Front Runner RRAC054 User manual

1
"
LED 10 FLOODLIGHT unit
INSTALL TIME: 1 Hour
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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
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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
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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
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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
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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
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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
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( 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

11
Looking underneath the Rack, place the
Floodlight Unit over the side of the Rack
(Hella Plugs facing down) Line up the slots
in the Floodlight Unit with the holes in the
side of the Rack (One either side of the
chosen slat) Secure the Floodlight Unit to
the Rack using two M8 x 20 Button Head
Bolts, four M8 Flat Washers and two Nyloc
Nuts (Items 8, 9 & 10) supplied
Side Mounting Inline wit a Slat
( )
A
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( )
B
( C )
Working from the top of the Rack, slide the two
M8 Nyloc Nuts from Step 4A underneath the
Floodlight Unit, lining the nuts up with the
mounting slots either end of the Floodlight Unit
Secure the top of the Floodlight Unit to the Rack
using two M8 x 20 Button Head Bolts and two
Flat Washers (Items 8 & 9) and the Nyloc Nuts
Congratulations, you have completed your
installation Take a step back and admire
your work Good Job!
Decide on which side of the Rack you would like to install the Floodlight Unit
On the chosen side, slide two M8 Nyloc Nuts (Item 10) dome side down into the U-channel through the gap
in the corner of the Tray as shown Slide the two Nyloc Nuts down the U-channel and into position either
side of the chosen slat as shown
Chosen Slat
Nyloc Nut Nyloc Nut

12
Looking underneath the Rack, loosen and remove
the two M8 Button Head Bolts (One either side of
the chosen gap) that secure the two slats to the
side of the Rack Place the Floodlight Unit over the
side of the Rack (Hella Plugs facing down)
Line up the mounting slots either end of the
Floodlight Unit with the M8 Bolt Holes (From the
two Button Head Bolts removed earlier) and secure
the Floodlight Unit to the Rack using the two M8 x
30 Button Head Bolts and two M8 Flat Washers
(Items 9 & 21) supplied
Side Mounting Between two Slats
( )
A
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( )
B
( C )
Working from the top of the Rack, slide the two M8
Nyloc Nuts from Step 5A underneath the Floodlight
Unit, lining them up with the mounting slots either
end of the Floodlight Unit Secure the top of the
Floodlight Unit to the Rack using two M8 x 20
Button Head Bolts and two Flat Washers (Items 8 &
9) and the Nyloc Nuts
Congratulations, you have completed your
installation Take a step back and admire your
work Good Job!
Decide on which side of the Rack you would like to install the Floodlight Unit On the chosen side, slide
three M8 Nyloc Nuts (Item 10) dome side down into the U-channel through the gap in the corner of the
Rack as shown Slide the three Nyloc Nuts down the U-channel and into position as shown below
Chosen gap
between two slats
Nyloc Nut Nyloc Nut
Nyloc Nut

13
/
FRONT REAR Mounting
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A
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( )
B
Place the Floodlight Unit over the Rack (Hella Plugs facing down) in the desired position Slide the M8
Nyloc Nuts inserted in Step 6A down the "U"-channels and lining both the top and bottom sets of nuts up
with the mountings slots either end of the Floodlight Unit
Secure the Floodlight Unit, both top and bottom four M8 x20 Button Head Bolts and four M8 Flat Washers
(Items 9 & 10) supplied Refit the corner removed in Step 6A
When mounting on the front or rear of the Rack, remove one of the appropriate corners by loosening the
M6 Button Head Bolt (as indicated by the arrow) and pulling the Corner free from the Rack
Insert two M8 Nyloc Nuts (Item 10) into each of the "U"-channels as shown
2 x Nyloc Nuts - Dome side facing down
2 x Nyloc Nuts - Dome side facing up
Congratulations, you have completed your installation Take a step back and admire your work Good
Job!
( C )

14
-
install Floodlig t Slimline Rack
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( )
A
Place the Floodlight Bracket over the side of
the rack (Hella Plug cut-outs facing down)
in the desired position Mark the position of
hole set "A" or "B" onto the side of the
Rack Remove the Floodlight Bracket and
drill a 6 mm hole on each of your two
markings
Place the Floodlight Unit onto the Rack (Hella Plugs facing down), lining the holes in the Floodlight Unit
up with the holes drilled in Step 7A Secure the Floodlight Unit to the Rack using two M6 x 20 Button Head
Bolts, Four M6 Flat Washers and two M6 Nyloc Nuts (Items 3, 6, 12) The Nyloc Nuts and two of the
Washers go on the inside of the Rack Once Secure place a M6 Nut Cap (Item 12) over each of the Nyloc
Nuts
( )
B
Complete Steps 3A to 3H (Pages 7-9)
( C )
Congratulations, you have completed your installation Take a step back and admire your work Good
Job!
( C )

15
Adjusting t e Angle
Loosen the two M6 Bolts (as indicated by the arrows) enough to allow the Floodlight to rotate and adjust
the Floodlight up or down until the desired angle has been achieved Tighten the two M6 Bolts
( )
A
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You will need:
5 mm Hex Key
INSTALL OTHER VEHICLE AND RACK ACCESSORIES
Now's the time to visit your favorite Front Runner dealer in person or online
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