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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.

Removing and Installing Battery

IMPORTANT: Avoid damage! The battery drain tube allows excess battery acid to flow away from the machine. Make sure the tube opening is free of obstruction.


Removing:

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

2. Secure the operator seat in the raised position.


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3. Remove service access panel (A) below operator seat platform.


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4. Loosen wing nuts (B) to remove battery hold-down (C).

5. Disconnect negative (-) battery cable (D).

6. Push red cover away from positive (+) battery cable (E) and disconnect cable from battery.

7. Remove battery.

Installing:

1. Install battery into vehicle.

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

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

4. Apply petroleum jelly on battery terminals to help prevent corrosion.

5. Install battery hold-down. Tighten wing nuts.

6. Install service access panel.

7. Lower operator seat.

Checking Battery Electrolyte Level

NOTE: Add only distilled water to replace normal electrolyte loss.

1. Park the vehicle safely. (See Parking Safely in the Safety section.)

2. Remove battery from vehicle and set it on a level surface.

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



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

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


5. Add only distilled water if necessary.

6. Install battery cell caps.

7. Install battery.

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 Electrical Control Box

The electrical control box is a diagnostic tool to help the operator verify correct electrical functions of the greensmower. For the control box to function correctly, all input switches, output solenoids and relays must be connected and functioning properly.

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

2. Turn the key to the RUN position.

3. Secure operator seat in the raised position.


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4. Locate electrical control box (A).

NOTE: The control box is equipped with a diagnostic light which indicates if the control box is functioning correctly. When the control box is functioning correctly, the diagnostic “HEARTBEAT” light (B) will be illuminated and blinking whenever the key switch is turned to the RUN position.

5. Check to see if the diagnostic “HEARTBEAT” light is blinking.

IMPORTANT: Avoid damage! DO NOT remove control box from position under operator seat platform if diagnostic “HEARTBEAT” light fails to operate.

If the “HEARTBEAT” light is not illuminated and blinking when the key switch is turned to the RUN position, this may indicate that the control box is without power or not functioning correctly.


6. Check:

• Check to see if battery is charged. Charge if needed.

• Battery connections.

• Blown 15 amp key switch fuse.

• Electrical harness connections.


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7. Use the control box display lights (E) to diagnose the problem. The control box will light as each function switch is actuated.

8. If further diagnostic assistance is needed, refer to the Technical Manual or consult your John Deere distributor.

Checking and Replacing 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 the vehicle safely. (See Park Safely in the SAFETY section.)

2. Secure operator seat in the raised position.


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3. Locate fuse holder (A) under operator seat platform.

4. Open fuse holder.

5. Check fuse visually for a broken filament.

6. Replace fuse if defective.

7. Close fuse holder.

8. Lower operator seat.

Replacing Engine Indicator Light Bulb

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


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2. Remove two screws (A) from left side of console control armrest.

3. Secure operator seat in the raised position.


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4. Loosen and remove cap screws and flat washers from locations (B) in bottom of console control armrest.

5. Carefully separate upper and lower console control armrest halves.


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6. Locate engine indicator light assembly (C).

NOTE: It may be necessary to remove hardware (D) and retainer bracket to access all engine indicator light bulb sockets.

7. Turn light bulb socket counterclockwise to remove.

8. Remove bulb from socket.

9. Push new bulb into socket.

10. Install socket and turn clockwise to secure in position.

11. Carefully assemble upper and lower console control armrest halves.

12. Install cap screws and flat washers into bottom of console control armrest locations. Do not tighten.

13. Install two screws into left side of console control armrest.

14. Tighten all hardware.

15. Lower operator seat.