Service Electrical

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

TS204

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

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

2. Raise the hood.

3. Remove manifold caps on top of battery.


IMPORTANT: Avoid damage! Acid may leak from the battery while it is charging. Make sure the battery is filled correctly. Do not fill the cells to the bottom of the filler neck.

M39772

4. Check electrolyte level. Electrolyte level (A) should be 6 mm (1/4 in.) above plates (B) and below filler neck (C).

5. Add distilled water if necessary.

6. Install manifold caps.

7. Check battery cable hardware and tighten if necessary.

Removing and Installing the Battery

Removing

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

2. Raise the hood.

M96016

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

4. Push red cover (B) away from positive (+) battery terminal and remove cable from battery.

5. Unhook rubber strap (C).

6. Remove battery.

Installing


IMPORTANT: Avoid damage! Follow instructions carefully. Battery and battery cables must be installed correctly. When installing battery, make sure battery posts are facing toward front of machine.

1. Place battery on battery tray so battery posts are facing toward front of machine.


IMPORTANT: Avoid damage! To prevent damage to fuel line on models GX325 and GX335, route positive (+) battery cable so it is not between fuel line and engine.

2. Connect positive (+) battery cable.

3. Connect negative (-) battery cable.

4. Apply general purpose grease or silicone spray to terminals to help prevent corrosion.

5. Slide red cover over positive battery terminal.

6. Secure black rubber strap (C).

Cleaning Battery and Terminals

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

2. 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. Apply petroleum jelly or silicone spray to terminal to prevent corrosion.

7. Install battery.

Using Booster Battery

TS204

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

· Do not attempt to jump start a frozen battery. Warm to 16 °C (60 °F).

· Do not smoke near battery.

· Wear eye protection and gloves.

· Keep sparks and flames away.

· 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.

MX4663

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).

4. Connect the other end (F) of negative (-) booster cable to a metal part of the disabled machine frame 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 Fuses

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

2. Raise hood.

MX8359

3. Pull defective starter fuse (A) or headlight fuse (B) out of socket.

4. Check metal clip in fuse window and discard fuse if clip is broken.

5. Push new 15 Amp fuse into socket.

6. Lower hood.

Replacing Headlight Bulb

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

2. Raise hood.

M63475

3. Turn bulb socket (A) 1/8 turn to the left to remove socket from headlight housing.

4. Push bulb down and turn 1/4 to the left to remove bulb from the socket.

5. Replace defective bulb with new bulb.

6. Insert bulb socket into housing, push in and turn 1/4 turn clockwise to install.

7. Lower hood.

Replacing Indicator Light Bulb

MX8343

Picture Note: Model GX345 shown.

1. Rotate indicator bulb socket 1/8 turn counterclockwise to remove:

· Oil pressure indicator light (A).

· Battery discharge light (B).

· Model GX345 Only - Coolant temperature light (C).

2. Pull bulb from socket.

3. Push new bulb into socket.

4. Install socket into holder and rotate 1/8 turn clockwise to secure.

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Service Engine - Models GX325 and GX335

Service Engine - Model GX345

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