Old 01-05-2013, 02:17 PM   #3
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Well the kit came with a 3. I tried upping it to a 10, then a 20 and it still blew.
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Old 01-05-2013, 02:42 PM   #4
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Is it the fuse in line with the white accessory wire or the yellow main power wire? Also make sure the black wire that comes off the relay harness is grounded to good clean paint free metal..
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Old 01-05-2013, 02:54 PM   #5
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Is it the fuse in line with the white accessory wire or the yellow main power wire? Also make sure the black wire that comes off the relay harness is grounded to good clean paint free metal..
It's the fuse in line with the white accessory wire. The black wire is a post that has other group wire ring terminals on it.
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Old 01-05-2013, 03:07 PM   #6
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Is the white wire ran straight to a 3 prong rocker switch? If so, unplug the wires from the switch and double check that the 12v+, load, & ground are hooked to the correct prongs. The white wire shouldn't need a bigger fuse than that 3, since it's basically just the "on" switch to the relay. It sounds like it's grounded though.
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Old 01-05-2013, 04:25 PM   #7
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I double checked the switch and it was hooked up correctly, I think it may be a bad switch. The minute I hooked it to the switch, no matter what configuration, the fuse would blow.
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Old 01-05-2013, 05:07 PM   #8
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You could bypass the switch to see if that's the problem. Just disconnect the white wire and hook it to +12v and see if the fuse blows or if the lights come on
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Old 01-06-2014, 02:56 PM   #9
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Have you found a solution to this issue. I just hooked up my KC's and I am having the same issue.
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Old 01-06-2014, 07:56 PM   #10
Knows a couple things...

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Those two driving lights draw 17 amps combined. They should ONLY be installed with an aftermarket extra-cost wiring kit that includes a relay to carry those 17 amps from the battery directly to the lights so the switch doesn't have to carry all those amperes. All major driving light manufacturers like KC, PIAA, Hella, etc. make pre-wired wiring kits that include the relay. They are pre-wired so you just plug the lights in and attach the harness to the battery and a ground connection.

Driving lights should NEVER be connected up with just a fuse and switch, they draw too many amps for that. Doing so will cause the lights to not be as bright as they should be unless you use an extra-large wiring gauge, but mainly the on-off switch is simply not designed to carry that much load... eventually the switch's contacts will burn.

The wiring harness with a relay works like below... the switch turns on the relay and the relay connects the lights to the battery.

These two wiring diagrams show slightly different ways of correctly wiring driving lights.

Click on the left wiring diagram to make it full size so its animation showing how it works will work.
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