INSTRUCTION DATA

PRODUCT: 240 XGT

VER: 1.0 PERFORMANCE LIGHTING
DATE: NOVEMBER 2006

240 XGT INSTALLATION INSTRUCTIONS

IMPORTANT
DO NOT TOUCH MIRRORED SURFACE OF THE REFLECTOR UPON BULB CHANGE.
This will result in contamination to the highly reflective surface. It is advisable to wear safety glasses and gloves when replacing
the bulb. A clean cloth and alcohol may be used to remove any finger prints or external residue from the bulb surface. The
XGT housing must only be washed with soapy water, do not use solvents or solvent based cleaning agents as they may cause
damage. The light is designed to be run with the clear covers at all times to prevent damage to the front lens. XGT lights can
be mounted and used in any orientation!

INSTALLATION
It is important that the light be mounted on a flat surface that supports the base fully and is isolated from excessive vibration. It
is equally important to ensure that there is adequate clearance once in position between the rear of the housing and any vehicle
structure to allow freedom of movement in the event of impact.

Carefully tighten the mounting bolt to 50 ft/lbs. Be particularly careful if using a spanner or wrench with greater than
normal leverage.

It is a good idea to have your existing electrical wiring relay with the terminals facing down. This helps protect the relay from
water spray damage. If the cable supplied as standard is not long enough, you must use the correct diameter cable to extend
the wiring harness. Ensure polarity by connecting RED to (+) positive and BLACK to (-) earth. If you are unsure PLEASE contact
a qualified electrician.

In a safe location, ideally on a flat long straight stretch of road loosen the adjustment on both axis and aim the lights as desired.

Lightforce Wiring Harness is available as an optional accessory.

BULB REPLACEMENT

1. Disconnect power to the light.

2. Evenly remove the four allen head screws (using a 2.5mm allen key) from the rear access plate. Note
Note: This cover is
kept under tension via a large retaining spring, apply pressure to the access cover whilst removing the four screws.
Remove the rubber gasket from the housing.

3. Gently grasp the bulb holder and withdraw from the housing with the attached wires ensuring the blue seat is retained
in the reflector.

4. Remove old bulb from the bulb holder by withdrawing straight out. DO NOT TOUCH NEW BULB WITH BARE FINGERS.
When fitting the bulb grasp the bulb by the glass while using the protective wrapping or tissue to prevent the bulb from
being touched. Carefully push both pins into the bulb holder without twisting the bulb. Insert the new bulb until its
glass base is touching the bulb holder. Make sure the bulb filament is directly in line with the centre line of the bulb
holder. (If the filament is set to one side this will result in an uneven beam pattern.)

5. Reinsert bulb holder assembly feeding the power wires back into the housing. Ensure the holder is seated squarely into
the blue bulb seat with the power wires inserted between the “X” of the bulb holder.

6. Be careful when reseating the gasket that it is positioned correctly and the four screws evenly tensioned to ensure that
the housing remains sealed.

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 | © Oct 2006 • Data and specifications contained maybe subject to change without notice.
LIGHTFORCE Australia Pty Ltd shall not be liable for damage, malfunction, failure resulting from accident, misuse, misapplication, unauthorised repair, neglect, modification, unauthorised or non standard replacement parts,
accessories, bulbs, batteries or voltage or operation of the product beyond its technical and or environmental specification.
 PERFORMANCE LIGHTING

COMPONENT BREAKDOWN

Optional Filters Available

DL240XGT1DR *

Bulbs Available:
GL02(12v)
GL13(24v)

HID240GKT

HID240MT

HID240DLLOOM

HID240SPK

* Optional Part - replaces existing unit to achieve a broader beam pattern.

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 | © Oct 2006 • Data and specifications contained maybe subject to change without notice.
LIGHTFORCE Australia Pty Ltd shall not be liable for damage, malfunction, failure resulting from accident, misuse, misapplication, unauthorised repair, neglect, modification, unauthorised or non standard replacement parts,
accessories, bulbs, batteries or voltage or operation of the product beyond its technical and or environmental specification.
INSTRUCTION DATA

PRODUCT: DRIVING LIGHT HARNESS

VER: 1.0 PERFORMANCE LIGHTING
DATE: MAY 2007

DRIVING LIGHT HARNESS INSTRUCTIONS

1. Remove the main ground wire from the negative battery terminal.

WARNING: This may result in loss of radio security code and clock settings. Please consult your owners manual
before disconnecting.

2. Install driving lights onto a suitable mounting surface.

3. Place all corresponding clear insulating terminal covers over the wires first, fit one female terminal and one male bullet
terminal to both auxiliary driving light wires.

NOTE: On the RMDL Series any one of the two wires can be used as positive with the second wire as negative. On the DL
series, strip 5mm of insulation and fit the male terminal onto the red wire (+) and the female terminal onto the black wire (-).

4. Find a suitable place within the engine bay (i.e inner guard) to mount the relay and fuse holder. Ensure that the yellow (+)
and black (-) ring terminals reach the appropriate battery terminals.

5. Secure black with yellow stripe wire fitted with tongue terminal to body frame obtaining a good earth.

6. Insert relay into base.

7. Mount the switch in a suitable position.

8. Locate a grommet through the firewall and pass the brown wire and black with red stripe wire through the pierced grommet
to the switch location.

9. Strip 5mm off the ends of the insulation of the brown wire and black with red stripe wire, then crimp a red terminal to each
end, connect to left and right terminals on the switch.

10. Route the two insulated white (+) and black (-) wires to each of your installed Lightforce driving lights, connect the
corresponding terminals together. Ensure your cables do not touch the radiator or come in contact with any sharp edges.

11. Secure all excess wire to the vehicle.

12. Using a multi-meter or test light find the active high beam switching wire located on the back of the head light. Connect
“Ezy Tap” connector onto this wire.

13. Strip 5mm of the insulation from the brown wire and crimp pink blade terminal to the end, connect onto “Ezy Tap” terminal.

14. Connect the yellow ring terminal to the positive battery terminal.

15. Connect the black-wired ring terminal to the negative battery terminal then reconnect main ground (negative) wire to the
negative battery terminal.

16. Test.

If the lights do not operate correctly check the following:

• Recheck all installation steps.

• Inspect fuse holder for blown fuse.

• Inspect all ground wires for good earth.

• Check switch operation.

• Some automotive manufacturers use the negative circuit to activate the high beam, in this situation discard the open ring
terminal with black and yellow stripe wire (A). Connect the remaining male bullet terminal (B) with the female terminal (C)
on the black with yellow stripe wire taped to the yellow wire at the base of the relay.

NOTE: This wiring harness is designed for the use of two lights only - not exceeding 9amps per light. Should extra light(s) be
fitted additional wiring harness is required.

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 | © Oct 2006 • Data and specifications contained maybe subject to change without notice.
LIGHTFORCE Australia Pty Ltd shall not be liable for damage, malfunction, failure resulting from accident, misuse, misapplication, unauthorised repair, neglect, modification, unauthorised or non standard replacement parts,
accessories, bulbs, batteries or voltage or operation of the product beyond its technical and or environmental specification.
 PERFORMANCE LIGHTING

COMPONENT BREAKDOWN

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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 | © Oct 2006 • Data and specifications contained maybe subject to change without notice.
LIGHTFORCE Australia Pty Ltd shall not be liable for damage, malfunction, failure resulting from accident, misuse, misapplication, unauthorised repair, neglect, modification, unauthorised or non standard replacement parts,
accessories, bulbs, batteries or voltage or operation of the product beyond its technical and or environmental specification.