EU Road Light Kit

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Lower the cutting unit.

4. Shut off the engine and remove the key.

5. Disconnect the battery; refer to the electrical system maintenance section of your Operator’s Manual.

Parts needed for this procedure:

1. Install the 6 clips and 2 speed nuts to the switch mount (Figure 1).

   

   Figure 1

   1. Clip
   2. Switch mount
   3. Speed nut

2. Install the U-type speed nuts to the fuse-mount plate (Figure 2).

   

   Figure 2

   1. U-type speed nuts
   2. Fuse-mount plate

3. Install the fuse block on the wire harness to the fuse-mount plate using 2 screws (#10 x 3/4 inch) as shown in Figure 3.

   

   Figure 3

   1. Fuse-mount plate
   2. Fuse block
   3. Screw (#10 x 3/4 inch)

Parts needed for this procedure:

1. Loosely install the switch mount around the steering column using 4 carriage bolts (1/4 x 2 inches), 2 mounting brackets, fuse-mount plate, and 4 locknuts (1/4 inch) as shown in Figure 4.

   

   Figure 4

   1. Locknuts (1/4 inch)
   2. Fuse-mount plate
   3. Mounting brackets
   4. Steering column
   5. Switch mount
   6. Carriage bolt (1/4 x 2 inches)

2. Install the multi-function switch to the switch mount and secure it using the switch clips under the hole for the switch (Figure 5).

   

   Figure 5

   1. Switch clips
   2. Multi-function switch

3. Install the rocker switch and hole plugs into the switch mount (Figure 6).

   

   Figure 6

   1. Rocker switch
   2. Hole plug

4. Install the flasher and relay to the fuse-mount plate using 2 screws (#10 x 3/8 inch) as shown in Figure 7.

   

   Figure 7

   1. Relay
   2. Screw (#10 x 3/8 inch)
   3. Flasher

5. Secure the flasher using a cable tie (Figure 8).

6. Plug the harness into the rocker switch and multi-function switch (Figure 8).

   

   Figure 8

   1. Rocker switch connector
   2. Relay connector
   3. Flasher connector
   4. Switch connector
   5. Cable tie

7. Plug the wire harness into the relay and flasher (Figure 8).

8. Loosen the bolts around the steering-column base (Figure 9).

9. Raise the base up and drill a 22 mm (7/8 inch) hole as shown in Figure 9.

   

   Figure 9

   1. Steering-column base

10. Route the harness through the hole you drilled in the base.

11. Leave the bullet connectors disconnected as shown in Figure 10.

    

    Figure 10

    1. Leave the bullet connectors disconnected.

12. Apply the decal to the fuse cover as shown in Figure 11.

    

    Figure 11

    1. 25 mm (1 inch)
    2. 6 mm (1/4 inch)
    3. Decal—inside of fuse cover

13. Install the fuse cover to the switch mount using 2 thumb screws and 2 push nuts (Figure 12).

    Note: Ensure that the push nuts are installed on the inside of the fuse cover (Figure 12).

    

    Figure 12

    1. Push nut
    2. Fuse cover
    3. Thumb screw

14. Adjust the control assembly so that the switches are accessible.

15. Tighten all the fasteners.

16. Install the control cover to the switch mount using 2 push rivets and 6 hex-head screws (1/4 x 3/4 inch) as shown in Figure 13.

    

    Figure 13

    1. Push rivet
    2. Hex-head screw
    3. Control cover

Parts needed for this procedure:

Parts needed for this procedure:

1. Remove the flange-head bolt (3/8 x 2-3/4 inches) and flange nut (3/8 inch) securing the bumper to the rear tube frame on each side of the bumper (Figure 21).

   

   Figure 21

   1. Rear tube frame
   2. Flange-head bolt (3/8 x 2-3/4 inches)
   3. Bumper
   4. Flange nut (3/8 inch)

2. Secure the left mount and right mount to rear frame tubes using 2 hex-head bolts (3/8 x 3 inches) and 2 locknuts (3/8 inch) on each side (Figure 22).

   

   Figure 22

   1. Hex-head bolt (3/8 x 3 inches)
   2. Left mount
   3. Locknut (3/8 inch)

3. Secure the left short mount and right short or long mount to the left mount and right mount using 4 carriage bolts (5/16 x 3/4 inch) and 4 flange nuts (5/16 inch) as shown in Figure 23.

   Note: Refer to the Light Position Table for the appropriate position of the lights.

   

   Figure 23

   1. Left short mount
   2. Flange nut (5/16 inch)
   3. Left mount
   4. Carriage bolt (5/16 x 3/4 inch)

4. Secure the left light housing and right light housing to the left short mount and right short mount using 4 carriage bolts (1/4 x 5/8 inch) and 4 locknuts (1/4 inch) as shown in Figure 24.

   

   Figure 24

   1. Left short mount
   2. Carriage bolt (1/4 x 5/8 inch)
   3. Left light housing
   4. Locknut (1/4 inch)

5. Apply the appropriate speed decal to the speed-plate mount (Figure 25).

   Apply the 20 kph decal for models 31900 and 31901.

   Apply the 24 kph decal for models 31902 and 31903.

   

   Figure 25

   1. Speed-plate mount
   2. Speed decal

6. Install the 2 speed nuts to the speed-plate mount (Figure 26).

   

   Figure 26

   1. Speed-plate mount
   2. Speed nut

7. Secure the speed-plate mount to the marker mount using 5 carriage bolts (1/4 x 1/2 inch) and 5 locknuts (1/4 inch) as shown in Figure 27.

   

   Figure 27

   1. Carriage bolt (1/4 x 1/2 inch)
   2. Speed-plate mount
   3. Marker mount
   4. Locknut (1/4 inch)

8. Remove the 7 plastic plugs shown in Figure 28 from the hood.

   

   Figure 28

   1. Plastic plug

9. Raise the hood (Figure 29).

   

   Figure 29

10. Secure the assembled speed-plate mount to the hood using 4 flange-head bolts (1/4 x 3/4 inch), 2 back mounts, and 4 locknuts (1/4 inch) as shown in Figure 30.

    

    Figure 30

    1. Flange-head bolt (1/4 x 3/4 inch)
    2. Assembled speed-plate mount
    3. Back mount
    4. Locknut (1/4 inch)

11. Drill a hole (1/2 inch) through the hood screen for routing the wire harness (Figure 31).

    Important: Ensure that you do not drill through any engine components, specifically the Diesel Particulate Filter (DPF).

    

    Figure 31

    1. Drill the 1/2-inch hole here.
    2. Front of the machine.

12. Remove the bolt and nut from the hydraulic-line mount (Figure 32).

    Retain the fasteners.

    

    Figure 32

    1. Nut
    2. Hydraulic-line mount
    3. Bolt

13. Secure the horn to the horn-mounting bracket using the previously removed bolt and nut (Figure 33).

    

    Figure 33

    1. Horn
    2. Nut
    3. Horn-mounting bracket
    4. Bolt

14. Apply the appropriate speed decal to each side of the hood (Figure 34).

    Apply the 20 kph decals for models 31900 and 31901.

    Apply the 24 kph decals for models 31902 and 31903.

    

    Figure 34

    1. Speed decal

Parts needed for this procedure:

Refer to the following figures and instructions for routing the light wire harness.

Figure 35

1. Wire-harness routing

1. Route the wire-harness connector labeled to the left side of unit. Connect harness to light (Figure 35).

2. Route the wire-harness connector labeled to the right side of unit. Connect harness to light (Figure 35).

3. Route the wire-harness connector labeled to the rear left side of unit (Figure 35).

4. Route the wire-harness connector labeled to the rear right side of unit (Figure 35).

5. Secure the taillights to the inner mount assemblies using 4 pan-head screws (#10 x 1-1/4 inches) and 4 flange nuts (#10) as shown in Figure 36.

   

   Figure 36

   1. Flange nut (#10)
   2. Inner mount assembly
   3. Amber lens
   4. Red lens
   5. Pan-head screw (#10 x 1-1/4 inches)

6. Connect the wire-harness connector labeled to rear light (Figure 35).

7. Connect the wire-harness connector labeled to rear light (Figure 35).

8. Secure the assembled taillights to the taillight housings using 8 button-head bolts (1/4 x 3/4 inch) as shown in Figure 37.

   Ensure that you install the taillights with the yellow lens on top (Figure 36 and Figure 37).

   

   Figure 37

   1. Button-head bolt (1/4 x 3/4 inch)
   2. Taillight assembly

9. Route the wire-harness connector labeled through the hood and connect it to the license light (Figure 38).

   

   Figure 38

   View from the bottom of the hood

   1. Wire-harness connnection—license plate
   2. Clamp locations
   3. Hex-socket screw (1/4 x 1 inch)
   4. Flat washer
   5. Clamp
   6. Flange nut (1/4 inch)

10. Secure the wire harness to the hood using 3 hex-socket screws (1/4 x 1 inch), 3 flat washers, 3 clamps, and 3 flange nuts (1/4 inch) as shown in Figure 38.

11. Connect the wire harness to the plate light (Figure 39).

12. Secure the plate light to the assembled speed-plate mount using the 2 speed nuts installed in Figure 26 and 2 button-head bolts (#10 x 3/4 inch) as shown in Figure 39.

    

    Figure 39

    1. Speed nut
    2. Plate light
    3. Button-head bolt (#10 x 3/4 inch)

Parts needed for this procedure:

Refer to the following figures and instructions for routing the control wire harness.

Figure 40

1. Wire-harness routing
2. Control wire harness and light wire harness connection

1. Route the wire harness through the platform opening and along the light-wire-harness routing.

2. Connect the control wire-harness connector labeled TO ROAD LTS HARNESS (P06) to light wire-harness connector labeled TO MAIN HARNESS (P03).

3. Connect the control wire-harness connector labeled TO POWER HARNESS (P05) to power wire-harness connector labeled POD CONTROL HARNESS (P04).

   

   Figure 41

   1. P05 (Control-wire-harness connector)
   2. P04 (Machine-wire-harness connector)

4. Connect the control wire-harness connectors labeled HORN (J01, J02) to the horn (Figure 42).

   

   Figure 42

   1. Wire harness
   2. Horn connection

Parts needed for this procedure:

1. Stamp the serial number into the frame.

   The text size must be 7 mm (1/4 inch) or larger.

2. Stamp the appropriate information into the serial plate.

3. Wipe down the bottom of the frame and serial plate with an alcohol-based wipe (Figure 43).

   

   Figure 43

   1. Clean the bottom of the frame.
   2. Serial plate
   3. Front of the machine

4. Apply the tape to the serial plate.

5. Install the plate to the frame (Figure 44).

   Use the dimensions shown in Figure 45.

   

   Figure 44

   1. Serial plate
   

   Figure 45

   1. 2.5 to 8.1 mm (1/8 to 5/16 inch)
   2. 162 to 168 mm (6-3/8 to 6-5/8 inches)

Connect the battery; refer to the electrical system maintenance section of your Operator’s Manual.