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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.


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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 the Battery

Removing

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

2. Raise the operator’s seat platform.


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3. Disconnect negative (–) battery cable (A).

4. Pull up red plastic cover (B) from positive (+) battery clamp and disconnect positive (+) cable clamp from battery post.

5. Remove wing nuts (C) from left and right side of battery hold-down bracket (D).

6. Remove battery from machine. Do not use battery terminals to lift battery.

Installing

1. Install battery with positive post (+) on right side of machine.

2. Install battery J-bolts, hold-down bracket, and secure with wing nuts.

3. Install positive cable clamp (red cable) onto positive (+) battery post. Pull red plastic cover over positive cable clamp.

4. Install negative cable clamp (black cable) onto negative (–) battery post.

5. Lower operator’s seat platform.

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 posts using washers and nuts.

8. Apply general purpose grease or silicone spray 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.


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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.

Checking and Replacing Fuses

Replacing Main Fuse

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

2. Raise seat platform.


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3. Locate the electrical control box (A) on the right side of the engine compartment.

4. Remove cover from electrical control box.


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5. Fuse (B) is a 15 amp fuse and controls the work lamps on steering column.

6. Fuse (C) is a 15 amp fuse that controls all other electrical functions.

7. Test fuses with voltmeter or test lamp and replace if burned out.

8. Install cover onto electrical control box.

Replacing 12-Volt Power Outlet Fuse

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

2. Open engine cover.


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3. Locate the power outlet fuse (D) on the right side of engine compartment.


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4. Pull out lock tab (E) and pull base of fuse holder down from cap.

5. Test fuse using a voltmeter or test lamp. Both sides of fuse should be hot with key switch in RUN position.

6. Replace fuse if burned out (10 amp).

7. Install fuse holder in cap.