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Service Electrical


Service the Battery Safely



c CAUTION: Avoid injury! Battery electrolyte contains sulfuric acid. It is poisonous and can cause serious burns:

• Wear eye protection and gloves.

• Keep skin protected.

• If electrolyte is swallowed, get medical attention immediately.

• If electrolyte is splashed into eyes, flush immediately with water for 15-30 minutes and get medical attention.

• If electrolyte is splashed onto skin, flush immediately with water and get medical attention if necessary.

The battery produces a flammable and explosive gas. The battery may explode:

• Do not smoke near battery.

• Wear eye protection and gloves.

• Do not allow direct metal contact across battery posts.

• Remove negative cable first when disconnecting.

• Install negative cable last when connecting.

Checking Battery Electrolyte Level

NOTE: Add only distilled water to replace battery electrolyte.

1. Park the machine safely. (See Parking Safely in the SAFETY section.)

2. Remove battery cell caps. Make sure cap vents are not plugged.


M39772

3. Check electrolyte level. Electrolyte (B) should be approximately halfway between bottom of filler neck (A) and top of plates (C).

IMPORTANT: Avoid damage! Do not overfill battery. Electrolyte can overflow when battery is charged and cause damage.


4. Add only distilled water if necessary.

5. Install battery cell caps.

Removing and Installing Battery

Removing:

1. Park machine safely. (See Park Safely in the SAFETY section.)

2. Raise hood.

3. Remove front grille.


MX35080

4. Disconnect black negative (-) cable (A) from battery first.

5. Slide red positive terminal cover (B) back and disconnect red positive (+) cable (C).

6. Loosen capscrews (D), to loosen hold-down bracket (E) on each side of battery.

7. Remove battery.

Installing:

1. Install battery into machine. Be sure battery is seated against backstop.

2. Check manifold caps to be sure vent holes are open.

3. Connect positive (+) cable to battery positive (+) terminal first, then negative (-) cable to battery negative (-) terminal.

4. Apply spray lubricant on battery terminals to help prevent corrosion.

5. Make sure battery is positioned correctly, and tighten battery hold-down assembly. Do not overtighten.

6. Install front grille.

7. Lower hood.

Cleaning Battery and Terminals

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Disconnect and remove battery.

3. Wash battery with solution of four tablespoons of baking soda to one gallon of water. Be careful not to get the soda solution into the cells.

4. Rinse the battery with plain water and dry.

5. Clean terminals and battery cable ends with wire brush until bright.

6. Install battery.

7. Attach cables to battery terminals using washers and nuts.

8. Apply spray lubricant to terminal to prevent corrosion.

Using Booster Battery

c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode:

• Do not smoke or have open flame near battery.

• Wear eye protection and gloves.

• Do not jump start or charge a frozen battery. Warm battery to 16?C (60?F).

• Do not connect the negative (-) booster cable to the negative (-) terminal of the discharged battery. Connect at a good ground location away from the discharged battery.


M71044

A - Booster Battery

B - Disabled Vehicle Battery

1. Connect positive (+) booster cable to booster battery (A) positive (+) post (C).

2. Connect the other end of positive (+) booster cable to the disabled vehicle battery (B) positive (+) post (D).

3. Connect negative (–) booster cable to booster battery negative (–) post (E).

IMPORTANT: Avoid damage! Electric charge from booster battery can damage machine components. Do not install negative booster cable to machine frame. Install only to the engine block.

Install negative booster cable away from moving parts in the engine compartment, such as belts and fan blades.


4. Connect the other end (F) of negative (–) booster cable to a metal part of the disabled machine engine block away from battery.

5. Start the engine of the disabled machine and run machine for several minutes.

6. Carefully disconnect the booster cables in the exact reverse order: negative cable first and then the positive cable.

Replacing Headlight Bulb

c CAUTION: Avoid injury! Halogen light bulb contains gas under pressure. The bulb may shatter if the glass is scratched or dropped. Wear eye protection and handle bulb with care when replacing.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood.


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3. Disconnect wire harness (A) from defective headlight bulb assembly.

4. Rotate bulb assembly (B) to remove from housing socket.

NOTE: Do not touch the new bulb assembly with bare hands. Use a clean cloth to install, and hold the bulb only by the connector.

5. Install new bulb assembly into housing socket and rotate to lock in place.

6. Connect wire harness to bulb assembly.

7. Check operation of headlights.

8. Lower hood.

Replacing Taillight and Warning Light Bulbs

Remove Front Side Taillight Bulbs

1. Park machine safely. (See Parking Safely in the SAFETY section.)


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Picture Note: Left side lens shown.

2. To remove rear taillights, remove two screws (A) and lens (B) from the warning light/taillight assembly.


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3. Push down, and rotate bulbs (C) counterclockwise to remove from tabs.

4. Push down and rotate bulbs clockwise to secure bulb into socket.

5. Check operation of taillights.

6. Install lens.

Remove Rear Side Taillight Bulbs

1. Park machine safely. (See Parking Safely in the SAFETY section.)


MX35847

Picture Note: Left side lens shown.

2. To remove rear taillights, remove two screws (A) and lens (B) from the warning light/taillight assembly.


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3. Push down, and rotate bulb (C) and smaller bulb (D) counterclockwise to remove from tabs.

4. Push down and rotate bulbs clockwise to secure bulb into socket.

5. Check operation of taillights.

6. Install lens.

Replacing Fuses

Main System Fuse

IMPORTANT: Avoid damage! The electrical system may be damaged if incorrect replacement fuses are used. Replace the bad fuse with a fuse of the same amp rating.


1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood.


MX22564

Location

Circuit

Fuse Size

A

Main System

40 amp


3. Open main system fuse assembly cover, and remove fuse (A).

4. Install new fuse assembly and close assembly cover.

5. Lower hood.

Accessory Fuses

IMPORTANT: Avoid damage! The electrical system may be damaged if incorrect replacement fuses are used. Replace the bad fuse with a fuse of the same amp rating.


1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood.


MX22565

3. Squeeze ends of fuse holder cover (A) to remove.

4. Identify fuses:

Location

Circuit

Fuse Size

B

Headlight and Taillight Lamps

25 amp

C

Engine, Glow Plugs and Starter

15 amp

D

Work lamps

10 amp

E

Turn/Warning Lamps

10 amp


5. Pull defective fuse from socket.

6. Push new fuse into socket.

7. Install fuse holder cover.

8. Lower hood.