NA Light Kit

1. Clean the front edge of the platform with alcohol, and allow it to dry (Figure 4).

   

   Figure 4

   1. Reflector decal (yellow)

2. Remove the backing film from the yellow reflector decal.

3. Align the reflector to the bottom edge of the platform as shown in Figure 4, and adhere it to the platform.

4. Wrap the edge of the reflector over the top of the platform.

5. Repeat steps 1 through 4 for the other yellow reflector decal.

1. Clean the front cab pillar above the headlight bracket with alcohol, and allow it to dry (Figure 5).

   

   Figure 5

   1. Front cab pillar
   2. Reflector decal (yellow)
   3. 23.8 cm (9-3/8 inches)
   4. Headlight bracket

2. Remove the backing film yellow reflector decal.

3. Align the decal 23.8 cm (9-3/8 inches) above the headlight bracket, and adhere the decal to the cab pillar (Figure 5).

1. Clean the face of the bumper with alcohol, and allow it to dry (Figure 6).

   

   Figure 6

2. Remove the backing film from the red reflector decal.

3. Align the reflector to the bumper as shown in Figure 6, and adhere it to the bumper.

4. Repeat steps 1 through 3 for the other red reflector decal.

At the bracket side of the headlight, look at the information printed on the housing (Figure 7). Note the part number and the “RH” or “LH” information.

Figure 7

Use Figure 8 and Figure 9 to identify the headlight mounts for your machine.

Figure 8

Machines with a Roll Bar

1. Light mounts

Figure 9

Machines with a Cab

1. Left light mount
2. Right light mount

Remove the 2 capscrews and 2 thin washers, 2 thick washers, and 2 flange locknuts that secure the front of the floor panel to the frame of the machine (Figure 10).

Note: Retain the hardware.

Figure 10

1. Capscrew (1/2 x 4-1/2 inches)
2. Floor panel
3. Thin washer (1/2 x 1-3/8 inch)
4. Flange locknut (1/2 inch)
5. Thick washer (1/2 x 2-1/4 x 3/8 inch)

1. Assemble the light mount to the floor panel and frame of the machine with the capscrew (1/2 x 4-1/2 inches), thin washer (1/2 x 1-3/8 inch), thick washer (1/2 x 2-1/4 x 3/8 inch), and flange locknut (1/2 inch) that you removed in Removing the Floor Panel Hardware.

   

   Figure 11

   1. Capscrew (1/2 x 4-1/2 inches)
   2. Thin washer (1/2 x 1-3/8 inch)
   3. Light mount (machines with a cab)
   4. Thick washer (1/2 x 2-1/4 x 3/8 inch)
   5. Flange locknut (1/2 inch)

2. Torque locknut and capscrew and locknut to 91 to 113 N∙m (67 to 83 ft-lb).

3. Repeat steps 1 and 2 for the light mount at the other side of the machine.

Important: Ensure that you assemble the headlight marked left and the left light mount, and the headlight marked right and the right light mount.

1. If assembled, remove the locknut (12 mm) and lock washer (12 mm) from the capscrew in the headlight bracket.

2. Align the light to the light mount as follows:

   • Groundsmaster 4010 Machines: Use the outside light-mount hole.

   • Groundsmaster 4110 Machines: Use the inside light-mount hole.

   

   Figure 12

   Right headlight shown.

   1. Capscrew (headlight)
   2. Outside light-mount hole (Groundsmaster GM4010 machines)
   3. Inside light mount hole (Groundsmaster GM4110 machines)
   4. Lock washer
   5. Locknut

3. Assemble the capscrew (12 mm) to the light mount (Figure 12) with the locknut (12 mm) and lock washer (12 mm).

4. Tighten the locknut and capscrew.

5. Repeat steps 1 through 4 for the headlight and light mount for the other side of the machine.

Important: Ensure that you assemble the headlight marked left at the left side of the machine, and the headlight marked right at the right side of the machine.

1. Remove the cable tie securing the 6-socket connector labeled and the 6-socket connector labeled of the machine wire harness to the chassis of the machine (Figure 13).

   

   Figure 13

2. Remove the cap from the 6-socket connector labeled or the 6-socket connector labeled of the machine wire harness, and plug the connector into the headlight (Figure 14).

   

   Figure 14

   1. 6-socket connector (labeled or —machine wire harness)
   2. Cap
   3. Headlight

3. If assembled, remove the locknut (12 mm) and lock washer (12 mm) from the capscrew in the headlight bracket.

4. Assemble the capscrew (12 mm) to the light mount (Figure 15) with the locknut (12 mm) and lock washer (12 mm).

   

   Figure 15

   Right headlight shown.

   1. Headlight
   2. Light mount (machines with a roll bar)
   3. Lock washer
   4. Locknut

5. Tighten the locknut and capscrew.

6. Bundle the excess wire harness and secure it to the chassis with a cable tie.

7. Repeat steps 2 through 5 for the other headlight at the other side of the machine.

1. Assemble the headlight and light mount to the headlight bracket (Figure 16) with a flange-head capscrew (1/2 x 1 inch) and flange locknut (1/2 inch).

   

   Figure 16

   1. Flange-head capscrew (1/2 x 1 inch)
   2. Light mount
   3. Headlight bracket
   4. Flange Locknut (1/2 inch)

2. Torque locknut and capscrew and locknut to 91 to 113 N∙m (67 to 83 ft-lb).

3. Repeat steps 1 and 2 for the other headlight and light mount at the other side of the machine.

4. Remove the cap from the 6-socket connector labeled or the 6-socket connector labeled of the machine wire harness, and plug the connector into the headlight (Figure 17).

   

   Figure 17

   1. 6-socket connector (labeled or —machine wire harness)
   2. Cap
   3. Headlight

5. Repeat step 4 for the other headlight at the other side of the machine.

1. Disconnect the single-pin connector from the single-socket connector labeled (Figure 18).

   

   Figure 18

   1. Cap plug
   2. Single-socket connector (labeled )
   3. Single-pin connector

2. Plug the single-pin connector and the single-socket connector into the cap plug (Figure 18).

1. Remove the boot from the steering cover, and slide the boot up (Figure 19).

   

   Figure 19

   1. Boot
   2. Flange-head screws
   3. Steering cover

2. Remove the 4 flange-head screws that secure the steering cover to the cover mounts, and lift the cover (Figure 19).

3. Grind a notch in the steering cover as show in Figure 20.

   

   Figure 20

   1. Notch (steering cover)
   2. 6 mm (1/4 inch)
   3. 11 mm (7/16 inch)

4. Align the 12-pin connector end of the control harness through notch in the steering cover (Figure 21).

   

   Figure 21

   1. 12-pin connector (control harness)
   2. Notch (steering cover)

5. Assemble the steering cover to the cover mounts with the 4 flange-head screws.

6. Pull the boot down and assemble the bottom of it into the steering cover (Figure 22).

   

   Figure 22

1. Assemble the clip nut (#10) onto the fuse mount plate (Figure 23).

   

   Figure 23

   1. Clip nut (#10)
   2. Fuse mount plate
   3. Flasher
   4. Flange head screw (#10 x 3/8 inch)
   5. Cable tie

2. Assemble the flasher to the mount plate (Figure 23) with a flange head screw (#10 x 3/8 inch).

3. Secure the flasher to the mount plate with a cable tie (Figure 23).

4. Plug the 12-socket connector of the console harness into the 12-pin connector of the flasher (Figure 24).

   

   Figure 24

   1. 12-pin connector (flasher)
   2. 12-socket connector (console harness)

5. Insert push-in anchor of the console harness into the 6.4 mm (1/4 inch) hole in the bracket mount (Figure 25).

   

   Figure 25

   1. Bracket mount
   2. Push-in anchor (console harness)

1. Assemble the 8 clip nuts (1/4 inch) to the switch mount as shown in Figure 26.

   

   Figure 26

   1. Switch mount
   2. Clip nut (1/4 inch)

2. Insert the multi-function switch into the 100 mm (2 inch) hole in the switch mount as shown in Figure 27.

   

   Figure 27

   1. Switch mount
   2. Multi-function switch

3. Secure the multi-function switch to the switch mount with the thick and thin switch clips (Figure 28).

   

   Figure 28

   1. Tab (multi-function switch)
   2. Switch clip (thick)
   3. Switch clip (thin)

4. Insert the 3 switch plugs into the switch mount as shown in Figure 29.

   

   Figure 29

   1. Switch plug

5. Align the rocker switch to the switch mount with the lens of the light to the front of the switch plate (Figure 30).

   

   Figure 30

   1. Rocker switch
   2. Front of the switch plate

6. Assemble the 2 knobs into the fuse cover, and secure the knobs with 2 bolt retainers (Figure 31).

   

   Figure 31

   1. Bolt retainer
   2. Fuse cover
   3. Knob

7. Assemble the fuse cover to the switch plate, and tighten the knobs (Figure 31).

1. Align the switch plate to the rearward side or the steering column (Figure 33).

   

   Figure 32

   1. Carriage bolt (1/4 x 2 inches)
   2. Bracket mount

2. At the upper 6.4 mm (1/4 inch) holes, assemble 2 carriage bolts bolt (1/4 x 2 inches) through the switch plate and the other bracket mount (Figure 32).

3. Assemble the fuse mount plate to the upper bracket mount and carriage bolts (Figure 33) with 2 flange locknuts (1/4 inch).

   

   Figure 33

   1. Bracket mount
   2. Carriage bolt (1/4 x 2 inches)
   3. Switch mount
   4. Fuse mount plate
   5. Flange locknut (1/4 inch)

4. At the lower 6.4 mm (1/4 inch) holes, assemble 2 carriage bolts bolt (1/4 x 2 inches) through the switch plate, bracket mount, and fuse mount plate (Figure 33) with 2 carriage bolts (1/4 x 2 inches) and 2 flange locknuts (1/4 inch).

5. Align the switch plate to the operator’s seat, and tighten the 4 flange locknuts.

1. Plug the 8-socket connector of the control harness labeled into the 8-pin connector of the rocker switch (Figure 34).

   

   Figure 34

   1. 8-pin connector (rocker switch)
   2. 8-socket connector (labeled —console harness)

2. Plug the 9-pin connector of the multi-function switch harness into the 9-socket connector of the console harness (Figure 35).

   

   Figure 35

   1. 9-pin connector (multi-function switch harness)
   2. 9-socket connector (console harness)

3. Secure the console harness to the steering column with 2 cable ties.

1. Align the holes in the control cover to the holes in the switch mount (Figure 36).

   

   Figure 36

   1. Switch mount
   2. Push-in fastener
   3. Control cover

2. Using the middle holes, secure the cover to the mount with 2 push-in fasteners as shown in Figure 36.

3. Secure the cover to the mount with 4 flange-heads screws (1/4 x 3/4) as shown in Figure 37.

   

   Figure 37

   1. Flange-heads screw (1/4 x 3/4 inch)
   2. Control cover

At the floor along right side of the operator’s seat, remove the 2 socket-head screws and 2 washers that secure the controller cover to the electrical-component mount, and remove the cover (Figure 40).

Figure 40

1. Electrical cover
2. Socket-head screw
3. Washer
4. Clip nut (electrical-component mount)

At the floor along right side of the operator’s seat, remove the 2 socket-head screws that secure the controller cover to the electrical-component mount, and remove the cover (Figure 41).

Figure 41

1. Electrical cover
2. Socket-head screw
3. Clip nut (electrical-component mount)

Insert the fuses (Figure 42) into the following fuse-block slots:

Figure 42

1. Fuse (10 A) and fuse-block slot A3
2. Fuse (15 A) and fuse-block slot A4

1. Align holes in the controller cover with clip nuts on the electrical-component mount (Figure 43).

   

   Figure 43

   1. Electrical cover
   2. Socket-head screw
   3. Washer
   4. Clip nut (electrical-component mount)

2. Install the controller cover to the electrical-component mount (Figure 43) with the 2 socket-head screws and 2 washers that you removed in Removing the Electrical Cover.

1. Align holes in the controller cover with clip nuts on the electrical-component mount (Figure 44).

   

   Figure 44

   1. Electrical cover
   2. Socket-head screw
   3. Clip nut (electrical-component mount)

2. Install the controller cover to the electrical-component mount (Figure 44) with the 2 socket-head screws that you removed in Removing the Electrical Cover.

1. Align the left light-housing mount into the left light housing as shown in Figure 45.

   

   Figure 45

   1. Left light housing
   2. Left light-housing mount
   3. Carriage bolt (1/4 x 5/8 inch)
   4. Flange locknut (1/4 inch)
   5. Right light housing
   6. Right light-housing mount

2. Secure the mount to the housing (Figure 45) with 2 carriage bolt (1/4 x 5/8 inch) and flange locknut (1/4 inch).

3. Align the right mount into the right light-housing mount as shown in Figure 45.

4. Secure the mount to the housing (Figure 45) with 2 carriage bolt (1/4 x 5/8 inch) and flange locknut (1/4 inch).

1. Assemble the 4-socket connector of the left taillight and license plate harness into the left light housing (Figure 46).

   Note: The left taillight and license plate harness has a 2-socket connector for the license-plate light.

   

   Figure 46

   1. Left light housing
   2. 4-socket connector (left taillight and license plate harness)
   3. 2-socket connector (left taillight and license plate harness)
   4. Right light housing
   5. 4-socket connector (right taillight harness)

2. Assemble the 4-socket connector of the right taillight and license plate harness into the right light housing (Figure 46).

3. Assemble 2 clip nuts onto the inner mount as shown in Figure 47.

   

   Figure 47

   1. Inner mount
   2. Clip nut (1/4 inch)
   3. Light housing
   4. Socket-head screw (1/4 x 3/4 inch)

4. Align the 4-socket connector of the harness through the inner mount (Figure 47).

5. Assemble the inner mount into the light housing, and secure the mount to the housing (Figure 47) with 4 socket-head screws (1/4 x 3/4 inch).

6. Repeat steps 3 through 5 for the other inner mount and light housing.

1. Align the taillight to the light housing with the yellow lens positioned as shown in Figure 48.

   

   Figure 48

   1. Yellow lens (taillight)
   2. Red lens (taillight)
   3. 4-socket connector (taillight harness)
   4. Phillips-head screw (#10 x 1-1/4 inches)
   5. Clip nut (#10)

2. Plug the 4-socket connector of the harness into the 4-pin connector of the taillight (Figure 48).

3. Assemble the taillight into the light housing, and secure the light to the housing (Figure 48) with 2 Phillips-head screws (#10 x 1-1/4 inches).

4. Repeat steps 1 through 3 for the other taillight and light housing.

5. Install a pivot bracket to the light-housing mount (Figure 49) with 3 capscrews (1/4 x 3/4 inch) and locknuts (1/4 inch).

   

   Figure 49

   1. Capscrew (1/4 x 3/4 inch)
   2. Light-housing mount
   3. Pivot bracket
   4. Locknut (1/4 inch)

6. Install the mount cover to the light-housing mount with 4 push-in fasteners (Figure 50).

   

   Figure 50

   1. Push-in fasteners
   2. Mount cover
   3. Light-housing mount

7. Repeat steps 5 and 6 for the other mount cover and light assembly.

1. At the left side of the bumper, remove the 2 capscrews (1/2 x 1-1/4 inches), 2 washers (1/2 inch), and 2 flange locknuts (1/2 inch) securing the bumper to the left frame rail (Figure 48).

   

   Figure 51

   1. Flange locknut (1/2 inch)
   2. Washer (1/2 inch)
   3. Capscrew (1/2 x 1-1/4 inches)
   4. Carriage bolt (1/4 x 1-1/4 inches)
   5. Swivel-adapter mount

2. Insert 2 carriage bolts (1/4 x 1-1/4 inches) into the slots in the swivel-adapter mount (Figure 48).

3. Assemble the swivel-adapter mount and bumper to the left frame rail with the 2 capscrews (1/2 x 1-1/4 inches), 2 washers (1/2 inch), and 2 flange locknuts (1/2 inch) that you removed in step 1.

4. Torque the capscrews and locknuts to 91 to 113 N∙m (67 to 83 ft-lb).

5. Install the pivot bracket to the carriage bolts in the swivel-adapter mount (Figure 52) with 2 flange locknuts (3/8 inch).

   

   Figure 52

   1. Carriage bolt (3/8 x 1-1/4 inches)
   2. Pivot bracket
   3. Flange locknut (3/8 inch)

6. Repeat steps 1 through 4 for the swivel-adapter mount at the other side of the bumper.

1. Unlatch and open the hood.

2. Route the 4-socket connector labeled of the machine wire harness under the left frame rail and forward (Figure 56).

   

   Figure 56

   1. 4-pin connector (labeled LH Rear Lights—left taillight harness)
   2. Magnetic harness anchor
   3. 2-socket connector (license-plate light branch—left taillight harness)

3. Adhere the magnetic harness anchor to the to the frame rail (Figure 56).

4. Route the 2-socket connector (license-plate light branch) of the left taillight harness under the hood and inboard (Figure 56).

5. Insert the push-in anchor of the license-plate light branch into the hole in the left hood-hinge mount (Figure 57).

   

   Figure 57

   1. Push-in anchor
   2. Hole (hood-hinge mount—left)
   3. 2-socket connector and cap (license-plate light branch—left taillight harness)

6. At the inboard side of the frame rail, remove the cap from the 4-socket connector labeled of the machine wire harness (Figure 58).

   

   Figure 58

   1. 4-socket connector (labeled —machine wire harness)
   2. Cap
   3. 4-pin connector (labeled LH Rear Lights—left taillight harness)

7. Plug the 4-pin connector labeled LH Rear Lights of the left taillight harness into the 4-socket connector labeled of the machine wire harness (Figure 58).

1. Route the 4-socket connector labeled of the machine wire harness under the left frame rail and forward (Figure 59).

   

   Figure 59

   1. Magnetic harness anchor

2. At the inboard side of the frame rail, remove the cap from the 4-socket connector labeled of the machine wire harness (Figure 60).

   

   Figure 60

   1. Cap
   2. 4-socket connector (labeled —machine wire harness)
   3. 4-pin connector (labeled RH Rear Lights—right taillight harness)

3. Plug the 4-pin connector labeled RH Rear Lights of right taillight harness into the 4-socket connector labeled of the machine wire harness (Figure 60).

   Important: Ensure that the harnesses are routed away from the exhaust pipe.

4. Close and latch the hood.

Figure 64

1. OFF
2. Road lights ON
3. Road lights and optional work light ON

1. Turn the key switch on and press the light switch to the ON position.

2. Rotate the light switch (Figure 63 and Figure 64) to the following positions:

   • OFF

   • Road lights ON

   • Road lights and optional work light ON

• Move the turn signal switch (Figure 63) up to signal a right turn.

• Move the switch down to signal a left turn.

• Move the switch to the middle position to shut off the turn signals.

Figure 65

1. Hazard switch

• Press the top of the switch (Figure 65) to run the hazard lights..

  Note: The hazard switch illuminates when running the hazard lights.

• Press the bottom of the switch to shut off the hazard lights.

1. Park the machine on a level surface, engage the parking brake, lower the cutting units, shut off the engine, and remove the key.

2. Remove the electrical cover, refer to Removing the Electrical Cover or Removing the Electrical Cover.

3. Replace the open fuse.

   Fuse-block slot	Protected Circuits	Fuse Rating
   A3	EU light kit power	10 A
   A4	Road light kit	15 A

   

   Figure 67

   1. Fuse (10 A) and fuse-block slot A3
   2. Fuse (15 A) and fuse-block slot A4

4. Install the electrical cover; refer to Installing the Electrical Cover or Installing the Electrical Cover.

1. Park the machine on a level surface, engage the parking brake, lower the cutting units, shut off the engine, and remove the key.

2. Unlatch and open the hood.

3. Remove the cap from the in-line fuse holder (Figure 68).

   

   Figure 68

   1. Cap
   2. Fuse
   3. In-line fuse holder

4. Replace the fuse; refer to the Fuse Table.

   Fuse Table

   Left taillight harness	Protected Circuits	Fuse Rating
   Labeled (left taillight harness)	Taillights	5 A
   Labeled	Brake lights	5 A
   Left taillight harness	Protected Circuits	Fuse Rating
   Labeled (right taillight harness)	Taillights	5 A
   Labeled	Brake lights	5 A

5. Install the cap onto the fuse holder (Figure 68).

6. Close and latch the hood.