North American Road Light Kit

Groundsmaster® 3200 or 3300 Series Traction Unit

Model No. 31991-Serial No. and Up

Safety

Safety and Instructional Decals

Graphic

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing.
decal140-1587

140-1587

  1. Horn—15 A
  2. Headlights—10 A
  3. Beacon—10 A
  4. Work lights—10 A
  5. Read the Operator’s Manual for fuse information.

Installation

Preparing the Machine

  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.

Installing the Clips, Speed Nuts, and Fuse Block

Parts needed for this procedure:

Switch mount1
Clip (1/4 inch)6
Speed nut2
Fuse mount plate1
U-type speed nut4
Fuse block1
Screw (#10 x 3/4 inch)2

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

    g319851

    Figure 1

    1. Clip
    2. Switch mount
    3. Speed nut

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

    g304335

    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.

    g304300

    Figure 3

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

Installing the Switch Mount

Parts needed for this procedure:

Mount bracket2
Carriage bolt (1/4 x 2 inches)4
Locknut (1/4 inch)2
Hex-head screw (1/4 x 3/4 inch)2
Flange nut (1/4 inch)2
Flasher1
Relay1
Wire harness1
Cable tie2
Fuse cover1
Thumb screw2
Push nut2
Decal1
Screw (#10 x 3/8 inch)2
Multi-function switch1
Hole plug3
Rocker switch1
Control cover1
Hex-head screw (1/4 x 3/4 inch)6
Switch clip2
Push rivet2

  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.

    g319856

    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).

    g319854

    Figure 5

    1. Switch clips
    2. Multi-function switch

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

    g319855

    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.

    g319853

    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).

    g319850

    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.

    g304296

    Figure 9

    1. Steering-column base

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

  11. Connect the bullet connectors as shown in Figure 10.

    g334269

    Figure 10

    1. Connected bullet connectors

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

    g304374

    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).

    g304295

    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.

    g319852

    Figure 13

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

Installing the Front Components

Parts needed for this procedure:

Left light base (for machines with a cab)1
Right light base (for machines with a cab)1
Left light mount (for machines with a cab)1
Right light mount (for machines with a cab)1
Left light assembly (for machines with a cab)1
Right light assembly (for machines with a cab)1
Button-head bolt (1/4 x 5/8 inch)—for machines with a cab6
Carriage bolt (3/8 x 3/4 inch)—for machines with a cab4
Locknut (3/8 inch)—for machines with a cab4
Light cross mount (for machines without a cab)1
Yellow reflective tape2

For Machines with a Cab

  1. Secure the left light base and right light base to the cab frame using 2 carriage bolts (3/8 x 3/4 inch) and 2 locknuts (3/8 inch) on each side.

    g303644

    Figure 14

    1. Carriage bolt (3/8 x 3/4 inch)
    2. Locknut (3/8 inch)
    3. Right light base
    4. Left light base

  2. Secure the left light mount and right light mount to the light bases using 3 button-head bolts (1/4 x 5/8 inch) through the speed nuts on each side.

    Note: Ensure that you install the left light mount and right light in the most narrow mounting position.

    g517595

    Figure 15

    1. Light base
    2. Light mount
    3. Button-head bolt (1/4 x 5/8 inch)

  3. Secure the left light assembly and right light assembly to the left light mount and right light mount using the hex nut on the light assemblies.

    Note: Install the lights with the low beam toward the outer edge of the machine.Look at the bottom of the lights for high beam and low beam orientation.

    g517596

    Figure 16

    1. Light assembly
    2. Light mount
    3. Hex nut

  4. Apply the yellow reflective tape to the left light base and right light base using the dimensions shown in below.

    g517597

    Figure 17

    1. 14.25 to 14.86 cm (5-5/8 to 5-7/8 inches)

For Machines without a Cab

  1. Remove the tie-down bracket from the platform.

    Retain the parts.

    g299562

    Figure 18

    1. Tie-down bracket
    2. Bolt
    3. Nut

  2. Apply the yellow reflective tape to the light cross mount using the dimensions shown below.

    g303699

    Figure 19

    1. 9.5 to 10.1 cm (3-3/4 to 4 inches)

  3. Secure the light cross mount to the platform using the previously removed bolts, nuts, and tie-down bracket.

    g303700

    Figure 20

    1. Bolt
    2. Tie-down bracket
    3. Light cross mount
    4. Nut

  4. Secure the left light assembly and right light assembly to the light cross mount using the lock washer and hex nut on the light assemblies.

    Note: Install the lights with the low beam toward the outer edge of the machine.Look at the bottom of the lights for high beam and low beam orientation.

    g303701

    Figure 21

    1. Light assembly
    2. Lock washer
    3. Hex nut

Installing the Rear Components

Parts needed for this procedure:

Left mount1
Right mount1
Left short mount1
Right short mount1
Carriage bolt (5/16 x 3/4 inch)4
Flange nut (5/16 inch)4
Carriage bolt (1/4 x 5/8 inch)4
Locknut (1/4 inch)11
Hex-head bolt (3/8 x 3 inches)4
Locknut (3/8 inch)4
Red reflective tape4
Marker mount1
Back mount2
Slow-moving vehicle sign1
Flat washer3
Flange-head bolt (1/4 x 3/4 inch)7
Left light housing1
Right light housing1

  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.

    g303770

    Figure 22

    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.

    g304042

    Figure 23

    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 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).

    g304044

    Figure 24

    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).

    g319940

    Figure 25

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

    Warning

    Using a drill without proper eye protection may allow debris to enter the eye, causing injury.

    When drilling, always wear eye protection.

  5. Using the marker mount as the template, drill 3 holes (5/16 inch) into the slow-moving vehicle sign.

    g304041

    Figure 26

    1. Slow-moving vehicle sign
    2. Marker mount

  6. Secure the slow-moving vehicle sign to the marker mount using 3 flange-head bolts (1/4 x 3/4 inch), 3 flat washers, and 3 locknuts (1/4 inch).

    g304128

    Figure 27

    1. Flange-head bolt (1/4 x 3/4 inch)
    2. Flat washer
    3. Slow-moving vehicle sign
    4. Marker mount
    5. Locknut (1/4 inch)

  7. Remove the 4 plastic plugs from the hood.

    g304129

    Figure 28

    1. Plastic plug

  8. Raise the hood.

    g285428

    Figure 29

  9. Secure the assembled slow-moving vehicle sign to the hood using 4 flange-head bolts (1/4 x 3/4 inch), 2 back mounts, and 4 locknuts (1/4 inch).

    g304127

    Figure 30

    1. Assembled slow-moving vehicle sign
    2. Flange-head bolt (1/4 x 3/4 inch)
    3. Back mount
    4. Locknut (1/4 inch)

  10. Apply 2 red reflective tape to the rear bumper and 1 reflective tape to each light housing using the dimensions in the figures below.

    g304126

    Figure 31

    1. 9.7 to 15.7 mm (3/8 to 5/8 inch)
    2. 11.7 to 17.8 mm (7/16 to 11/16 inch)
    g304125

    Figure 32

    1. 28.7 to 34.8 mm (1-1/8 to 1-3/8 inches)
    2. 22.4 to 28.4 mm (7/8 to 1-1/8 inches)

Routing the Light Wire Harness

Parts needed for this procedure:

Light wire harness1
Cable tie2
Inner mount assembly2
Taillight2
Pan-head screw (#10 x 1-1/4 inches)4
Flange nut (#10)4
Button-head bolt (1/4 x 3/4 inch)8

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

g517608

Figure 33

  1. Wire-harness routing

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

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

  3. Route the wire-harness connector labeled to the rear left side of unit.

  4. Route the wire-harness connector labeled to the rear right side of unit.

  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).

    g304304

    Figure 34

    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.

  7. Connect the wire-harness connector labeled to rear light.

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

    Ensure that you install the taillights with the yellow lens on top.

    g305040

    Figure 35

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

  9. Use a cable tie coil the remaining connectors (J01 and J02) together.

    g304233

    Figure 36

    1. Coil the remaining connectors here.

Routing the Control Wire Harness

Parts needed for this procedure:

Control wire harness1

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

g304234

Figure 37

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

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

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

    g304373

    Figure 38

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

  3. Use a cable tie to coil the remaining connectors (J01 and J02) together.

    g304232

    Figure 39

    1. Coil the remaining connectors here.

Connecting the Battery

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