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WARNING: Battery posts, terminals and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

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.

NOTE: One headlight needs to be removed so there is clearance to remove the battery.

3. Remove two hex head bolts (A) then remove headlight (B).


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MX46337

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

5. Slide red positive terminal cover (D) back and disconnect red positive (+) cable (E).

6. Remove strap securing battery from both tabs (F) on battery tray.

7. Pull battery vent tube from battery tray.

8. Remove battery.

Installing:

1. Position battery in machine.

2. Route battery vent tube (G) through hole in battery tray.

3. Install strap securing battery to both tabs (F) on battery tray.

4. Connect positive (+) cable (E) to battery positive (+) terminal first, then negative (-) cable (C) to battery negative (-) terminal.

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

6. Position red positive battery terminal cover (D) on red positive (+) cable.

7. Install headlight using two hex head bolts (A).

8. 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, beginning with the positive cable, 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

IMPORTANT: Avoid damage! Do not touch glass headlight bulb with bare skin or bulb may fail prematurely. Use gloves or a cloth when inspecting or replacing the bulb.


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

2. Raise hood.


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3. Remove connector from base of bulb (A).

4. Rotate base counterclockwise to remove bulb assembly from housing.

5. Insert new bulb in housing and turn clockwise to secure.

6. Insert connector into base of bulb.

7. Lower hood.

8. Check operation of headlights.

Replacing Taillight Bulb

NOTE: Taillight can be serviced by removing the rear assembly lens only.

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


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2. Remove two screws (A) and lens (B) from the warning light/taillight assembly.


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3. Pull top bulb (C) to remove. Do not twist bulb. Push new bulb into socket.

4. Twist lower bulb (D) counter-clockwise and pull to remove. Push new bulb into socket and twist clockwise to secure.

5. Check operation of taillights.

6. Install lens.

Replacing Worklight Bulb (1026R)


MX46342

1. Remove connector (A) from base of bulb.

2. Rotate base (B) counterclockwise to remove bulb assembly from housing.

3. Insert new bulb in housing and turn clockwise to secure.

4. Insert connector into base of bulb.

5. Check operation of worklights.

Replacing Relays and 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 and remove right side panel.

3. Identify relay or fuse.


MX46357

Location

Circuit

Fuse Size

A

Relay - Glow Plug

N/A

B

Relay - Starter

N/A

C

Relay - Fuel Solenoid

N/A

D

Fuse - Taillights

10 amp

E

Fuse - Headlights

10 amp

F

Fuse - Fender Lights (1026R only) and Worklights (Option)

20 amp

G

Fuse - Ignition Run Power

10 amp

H

Fuse - Ignition Switch

20 amp

I

Fuse - Light Switch

30 amp

J

Fuse - Power Outlet (1026R Only)

15 amp


4. Pull defective relay or fuse from socket.

5. Push new relay or fuse or into socket.

6. Install right side panel and lower hood.

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