Ignition Update Kit

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the machine and remove the key.

4. Disconnect the main negative battery cable (black) that connects the bank of batteries to the ground point of the machine; refer to your Operator’s Manual.

Parts needed for this procedure:

1. Remove the existing ignition switch assembly.

2. Disconnect the wires from the terminals on the existing ignition switch.

3. Connect the previously disconnected wires to terminals B1 and 3 on the new ignition switch (Figure 1).

   

   Figure 1

4. Install the new ignition switch assembly as shown in Figure 2.

   

   Figure 2

   1. Key
   2. Mounting nut
   3. Backup washer
   4. Ignition switch
   5. Screw

Remove the existing converter module (Figure 3).

Note: Discard the converter module.

Figure 3

1. Converter module

Parts needed for this procedure:

1. Install the left side of the converter to the converter bracket with 2 self-tapping screws (1/4 x 3/4 inch) as shown in Figure 4.

   

   Figure 4

   1. Converter bracket
   2. Converter
   3. Self-tapping screw (1/4 x 3/4 inch)

2. Install the relay to the converter bracket with the 2 hex-head screws (#6 x 1/2 inch) as shown in Figure 5.

   

   Figure 5

   1. Converter bracket
   2. Relay
   3. Hex-head screw (#6 x 1/2 inch)

3. Install the converter bracket to the machine with 2 self-tapping screws (1/4 x 3/4 inch) on the left side of the bracket and 2 self-tapping screws (1/4 x 3/4 inch) to the right side of converter (Figure 6).

   

   Figure 6

   1. Converter bracket
   2. Converter
   3. Self-tapping screw (1/4 x 3/4 inch)

4. Connect the power-upgrade wire harness connections to the relay as follows:

   • Connect the relay-coil wires (black with white stripe and orange) to the small terminals on the bottom of the relay (Figure 7).

   • Connect the relay-contact wires (green and blue) to the large terminals (Figure 7).

   Note: The terminals are not polarity sensitive.

   

   Figure 7

   1. Relay
   2. Relay-coil wires (black with white stripe and orange)
   3. Relay-contact wires (green and blue)

5. Connect the power-upgrade wire harness connector to the converter (Figure 8).

   

   Figure 8

   1. Wire-harness connector
   2. Converter

6. Connect the power-upgrade wire harness to the 48 V/12 V converter and the power-option connectors on the machine wire harness.

Parts needed for this procedure:

Install the fuse (20 A) into the slot in the fuse block (Figure 9).

Figure 9

1. Fuse (20 A)
2. Fuse block

Connect the main negative-battery cable (black) that connects the bank of batteries to the ground point of the machine; refer to your Operator’s Manual.