Front Runner RRAC054 User manual

1
"
LED 10 FLOODLIGHT unit
INSTALL TIME: 1 Hour
REV_A03
IMPORTANT WARNING!
IT IS CRITICAL THAT ALL FRONT RUNNER PRODUCTS BE PROPERLY AND SECURELY ASSEMBLED AND ATTACHED TO YOUR
VEHICLE IMPROPER ATTACHMENT COULD RESULT IN AN AUTOMOBILE ACCIDENT, AND COULD CAUSE SERIOUS BODILY
INJURY OR DEATH TO YOU OR TO OTHERS YOU ARE RESPONSIBLE FOR ASSEMBLING AND SECURING ALL FRONT RUNNER
PRODUCTS TO YOUR VEHICLE, CHECKING THE ATTACHMENTS PRIOR TO USE, AND PERIODICALLY INSPECTING THE
PRODUCTS FOR ADJUSTMENT, WEAR, AND DAMAGE THEREFORE, YOU MUST READ AND UNDERSTAND ALL OF THE
INSTRUCTIONS AND CAUTIONS SUPPLIED WITH YOUR FRONT RUNNER PRODUCT PRIOR TO INSTALLATION OR USE IF YOU DO
NOT UNDERSTAND ALL OF THE INSTRUCTIONS AND CAUTIONS, OR IF YOU HAVE NO MECHANICAL EXPERIENCE AND ARE NOT
THOROUGHLY FAMILIAR WITH THE INSTALLATION PROCEDURES, YOU SHOULD HAVE THE PRODUCT INSTALLED BY A
PROFESSIONAL INSTALLER OR OTHER QUALIFIED PERSONNEL
Depending on the type of installation chosen, not all components supplied will be used Refer to Page 15 Section
8 on how to set the angle of the Floodlight
RRAC054 / RRAC058

2
GET ORGANIZED
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Familiarize yourself with the parts and then step away from the work area and read through these
instructions from beginning to end Take a moment as a little prep now may save you a lot of time later
( )
A
You will need:
13 mm Flat Wrench
4 mm Hex Key (Front/Rear Mounting Option)
5 mm Hex Key
Side Cutter
Wire Stripper
Crimping Tool
Tape Measure
6 mm Drill Bit (Slimline fitment only)
Drill Machine (Slimline Fitment only)
Here is what you are looking at:
Item # Quantity Description
1 1 10" LED FLOODLIGHT
2 2 D-SHAPED NUT
3 6 M6 NYLOC NUT
4 2 MOUNTING ARM
5 2 M6 x 18 STAINLESS ALLEN CAP BOLT
6 2 M6 x 16 BUTTON HEAD BOLT
7 6 M6 FLAT WASHER
8 4 M8 x 20 BUTTON HEAD BOLT
9 6 M8 FLAT WASHER
10 4 M8 NYLOC NUT
11 4 M6 x 12 BUTTON HEAD BOLT
12 4 M6 NUT CAP
13 1 ELECTRICAL COVER
14 2 HELLA PLUG HEX NUT
15 1 EARTH PLATE
16 1 10" FLOODLIGHT MOUNTING BRACKET
17 2 HELLA PLUG
18 3 FLAG TERMINAL
19 3 INSULATING BOOT
20 1 RUBBER GROMMET
21 2 M8 x 30 BUTTON HEAD BOLT**
* Only used when mounting to
Slimline Rack - Refer to Page 14
** Only used when mounting inline
with a slat on a Slimline II Rack -
Refer to Page 10 Step 3I

3
( )
Prepare Wiring Suggested Met od
Measure and cut the Floodlight's electrical cable to 300 mm Keep the off-cut for Step 2C ( )
A
REV_A03
The 10" Floodlight may be wired and connected to the the vehicle's electrical system according to personal
preferences and requirements Steps 2A -2I below, illustrate Front Runners suggested method for wiring and
connecting your 10" Floodlight to the vehicle's electrical system
If the suggested method is selected, power to the Floodlight is supplied by running an Extension Cable ( Not
supplied) from a power outlet on the vehicle to one of the Hella Plugs found on the front of the Floodlight's
mounting bracket (Refer to Pages 8 & 9, Steps 3F & 3G) Should you wish to purchase the Front Runner
Extension Cable, the Part Number / Item Code is ECOM076
300 mm
Cut Here
Strip the black, outer insulation on the cut end of the electrical cable back 50 mm ( )
B
50 mm
( C ) From the off-cut in Step 2A, cut a section of wire 60 mm long Strip off the black outer insulation Keep
the 60 mm length of RED wire and dispose of the remaining wire
60 mm RED wire

4
( )
Prepare Wiring Suggested Met od ... CONT
Strip one end of the insulation on the red wire from Step 2C back 5 mm and crimp the Flag Terminal (Item
18) to the wire as shown below
( )
D
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Strip insulation back 5 mm
Red wire from Step 2D
Crimp
Crimp
( )
E
Fit an Insulating Boot (Item 19) over the crimped Flag Terminal as shown below
( F )
Insert the Rubber Grommet (Item 20) into the whole in the Electrical Cover (Item 13) as shown

5
( )
Prepare Wiring Suggested Met od ... CONT
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( H ) Following the steps below, strip and twist the red wires together as shown
Strip back the insulation by 10 mm on the
RED wire of lights power cable
From Step 2E, strip insulation back 10 mm
on opposite end to Flag terminal
Twist together
( )
G
Feed the Floodlight's electrical cable through the the hole in the Rubber Grommet inserted in Step 2F as
shown below

6
( )
Prepare Wiring Suggested Met od ... CONT
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( K ) Slide the last remaining Insulating Boot over the black wire on the lights power cable as shown Strip
back 5 mm of insulation from the end of the black wire Crimp the last remaining Flag Terminal onto the
end of the black wire and cover the Flag Terminal with the Insulating Boot
If you have a Slimline Rack, please turn to Page 13
( J ) Slide the Insulating Boot over the Flag
Terminal from Step 2I as shown
Slide an Insulating Boot (Item 19) over the twisted pair of red wires from Step 2H and crimp a Flag
Terminal (Item 18) onto the end of the twisted pair as shown
( )
I

7
Prepare for light install
Fit the two Mounting Arms (Item 4) to the outer
mounting positions found at either end of the
Light Mounting Bracket (Item 16) using the two
M6 x 12 Button Head Bolts and M6 Nyloc Nuts
(Items 3 & 11). The Mounting Arms must face
down as shown.
DO NOT US THE RUBBER MOUNTS SUPPLIED
WHEN USING THE FRONT RUNNER BRACKET
()
A
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Insert the D-Shaped Nut
(Item 2) into each end of the
light as shown. The domed
side of the nut must go to
the outside of the light.
()
B
()
C
Place the Mounting Bracket (Item 16) over the Floodlight, making sure that the electrical cable is on the
right. Align the D-Shaped Nuts, inserted in Step 3B, with the Mounting Arms fitted in Step 3A and secure
the Floodlight to the Mounting Bracket using two of the M6 x 18 Stainless Steel Allen Cap Bolts (Item 5).
This Assembly, as shown below, will be referred to as the Floodlight Unit for the remainder of these in-
structions.

8
Prepare for lig t install
Looking at the two Hella Plugs (Item 17),
cut off the outer "tab" on each using a
pair of side cutters
( )
D
REV_A03
Bend the "tab" on the Earth Plate (Item 15) to 90 degrees as shown below ( )
E
Cut Off
Bend "tab" to
90 Degrees
Remove the Hex Nut (Item 14) from the back
of each Hella Plug and secure the Earth Plate
and Hella Plugs to the Mounting Bracket
(Item 16) as shown
( F )
DO NOT CUT OFF THE MIDDLE TAB

9
Prepare for lig t install
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Connect the Floodlight to the Hella Plugs as shown below The two red wires go onto the center "tabs" of
the Hella Plugs and the black wire goes onto the "tab" on the Earth Plate
( )
G
Red Wire to "tab" in center of Hella Plug Black wire to "tab" on Earth Plate
Fit the Electrical Cover (Item 13) Over the rear of the Hella Plugs and electrical connections and secure in
place using two M6 x 12 Button Head Bolts, tow M6 Flat Washers and two M6 Nyloc Nuts (Items 3, 7, 11)
Place a M6 Nut Cap (Item 12)over each of the Nyloc Nuts
( H )

10
Prepare for lig t install
REV_A03
( i )
The Floodlight Unit may be mounted on the front, rear, left or right hand side of your Rack When
mounting on the side of the rack, the Floodlight Unit may be mounted inline with a slat (recommended) or
between two slats as shown below Decide where you would like to mount your Floodlight Unit Ensure
that there is enough clearance between the Floodlight Unit and vehicle If your vehicle's rear door opens
upwards and you wish to mount the Floodlight Unit on the rear of the Rack, you will need to check the
clearance between the Floodlight Unit and the vehicle with the rear door in the open position
For Side Mounting inline with a slat, refer to Section 4 For Side Mounting between two slats, refer to
Section 5 For Font/Rear Mounting, refer to Section 6