I recently installed three kc hilites on the front of my jeep. I attached all the power wires together and then attached one 16 gauge wire to run to the battery. I attached all three ground wires together and also used one wire to ground them all. I have them running through a 25a fuse. The night after installing them I drove around a bit and they worked great, didn't use them too much maybe 10 miles or so. The next day I had them on for maybe 15 to 20 minutes and then they shut off. I checked the fuse and it's melted, not just blown, but in like two pieces. Should I have a higher amp fuse in there? Will it burn out my 16g wire? I do have them running through a relay also if that makes a difference. Please help!

 

What wattage are the bulbs? I had Hella 500's on my last Jeep and upgraded the bulbs from 55w to 100w, but took a chance and didn't upgrade the wiring. Sure enough, my inline fuse melted just like you said yours did. I pulled out the shitty stock harness that came with the lights and made my own with 12 gauge wire and hooked everything back up. Never had an issue again, and they were way brighter. Maybe the wiring is the issue in your case also. I'm no wiring guru, so hopefully others with more experience will chime in also.

 

You need 12-10ga wire or that setup. The thin wire is causing the heat issue

 

Here is a chart to help you