Light Kit

1. Move the machine to level ground and engage the parking brake.

2. Lower the cutting deck to the ground.

3. Shut off the engine and remove the key.

4. Unlatch and raise the engine cover, and secure it in the raised position with the prop rod.

5. Disconnect the negative (-) battery cable from the battery.

1. Drill the hole as shown in Figure 1.

   

   Figure 1

   Front of the machine

   1. 29.2 cm (11-1/2 inches)
   2. 8.9 cm (3-1/2 inches)
   3. Hole (3.2 cm or 1-1/4 inch)

2. Drill the holes as shown in Figure 2.

   

   Figure 2

   Front of the machine

   1. 40.6 cm (16 inches)
   2. 18.6 cm (7-5/16 inches)
   3. 25 mm (1 inch)
   4. 13/32 inch diameter

3. Drill the holes for the horn as shown in Figure 3.

   

   Figure 3

   1. 13/32 inch diameter
   2. 6.4 cm (2-1/2 inches)
   3. 25 mm (1 inch)

4. Drill the holes as shown in Figure 4.

   

   Figure 4

   Front view of the foot rest

   1. 26 cm (10-1/4 inches)
   2. 3.2 cm (1-1/4 inch)
   3. 11.4 cm (4-1/2 inches)

Parts needed for this procedure:

1. Unlatch the side cover of the control panel (Figure 5) and set it aside.

   

   Figure 5

   1. Control panel side cover
   2. Latches

2. Locate and remove the knockout plug located towards the front of the control panel under the decal (Figure 6).

   

   Figure 6

   1. Control panel top
   2. Light switch
   3. Knockout plug

   Note: Position the lens on the hazard switch away from the operator.

3. Insert the light switch as shown in Figure 6.

Parts needed for this procedure:

1. Install the left and right rear lights with 4 U-bolts and 4 flange nuts (3/8 inch) (Figure 7). Ensure that you do not cover the decal.

   

   Figure 7

   1. Right-rear light
   2. U-bolt
   3. Left-rear light
   4. Flange nuts (3/8 inch)

2. Install the light plate and center rear light (Figure 8).

   Note: You may need an extra person to hold the light plate as you secure it to the machine.

   

   Figure 8

   1. Light plate
   2. Center rear light
   3. Bolt (#10 x 7/8 inches)
   4. Flange nut (1/4 inch)
   5. Bolt (1/4 x 3/4 inch)
   6. Flange nut (#10)

Parts needed for this procedure:

Install the headlight-mount assembly to the front of the machine with 2 bolts (3/8 x 1 inch) and 2 flange nuts (3/8 inch); refer to Figure 9.

Figure 9

1. Bolt (3/8 x 1 inch)
2. Headlight-mount assembly
3. Flange nut (3/8 inch)

Parts needed for this procedure:

1. Remove the shields from the headlights (Figure 11).

   Note: The optional headlight extensions are for the 183 cm (72 inch) and 254 cm (100 inch) mower decks only (Figure 10).

2. If needed, install the headlight extension with 4 bolts (1/4 x 3/4 inch) and 4 locknuts (1/4 inch); refer to Figure 10.

3. Install the headlight to the extension or the headlight mount assembly with 4 bolts (1/4 x 3/4 inch) and 4 locknuts (1/4 inch); refer to Figure 10.

   

   Figure 10

   Right side shown

   1. Locknut (1/4 inch)
   2. Headlight assembly
   3. Bolt (1/4 x 3/4 inch)
   4. Optional headlight extension for 183 cm (72 inch) and 254 cm (100 inch) mower decks only.
   5. Light harness

4. Install the front light electrical connectors (Figure 11).

   

   Figure 11

   Right side shown

   1. Terminal receptacle
   2. Bolt (1/4 x 3/4 inch)
   3. Headlight shield
   4. Connector

5. Install the shields to the headlights (Figure 11).

Parts needed for this procedure:

Important: This procedure is only for 254 cm (100 inch) mower decks.

Secure the caster-fork latch as shown in Figure 12.

Figure 12

1. Flange bolt (3/8 x 1-1/2 inches)
2. Flange nut (3/8 inch)

Parts needed for this procedure:

1. Remove the existing left handle and retain the washers and bolts.

2. Install the new handle with the existing washers and bolts (Figure 13).

   

   Figure 13

   1. Lever
   2. Washer (existing)
   3. Bolt (existing)

Parts needed for this procedure:

Install the horn as shown in Figure 14.

Figure 14

1. Carriage bolt (5/16 x 5/8 inch)
2. Horn
3. Flange nut (5/16 inch)

Parts needed for this procedure:

Note: Do not attach the black (negative) lead until the whole kit is installed.

1. Thread the wiring harness branch with the flasher relay up into the side cover, where the main harness enters the panel (Figure 14).

   

   Figure 15

   1. Switch
   2. 10A fuse
   3. Blade connectors
   4. Flasher module
   5. Flasher relay
   6. Right rear lamp
   7. License plate lamp
   8. Left rear lamp
   9. Connect the red (positive) leads to the battery.
   10. Control-lever connections
   11. Headlamp connector
   12. Horn connector

2. Use the blade connectors under the control panel as follows:

   Note: Use only 1 of the blade connectors shown in Figure 15.

   • If the Auxiliary Power Unit (model 30382) is installed, connect the correct blade connector to the open blade on the auxiliary power module.

   • If the Auxiliary Power Unit (model 30382) is not installed, connect the correct blade connector that fits to the existing pink wire.

3. Use Figure 15 to route the wiring harness into the machine.

4. Use the magnetic holders shown in Figure 16 to secure the wire harness.

   

   Figure 16

   1. Magnetic harness holders
   2. Wire harness

Parts needed for this procedure:

1. Install the 20 kmp decals as shown in Figure 17.

2. Install the serial plate as shown in Figure 17.

3. Stamp the date into the side of the metal frame in the area shown in Figure 17.

   

   Figure 17

   1. 20 kpm decal
   2. 3.8 cm (1-1/2 inches)
   3. 6 mm (1/4 inch)
   4. Serial number decal
   5. For German customers, stamp the required information into the side of the frame in this area.
   6. 7.6 cm (3 inches)
   7. 12.7 cm (1-1/4 inches)

1. Attach the negative battery cable and the black (negative) lead to the battery.

2. Latch the engine cover.

3. Test all the functions of the kit.

• The hazard warning switch operates the hazard warning lights and will work whether the ignition is switched to the ON or OFF position (Figure 18).

  

  Figure 18

  1. Light switch

  • Press the side of the rocker switch with the hazard warning symbol to operate the hazard warning lights.

  • Press the other side of the rocker switch to turn off the hazard warning lights.

• The direction-indicator switch operates the right and left direction indicator lights when the ignition is switched to the ON position (Figure 19).

  

  Figure 19

  1. Headlamp and dipped-beam switch
  2. Direction-indicator switch
  3. Horn button

  • Press the left side of the indicator switch to turn on the left direction-indicator lights.

  • Press the right side of the indicator switch to the central position to turn off the left direction-indicator lights.

  • Press the right side of the indicator switch to turn on the right direction-indicator lights.

  • Press the left side of the indicator switch to the central position to turn off the right direction-indicator lights.

• The headlamp and dipped beam switch operates the headlamps only when the ignition is switched to On (Figure 19).

  • Push the switch forward to turn on the headlamp.

  • Push the switch backward to turn on the dipped-beam headlamp.

• Push the horn button to operate the horn.

• Keep the lenses clean by wiping them with a damp cloth. Do not use solvent-based cleaners.

• Replace all light bulbs as needed. Use replacement bulbs that have the proper voltage and wattage rating; refer to the old bulb for details.