Issues with KC Light Bar

[blemm13]

Hey all,

My Gen 2 has a KC Pro6 light bar attached to the top. I purchased the truck used and the lights were already attached, so I have not touched any of the wiring.

Recently, I went to turn the lights on (Aux Switch 5). The lights briefly turned on, then seemed to die. I have attempted to disconnect and reconnect at the disconnect point near where the lights are, but it has not fixed the situation. I did notice there was a small amount of a green liquid in this area, which I dried up.

I have checked under the hood and the connections appear fine, although I’m not an expert.

Any advice?

 

[blemm13]

For reference

 

[MGA]

I am not the best person to answer this however --- are you using a relay? I do not believe AUX 5 has enough amps for that light set-up but cannot remember what the rating was for my '19 Aux 5

 

[brianh87]

That's a lot of light for Aux switch 5. If I'm not mistaken, they are only 5-10 amp. Did you check the fuses? I would wire them to 1 or 2 or like the guy above me said, use a relay.

 

[FordTechOne]

You’ll need to trace back P.O.’s wiring. Most aftermarket electrical installations are complete hack, using quick splices, butt connectors, electrical tape, etc.

The upfitter relay should control a second relay or control box, it should not be used to power accessories directly.

 

[smurfslayer]

sounds like a poor connection, resulting additional heat, resistance and overload. I wonder if it might be not enough wire.

Trace the circuit from up fitter to source and ground wire to ground. You should find a 4 or 5 post relay in the power circuit as well as an inline fuse. Do you know what lights they are and what the draw is?
I count 9 lights, if the draw is > 4a per light, you may have too small a relay. most of the inexpensive relays available are 30 or 40 amp. if you’re over 40 amps with that light bar, you may need to rewire and replace the relay.

Good luck

 

[blemm13]

Thank you all for the help so far! It appears the kit came with a relay, which was installed. All connections seem to be in place. I attached photos of the instructions and wiring as best I could.

Also, per the KC website, the light bar draws 14.67 amps.

 

[smurfslayer]

That is right on the upper limit of what the up fitter can take without a relay. Close enough that if you have a voltage fluctuation, you could pop the up fitter fuse.

So there’s a relay installed, you probably need to do some testing now. You could disconnect the relay, and connect the light bar directly to battery power, and leave it connected for a couple minutes. I prefer to have a fused connection for this test, in case there’s an issue.

if the light goes on and remains on, you know that the issue is within the circuit, north of the battery. Connections can be a bîtch, check those visibly first, tug on them to ensure they haven’t come loose. if that doesn’t find it for you, you can put 12v light (tester) on the end of your power TO the light bar, ground it, activate see what happens, etc.

I don’t see anything in the pics, but check that relay, see if the connections are good, contacts clean and go from there.

 

[blemm13]

That is right on the upper limit of what the up fitter can take without a relay. Close enough that if you have a voltage fluctuation, you could pop the up fitter fuse.

So there’s a relay installed, you probably need to do some testing now. You could disconnect the relay, and connect the light bar directly to battery power, and leave it connected for a couple minutes. I prefer to have a fused connection for this test, in case there’s an issue.

if the light goes on and remains on, you know that the issue is within the circuit, north of the battery. Connections can be a bîtch, check those visibly first, tug on them to ensure they haven’t come loose. if that doesn’t find it for you, you can put 12v light (tester) on the end of your power TO the light bar, ground it, activate see what happens, etc.

I don’t see anything in the pics, but check that relay, see if the connections are good, contacts clean and go from there.

Awesome, thanks for the great advice!

 

[smurfslayer]

No problem, we’ve all been there.
be ready when you get it fixed, pictures. or it never happened !