Replacing Headlight Bulb and Housing

NOTE: There are two types of headlight assemblies. Earlier models use a 48 volt system and newer models use a 12 volt system. If a converter kit has been installed, you will have a 12 volt lighting system.

Replace 48 Volt Headlight Bulb

MXAL47829-UN-12APR13

1. Remove hood (A), and locate headlight housing in the front frame.

2. 
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   Locate headlight assembly housing (B).

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3. Rotate bulb socket (C) counterclockwise approximately 1/3 turn and remove from headlight housing (B).

4. 
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   Push down top of bulb (D) and rotate counterclockwise to remove from socket.

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5. IMPORTANT: This is not a standard replacement bulb. If bulb replacement is required, use only a 48 volt bulb. Using a 12 volt replacement bulb could cause a blown vehicle fuse.

   Install new headlight bulb (E) into bulb socket (C).

   • Push down top of bulb and rotate clockwise into locked position.
   
   

6. Install bulb socket (C) into headlight housing (B).

   • Rotate bulb socket clockwise into a locked position.
   
   

7. Test head lamp function.

8. IMPORTANT: When installing the hood be sure there is clearance all around each headlight housing. Premature failure of headlight bulbs may occur if the hood should make contact with a headlight housing.

   Install hood onto vehicle.

Replace 12 Volt Headlight Bulb

1. NOTE: This procedure is for vehicles equipped with the 48v to 12v converter kit already installed.

   
   MXAL47832-UN-12APR13

   Remove hood (A), and locate headlight housing in the front frame.

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2. 
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   Locate headlight assembly housing (B).

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3. Rotate bulb socket (C) counterclockwise approximately 1/8 turn and remove from headlight housing (B).

4. 
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   Release tabs (D), and disconnect wire connector (E) from bulb/socket assembly (F). Discard the bulb/socket assembly.

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5. Connect wiring connector to new bulb/socket assembly. Install the assembly into housing and rotate 1/8 turn to lock in place.

6. Test head lamp function.

7. IMPORTANT: When installing the hood be sure there is clearance all around each headlight housing. Premature failure of headlight bulbs may occur if the hood should make contact with a headlight housing.

   Install hood onto vehicle.

Replace Headlight Housing

1. Remove vehicle hood.

2. 
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   48 volt system shown

   
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   12 volt system shown

   Remove bulb socket:
   • 48 volt system: Rotate bulb socket (A) counterclockwise approximately 1/3 turn and remove from headlight housing (B).
   • 12 volt system: Rotate bulb/socket assembly (C) counterclockwise approximately 1/3 turn and remove from headlight housing (D).
   
   

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3. Remove screws (E) securing headlight housing to the utility vehicle frame.

4. Install replacement headlight housing.

   • Attach housing to utility vehicle frame with screws.
   
   

5. Install bulb socket into headlight housing.

   • Rotate bulb socket clockwise into locked position.
   
   

6. Install hood onto utility vehicle.