INSTRUCTION DATA
PRODUCT: HID BULB REPLACEMENT
VER: 1.0
DATE: MARCH 2013
HID bulb rated life is 3,000 hours and since they do not have a fragile filament their resistance to vibration and shock gives far
greater service life than traditional bulbs. In many cases the HID bulb never requires replacement and lasts for the life of the
product. Nevertheless, as the bulb ages the efficiency declines and it may be desirable to replace the bulb before it actually fails
in order to restore full light output.
Safety Warnings
HID bulbs operate at high pressure and may explode at end of life. Do not operate bare bulbs, ensure reflector is fitted before
illuminating. Always wear safety glasses when handling bare bulbs. Clean gloves should be worn to avoid contamination of the
bulb, substances passed onto the bulb may cause early failure.
Broken arc-tube: take care in handling and disposing of this lamp. If arc-tube is broken, avoid skin contact with any of the
contents and fragments.
Danger, high voltage. Always disconnect power before servicing the light
Demand Authentic Lightforce replacement bulbs, do not accept bulbs that are not packed in authentic Lightforce packaging.
Contents
1 x HID Bulb in protective container
1 x Accessory kit , containing:
1 x Replacement dust water seal rubber grommet
2 x Heat shrink insulating seals
1 x Push on socket (for black negative wire)
1 x Push on plug (for red positive wire)
Disassembly instructions
Ensure power supply is not connected to the ballast before you begin. Unplug the wires from the rear of the light that run toward
the ballast and ignitor.
Remove the driving light from the vehicle by removing the cross bolt. Remove the reflector by rotating it anti-clockwise.
Cut the flying lead and socket off the old bulb holder wires from the rear of the light to allow the wires to pull through the driving
light arm. See fig. A
Prize out the old dust water seal rubber grommet away from the arm and discard. A new grommet is supplied in the kit. See fig.
B
Remove the anodised bulb holder from the arm, use an M2mm Allen key to free the holder from the arm. Carefully remove the
bulb and holder by working the wires through the arm. See fig. C
Remove the old HID bulb away from the anodised bulb holder that is reused. Note the position of the old bulb and ensure new
bulb is installed in the same location. A 2.4mm Allen key will be required.
Dispose of the old bulb, pay attention to the safety warnings at the top of this sheet.
Instructions for bulb replacement
Fit the new bulb into the anodised bulb holder. Tighten the grub screws onto flat surface of white porcelain, making sure the top
surface is flush with the alloy face.
Reinstall the complete bulb and holder into the arm.
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 M2 hex set screw and fit the new HID bulb holder into the arm (electrode at the 12 o’clock position). See fig. C
LIGHTFORCE AUSTRALIA PTY LTD • 28 Orsmond Street, Hindmarsh SA 5007 Australia • www.lightforce.com | email: info@lightforce.net.au
Australia: Tel: 08 8440 0888 | Fax: 08 8346 0504 • Int’l: Tel: +618 8440 0888 | Fax: +618 8346 0504
All logos and images are subject to relevant trademark and copyright protection LIGHTFORCE Pty Ltd | © March 2013• Data and specifications contained maybe subject to change without notice.
LIGHTFORCE AUSTRALIA Pty. Ltd., shall be not be liable for damage, malfunction, failure resulting from accident, misuse, misapplication, unauthorised repair, neglect, modification, unauthorised or non standard replacement parts, accessories,
globes, batteries or voltage or the operation of the Product beyond its technical and environmental specifications.
INSTRUCTION DATA
PRODUCT: HID BULB REPLACEMENT
VER: 1.0
DATE: MARCH 2013
It is recommended to refit the reflector at this time before proceeding (as the HID bulb is very fragile).
The yellow dust seals fitted on the ends of the black and red wires must be removed to allow them to pass through the grommet.
Pass terminals through the new rubber grommet by using a 1mm jewellers screw driver (or similar) to push the terminals all the
way through.
OLD ARM
NEW ARM
NOTE: THIS IS A VERY TIGHT FIT TO CREATE A COMPLETE SEAL AGAINST THE ELEMENTS.
K
J
B
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
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
M
L
D
Place the supplied heat shrink on each cable. See fig. H
20 mm
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). See fig. J
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.
OLD ARM
G
Refit WRONG
light and connect toRIGHT
ballast.
F
J
O
N
K
NEW ARM
A
OLD ARM
J
B
QTAG
P
I
K
J
POINTS
TOWARD THE CATCH
BLACK
M
L
D
C
3
4
M
L
RED
20 mm
O
N
E
F
WRONG
PH
G
RIGHT
IQ
3
O
N
P
4
Q
4
LIGHTFORCE AUSTRALIA PTY LTD • 28 Orsmond Street, Hindmarsh SA 5007 Australia • www.lightforce.com | email: info@lightforce.net.au
Australia: Tel: 08 8440 0888 | Fax: 08 8346 0504 • Int’l: Tel: +618 8440 0888 | Fax: +618 8346 0504
All logos and images are subject to relevant trademark and copyright protection LIGHTFORCE Pty Ltd | © March 2013• Data and specifications contained maybe subject to change without notice.
LIGHTFORCE AUSTRALIA Pty. Ltd., shall be not be liable for damage, malfunction, failure resulting from accident, misuse, misapplication, unauthorised repair, neglect, modification, unauthorised or non standard replacement parts, accessories,
globes, batteries or voltage or the operation of the Product beyond its technical and environmental specifications.