Road Light Kit

1. Park the machine on a level surface.

2. Disengage the PTO and move the motion-control levers outward to the NEUTRAL-LOCK position.

3. Shut off the machine and remove the key.

4. Remove the battery charger plug.

5. Use the battery-disconnect switch to shut off the machine; refer to your machine Operator’s Manual.

Parts needed for this procedure:

1. Loosely install the left light assembly to the left side of the lower roll bar frame with a U-bolt and 2 locknuts (3/8 inch).

2. For model 18765TE only: perform the following steps to install the wide pivot bracket.

   1. Remove the 3 bolts (1/4 x 3/4 inches) and 3 locknuts (1/4 inch).

   2. Replace the standard bracket pivot with the wide pivot bracket.

   3. Secure the bracket with the previously removed nuts and bolts.

3. Loosely install the right light assembly to the right side of the lower roll bar frame with a U-bolt and 2 locknuts (3/8 inch).

   

   Figure 1

   1. Flange nut (3/8 inch)
   2. Right light assembly
   3. Front of the machine
   4. U-bolt
   5. Left light assembly
   6. Wide pivot bracket for model 18765TE only

Parts needed for this procedure:

1. Remove the caps from each of the machines castor-arm hubs.

2. Using the groove in the light mount assembly bushings, mark the center of the caster tubes by temporarily using the light mounts and a straight edge.

   

   Figure 2

   1. Light mounts
   2. Straight edge

3. Mark a line 10 mm (13/32 inch) down and drill a 7 mm (9/32 inch) hole in the front caster housing.

   Warning

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

   When drilling, always wear eye protection.

   

   Figure 3

   1. 10 mm (13/32 inch)
   2. Drill a 7 mm (9/32 inch) hole.
   3. Front caster tire
   4. Groove

4. Install a light mount assembly into each caster arm and secure each with a screw (1/4 x 3/4 inch).

5. Replace the existing light assembly mounting screw (M12 X 30 mm) with the new screw (M12 X 60 mm) supplied in the kit for each light assembly.

6. Install the left light assembly to the left side of the front light bracket with the washer and nut supplied with the light.

7. Install the right light assembly to the right side of the front light bracket with the washer and nut supplied with the light.

   Note: Ensure that both headlights are pointing straight forward.

   

   Figure 4

   1. Right light
   2. Cap
   3. Existing hardware with light
   4. Screw (1/4 x 3/4 inch)
   5. Left light
   6. Drill a 7 mm (9/32 inch) hole.
   7. Screw (M12 X 60 mm)

Parts needed for this procedure:

1. Behind the seat, remove the nuts holding the MyRIDE suspension bracket. Do not remove the bolts and retain the nuts.

2. Remove the control panel from the control assembly and retain the fasteners.

3. Install the control assembly to the license-plate mount assembly with 2 carriage bolts (1/4 x 3/4 inch), 2 carriage bolts (1/4 x 1-1/4 inches), and 4 locknuts (1/4 inch).

4. Install 2 push-in fasteners into the 2 holes on the license-plate mount assembly.

5. Install the license plate and control box assembly to the MyRIDE suspension bracket with 3 bolts (3/8 x 1-1/4 inches) and 3 locknuts (3/8 inch).

   Note: Replace the bolts individually to ensure the suspension plate remains secured.

   

   Figure 5

   1. Carriage bolt (3/8 x 1-1/4 inches)
   2. MyRIDE suspension
   3. Existing bolts
   4. Control panel cover
   5. Carriage bolt (1/4 x 1-1/4 inch)
   6. Control assembly
   7. Push-in connector
   8. Locknut (1/4 inch)
   9. License-plate mount assembly
   10. Locknut (3/8 inch)
   11. Carriage bolt (1/4 x 3/4 inch)

Parts needed for this procedure:

1. Remove the existing left control lever and retain the fasteners.

2. Install the new left control lever with the light control switch.

3. Align both control levers and tighten the levers.

   Note: The harness will be connected with the main harness later in this instruction.

   

   Figure 6

   1. Switch cap
   2. Switch
   3. Existing bolts
   4. Control lever base

Parts needed for this procedure:

1. Install the horn using the existing horn screw and nut. Ensure that there is a gap (5 mm) from the inside face of the horn bracket.

2. Install the horn on to pre-assembled fasteners.

3. Loosely mount 1 screw (3/8 x 1-1/4 inches) to chassis with flange (3/8).

4. Slot in the screw to the horn bracket.

5. Install the other side of the horn bracket using the screw (M10 x 30 mm) and flange nut (M10).

6. Install the screw (3/8 x 1-1/4 inches) to the flange (3/8).

   

   Figure 7

   

   Figure 8

Parts needed for this procedure:

1. Use the clamp (50 mm) to loosely secure the beacon bracket to the left side of the roll bar.

   Note: Secure the beacon bracket with the top surface approximately 147.5 cm (58 inches) above the ground.

2. Secure the beacon socket to the beacon bracket using the nut, washer, and serrated washer supplied with it.

   Note: Ensure the socket is vertical when viewed from the side of the machine; adjust accordingly when you tighten the bracket.

3. Route the wire harness from the beacon down the front of the roll bar and leave it loose for installation later.

4. Install the beacon to the beacon socket.

   

   Figure 9

   1. Bolt (M8 x 30 mm)
   2. Clamp (50 mm)
   3. Beacon socket
   4. Beacon light
   5. Ferrite
   6. Beacon wire harness
   7. Locknut (M8)
   8. Washer (5/16 inch)
   9. Beacon bracket

Parts needed for this procedure:

1. Remove the top rear guard and rear cover.

   

   Figure 10

   1. Shoulder screw
   2. Rivet

2. Using the battery bracket, measure from the edge of the right hand rear guard to 12 cm (4-3/4 inches) and mark 3 holes on the right hand rear guard.

3. Drill 3 holes using a 6.5 mm drill bit.

   

   Figure 11

   1. Battery bracket
   2. Drilling locations
   3. Measure 12 cm (4-3/4 inches) from the edge of the right hand rear guard.

4. Install the battery box assembly to the battery bracket using 2 plastic screws (5 x 20 mm).

5. Install the mini relay to the battery bracket using 1 screw (M5 x 12 mm) and 1 flange nut (M5).

6. Place the battery and foam into the battery box assembly.

   

   Figure 12

   1. Relay assembly
   2. Foam
   3. Battery

7. Fasten the bracket sub-assembly to the chassis using 3 bolts and 3 nuts.

   

   Figure 13

8. Install high voltage decals to the areas on the machine. Ensure a decal is placed on top of each motor.

   

   Figure 14

   

   Figure 15

   1. Place decals on top of each motor on the deck.
   

   Figure 16

   1. Place decals on the right side of the machine.
   2. Place decal on the top cover.
   3. Place decal on the left side of the machine.

Parts needed for this procedure:

Install the EU Road Light Harness

Figure 17

1. Light kit connector
2. Light controls box
3. Rear-blinker harness connection
4. Sunshade-beacon harness
5. Telematics
6. Beacon
7. Ground
8. Accessory and ground
9. Work light extension harness
10. Work light extension work light connector
11. EU Light kit power accessory
12. Ferrite location
13. Handle connector
14. Controls harness connector
15. Work-light harness
16. Work-light harness connector (left side)
17. Horn
18. Work-light harness (right side)

1. Remove the 4 Torx screws securing the side cover on the right side of the machine. Repeat on the left side. Retain all parts.

   

   Figure 18

2. Remove the nut and bolt securing the electrical plate cover and remove the cover. Retain all parts.

   

   Figure 19

3. Starting from the back of the machine, lay the EU Road light kit wire harness on to the license plate mount and light assembly. Route the headlight, horn, and light switch connectors through the left side.

   Note: If machines have MyRIDE, route the harness through the opening.

4. Route the headlight, horn, and light switch through the left side of the chassis behind the console.

5. Connect the 12-pin connector on the EU Light kit wire harness to the control lever assembly left connector.

6. Route the horn headlight cable on left side chassis rail and under the toe board, avoiding interference with the MyRide platform.

7. Route the harness along the height-of-cut bar at the front of the machine and around the anchor point to the left chassis rail interior below the operator platform.

8. Identify the left and right front light connectors. Mark the connectors.

   Note: The right connector has blue, yellow, gray, and black wires. The left connector has brown, yellow, grey, and black wires.

9. Route the front light connectors to their corresponding lights.

10. Connect the front light connectors on the light kit harness to the front lights. Ensure that the harness conduit is secure to the shell.

11. Connect the terminals white wire to (+), black wire to (-).

    Note: Due to the horn blocking access to the existing tie-down point, the cords can be secured on the side of the chassis.

    

    Figure 20

    1. Tie-down point

12. Lay the wiring harness connections to their approximate positions at the machine rear.

13. Connect the beacon wire harness to the beacon connector on the light kit wire harness.

14. Route the left-rear light connector up the front of the roll bar next to the beacon wire harness.

15. Route the connector through the rear light mount and connect it to the rear light mount with 2 screws (#10 x 1-1/4 inches).

    

    Figure 21

    

    Figure 22

16. Secure the bracket height until the red light is approximately 90 cm (35 inches) above the ground.

17. Repeat the previous steps to install the rear right light.

18. Secure the rear light leads and beacon harness to the ROPS frame.

    Note: Allow some slack in the beacon cable to allow the ROPS frame to be folded.

19. Open the main machine harness fuse box and remove the fuse (5 A). Retain the fuse.

    

    Figure 23

20. Install the mini-blade fuse (7.5 A) in place of the fuse (5 A) and close the cover.

21. In the fuse box for the light-kit control panel, replace the horn fuse (10 A) with the retained fuse (5 A). Ensure that the control panel fuse box remains open.

22. Install the fuse box to the control panel with 2 screws (M6 x 16 mm). Close the fuse box cover.

23. In the control panel, connect each switch, flasher unit, and license plate light.

1. Turn on the hazard lights and ensure all 4 lights flash.

2. Turn on the ignition switch to the RUN position and check the beacon.

3. Move the light switch rearward to activate the road lights. The front lights and the red rear lights should turn on.

4. Move to the left control arm and switch on the headlights. Ensure both lights have turned on.

5. Check that each direction indicator lights work. Ensure that the correct lamp flashes when selected at the control-arm switch.

6. Check the horn.

7. If the lights and horn are working, use cable ties to secure the wire harnesses in all areas.

8. If any lights or the horn are not working, check the connections to the failed item and switch.

   Note: Ensure that all grounded wires and battery connections are installed properly.

Parts needed for this procedure:

1. Install the removed electrical cover.

2. Install the removed rear cover.

3. Install the removed rear guard.

4. Secure the light control panel to its mount with the existing 6 screws (1/4 x 3/4 inch).

5. Install 2 PVC signs in the locations specified in Figure 35. For machines used in France, apply the speed decal over the top of this sign.

   

   Figure 35

   1. License plate sign location
   2. Rear cover sign location

6. Install the red reflectors to the machine.

   

   Figure 36

   1. Reflector

7. For machines used in Germany, stamp the required information onto the vehicle information plate. Refer to the following table.

   TYP	Model number
   Fz-Ident-HR	Enter the machine serial number.
   Zul- Gesamtgewicht Kg	840
   Baujahr	Enter the year that the machine was manufactured.
   Zul-Achslast vorn Kg	436
   Zul-Achslast Hinten Kg	624

8. Using the vehicle information plate as a template, align the plate and mark the holes; refer to Figure 36.

9. Drill 4 holes (3 mm) into the right hand side of the chassis.

   Important: Use caution when drilling to ensure no parts are damaged on the right side of the chassis.

10. Rivet the plate onto the engine deck.

    

    Figure 37

    1. Vehicle information plate
    2. Machine serial number plate
    3. Light kit serial number decal

11. Install the light-kit serial number decal.

12. If there is a requirement in your country to stamp the serial number on the machine frame, and the authority does not state a specified location, stamp the serial number on the right caster arm.

Important: This procedure is only for machines used in France.

To set the machine speed, refer to your Operator’s Manual.

• To illuminate the marker lights, switch the ignition to the run position and press the rear of the light switch on the control panel (Figure 38).

• To illuminate the headlights and marker lights, switch the ignition to the run position, press the rear of the light switch on the control panel and push the light switch on the left control arm to the I position (Figure 38).

  To switch off the lights, push the front of the light switch on the control panel.

• To operate the work lights when installed, press the front of the light switch on the control panel.

  Note: You cannot use the work lights when using the road lights.

• To illuminate the hazard lights, press the top of the hazard light switch to flash all indicator lights simultaneously (Figure 38).

  Note: You do not need the ignition switch in the RUN position.

  

  Figure 38

  1. Fuse block
  2. Hazard lights
  3. Lights switch (Work/Off/Road)
  4. Beacon light

• The direction indicator switch operates the right and left direction indicator lights. It works only if the ignition is switched to ON.

  

  Figure 39

  1. Light switch
  2. Direction indicator switch
  3. Horn button

  • Press the left side of the switch toggle to turn on the left direction indicator lights.

  • Press the right side of the switch toggle to the central (OFF) position to turn off the left direction indicator lights.

  • Press the right side of the switch toggle to turn on the right direction indicator lights.

  • Press the left side of the switch toggle to the central (OFF) position to turn off the right direction indicator lights.

• The horn switch operates the horn only when the ignition is switched on.

  • Push the button to sound the horn.

  • Release the button to stop the horn.

• To switch the beacon light on, push the top of the beacon switch (Figure 38).

• Periodically check that all lights are working.

• Ensure that the headlights are adjusted correctly.

• Clean the lights daily.

• Keep the lenses clean by wiping them with a damp cloth. Do not use solvent-based cleaners.