EU Light Kit

Note: The left and right lights and mounts are different. Ensure that each light and mount is installed on the appropriate side.

1. Unplug the shroud headlight connectors and remove the fasteners that secure the platform shroud to the machine frame (Figure 1).

   Retain the fasteners to secure the shroud to the machine.

   

   Figure 1

   1. Platform shroud
   2. Shroud headlights

2. Remove the shroud from the frame.

3. Use 5 hex-head bolts (3/8 x 3/4 inch) and 5 flange nuts (3/8 inch) to secure the left headlight mount to the left floor bracket (Figure 2).

   

   Figure 2

   1. Hex-head bolt (3/8 x 3/4 inch)
   2. Flange nut (3/8 inch)
   3. Left headlight mount
   4. Right headlight mount

4. Use 4 hex-head bolts (3/8 x 3/4 inch) and 4 flange nuts (3/8 inch) to secure the right headlight mount to the right floor bracket (Figure 2).

5. Fasten the left and right headlights to the headlight mounts (Figure 3) with the fasteners supplied with the lights.

   Note: Ensure that the turn-signal lens on the headlight is positioned toward the outside of the traction unit.

   

   Figure 3

   Right headlight assembly shown

   1. Right headlight bracket
   2. Articulated-joint shell
   3. Articulated joint
   4. Headlight arm
   5. Locknut (10 mm)

6. Tighten the locknut to firmly hold the headlight assembly to the headlight bracket.

   Note: Do not overtighten the locknut.

Note: The left and right tail light mounts are different. Ensure that each mount is installed on the appropriate side.

1. Raise the hood; refer to your machine Operator’s Manual.

2. Install the light mounts; refer to the following steps based on your machine:

   • For Model No. 03674 (Reelmaster 5010-H), 03675 (Reelmaster 5410), and 03676 (Reelmaster 5510) machines:

     1. Remove the bolts from the frame rail on each side of the machine (Figure 4).

        

        Figure 4

        Left side of the machine shown

        1. Bolt
        2. Rear of the machine

     2. Use the previously removed bolts to secure the tail light extension brackets to the frame rail (Figure 5).

        

        Figure 5

        Left side of the machine shown

        1. Bolt
        2. Tail light extension bracket
        3. Nut (5/16 inch)
        4. Bolt (5/16 x 3/4 inch)
        5. Tail light mount

     3. Use 4 bolts (5/16 x 3/4 inch) and 4 nuts (5/16 inch) to secure the tail light mounts to the extension brackets (Figure 5).

   • For all other machines:

     Note: Older machines may have a chassis leg that extends in front of the radiator-frame fasteners. Remove the chassis leg, then file and paint over the new chassis end (Figure 6).

     

     Figure 6

     1. Cut location—chassis
     2. Chassis leg

     1. Remove the existing fasteners from both sides of the radiator frame near the machine frame rail (Figure 7).

        

        Figure 7

        Left side of the machine shown

        1. Bolt
        2. Nut

     2. Use 4 bolts (5/16 x 3/4 inch) and 4 nuts (5/16 inch) to secure the tail light mounts to the radiator frame (Figure 8).

        

        Figure 8

        Left side of the machine shown

        1. Nut (5/16 inch)
        2. Bolt (5/16 x 3/4 inch)
        3. Tail light mount

3. Mount the tail lights to the light mounts with the bolts and nuts included with each light.

Use the following instructions and illustrations to route and connect the wire harness. Refer to Figure 14 for an overview of the wire harness.

Figure 14

Wire harness overview

1. Registration plate lights
2. Fuse block
3. Starter
4. Tail light—left side
5. Engine ground
6. Beacon, hazard, turn signal, and horn switch
7. Kit headlight—left side
8. Shroud headlight—left side
9. Shroud headlight—right side
10. Horn
11. Kit headlight—right side
12. Neutral switch
13. Beacon
14. Tail light—right side
15. Main wire harness and long adapter harness connection

1. Raise the hood; refer to your machine Operator’s Manual.

2. Use 2 flange bolts (5/16 x 1 inch) and 2 flange nuts (5/16 inch) to secure the fuse block mount to the engine mount frame on the right side of the machine (Figure 15).

   

   Figure 15

   1. Flange bolt (5/16 x 1 inch)
   2. Fuse block bracket
   3. Flange nut (5/16 inch)

3. Use 2 flange bolts (M6) and 2 locknuts (M6) to secure the fuse block to the fuse block mount (Figure 16).

   

   Figure 16

   1. Flange bolt (M6)
   2. Fuse block
   3. Locknut (M6)

4. Route the wire harness to the left side of the machine as shown in Figure 17.

   

   Figure 17

   1. Registration plate lights
   2. Fuse block
   3. Starter
   4. Tail light—left side
   5. Engine ground
   6. Neutral switch
   7. Beacon
   8. Tail light—right side
   9. Main wire harness and long adapter harness connection

5. Connect the engine ground leg of the wire harness to the ground block (Figure 17).

6. Connect the wire harness to the right and left tail lights (Figure 17).

7. Insert a tie clip into the rear hole of the right tail light (Figure 18).

   

   Figure 18

   1. Right tail light
   2. Tie clip

8. Use the long adapter harness to connect the wire harness to the registration plate lights. (Figure 17 and Figure 19).

   Refer to Figure 19 for the appropriate magnet-tie-mount location on the machine. Place 1 magnet on the inside surface of the license plate mount. Route the adapter harness through the tie clip that you installed in the previous step.

   

   Figure 19

   1. Registration plate light
   2. Magnet tie mount
   3. Tie clip

9. Continue to route the wire harness along the right frame rail (Figure 17).

10. Connect the ring terminal to the starter (Figure 17).

11. Connect the wire harness to the beacon (Figure 17).

12. Connect the wire harness to the neutral switch (Figure 17).

1. Route the front end of the wire harness under the operator platform to the front of the machine (Figure 20).

   

   Figure 20

   1. Beacon, hazard, turn signal, and horn switch
   2. Kit headlight—left side
   3. Shroud headlight—left side
   4. Shroud headlight—right side
   5. Horn
   6. Kit headlight—right side

2. Thread each harness connector through the appropriate headlight bracket and connect it to the headlight (Figure 20).

   Non-hybrid machines: Use the short adapter harnesses to connect the wire harness to each headlight.

3. Plug the wire harness lead with the 2 connectors into the horn (Figure 20).

4. Position the platform shroud on top of the frame.

5. Plug the light-kit wire harness connectors into the shroud headlights (Figure 20).

6. Cut out a U-shaped notch on the shroud (Figure 21).

   Note: The U-shaped notch allows you to route the wire harness up towards the switches on the steering column.

   

   Figure 21

   1. U-shaped notch—shroud

7. Secure the shroud to the frame with the fasteners that you previously removed.

8. Route the wire harness to the column-bracket assembly on the steering column (Figure 20).

9. Plug the connectors into the flasher module, horn, turn signal, and hazard switches (Figure 22).

   

   Figure 22

10. Install the cover onto the column-bracket assembly with 2 hex socket button-head screws as shown in Figure 23

    

    Figure 23

    1. Cover
    2. Hex socket button-head screws

Press the hazard switch (Figure 26) to the ON position to activate the front and rear flashing hazard lights.

Press down on the left side of the turn-signal switch (Figure 26) to activate the left-turn signal. The center position is off.

Press down on the right side of the turn-signal switch (Figure 26) to activate the right-turn signal. The center position is off.

Press the beacon switch (Figure 26) to activate the beacon.

Press the horn button (Figure 26) to activate the horn.