Lightforce HID UPGRADE KIT - Manual (Page 3)

Installation
Option 1 - NEW ARM
Fitting
l Remove existing driving light from the vehicle by removing the cross bolt.
l Remove the reflector, rotating it anti-clockwise until free of the arm.
l Pull out bulb (recommended wearing cotton gloves and safety glasses).
l Drill out the single rivet that retains the alloy bulb holder using a sharp 3mm (1/8”)
sized drill bit (if a larger or blunt drill bit is used the rivet may spin within the arm
causing damage to the arm itself).
see fig.A
l Remove the black rubber grommet. This is located at the back of the arm and using
pliers on the bottom lip pull down and discard (a new grommet is supplied).
see fig.B
l Withdraw the complete bulb holder assembly from the arm and discard (this will not
be reused).
l Remove the yellow dust seals, which are fitted on the ends of the red and black cables
of the HID bulb, and discard. Unscrew the clear protective cover housing the HID bulb
and blue anodized bulb holder.
l Working in reverse: fit the new HID bulb holder by sliding the two cables through the
throat of the arm exiting out the rear. Using the M3 hex set screw and 2mm hex key
supplied fix the new HID bulb holder into the arm (electrode at the 12 o’clock
position).
see fig.C
l It is recommended to refit the reflector at this time before proceeding (as the HID bulb
is very fragile).
l Pass terminals through the new rubber grommet by using a 1mm jewellers screw
driver (or similar) to push the terminals all the way through.
NOTE: THIS IS A VERY TIGHT FIT TO CREATE A COMPLETE SEAL AGAINST THE
ELEMENTS.
l Leave a 20mm gap between the top of the grommet and opening on the rear of the
arm. This ensures there is no tension on the cables within the arm once it is pushed
back into place.
see fig.D
l Using a medium sized screw driver, inserted into the centre of the grommet, push up
into the arm (it is recommended using a few drops of gel superglue to retain). The
top of the grommet must finish flush with the arm. see fig.E, F, G
l Place the supplied heat shrink on each cable. see fig.H
l Push each cable into the high voltage connectors until the terminal 'clicks' into place.
(note the small red tab on the female plug must be protruding before it will fit)
l Locate the heat shrink over the fitted connector, using a heat gun or similar, heat until
the material shrinks around the connector and wire.
see fig.I
NOTE: THE HEAT SHRINK SUPPLIED HAS A LIQUID GEL INSIDE THAT ENSURES A
PERFECT SEAL.
l Refit light and connect to ballast. Refer to page 6 for ballast mounting instructions.
2
Installation
Option 2 - OLD ARM
Fitting
l
l Remove the reflector, rotating it anti-clockwise until free of the arm.
l Drill out the single rivet that retains the alloy bulb holder using a sharp 3mm (1/8”)
sized drill bit (if a larger or blunt drill bit is used the rivet may spin within the arm
causing damage to the arm itself).
see fig.J
l
Remove existing driving lights from the vehicle by removing the cross bolt.
l Pull out bulb (it is recommended wearing cotton gloves and safety glasses).
l On the side of the arm, remove the single Phillips head screw retaining the two side
plates. Lift off the two side plates with the end of a small screw driver (keep for
reassembly)
see fig.J
Pull the two wires up pulling away the clear sealant. see fig.K
l Withdraw the complete bulb holder assembly from the arm and discard (this will not
be reused) you may need to cut the wires.
l Using a 7mm (9/32”) sized drill bit increase the size of the existing hole using the
same line of draw.
see fig.L
CAUTION: IF A LARGER DRILL BIT IS USED THE LIKELY HOOD OF PENETRATING THE
OUTER SURFACE IS HIGH)
l Unscrew clear protective cover, housing the HID bulb and blue anodized bulb holder.
l Working in reverse: fit the new HID bulb holder by sliding the two cables through the
throat of the arm exiting out the side of the arm. (We recommend inserting the larger
crimp terminal first.) Using the M3 hex set screw and 2mm hex key supplied fix the
new HID bulb holder into the arm (electrode at the 12 o’clock position).
see fig.M,N
NOTE: DO NOT REMOVE THE TWO YELLOW DUST SEALS.
l It is recommended to refit the reflector at this time before proceeding (as the HID
bulb is very fragile).
l Place the supplied heat shrink on each cable (this is optional as the existing dust seals
are in place, but highly recommended). see fig.P
l Push each cable into the high voltage connectors until the terminal 'clicks' into place.
(note the small red tab on the female plug must be protruding before it will fit)
l Locate the heat shrink over the fitted connector, using a heat gun or similar, heat until
the material shrinks around the connector and wire.
see fig.Q
NOTE: THE HEAT SHRINK SUPPLIED HAS A LIQUID GEL INSIDE THAT ENSURES A
PERFECT SEAL.
l Using a water based sealant apply in and around the drilled hole ensuring a water
proof seal. Place the wires into either side of the grooves within the arm.
see fig.O
l Refit the two side plates using the Phillips screw - before the sealant drys. see fig.J
l Refit light and connect to ballast. Refer to page 6 for ballast mounting instructions.
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