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Service Electrical


Removing and Installing Battery

c CAUTION: Avoid injury! 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

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

2. Access battery:

4x2 - Raise and secure cargo box. Raise passenger seat.

6x4 - Access through opening at rear of vehicle.


MX4661

Picture Note: GATOR 6x4 shown.

3. Disconnect all black negative cables (A) from battery first.

4. Slide back rubber protective cover (B) and disconnect all red positive cables.

5. Disconnect rubber hold-down strap (C).

6. Release latches on air cleaner canister cover (D). Remove cover to provide clearance for battery removal.

NOTE: If your battery is equipped with rubber vent hose, be sure hose does not detach from vent cap when removing battery.

7. Lift battery from vehicle.

IMPORTANT: Avoid damage! Dirt and debris can enter engine when air cleaner canister is opened. Install cover immediately after removing battery to keep contamination to a minimum.


8. Install air cleaner canister cover with rubber dust unloading valve pointing downward. Check instruction molded into canister cover for proper installation.

Installing

1. Release latches on air cleaner canister cover. Remove cover to provide clearance for battery installation.

NOTE: If your battery is equipped with rubber vent hose, make sure vent cap is installed so hose is on positive (+) side of battery.

2. Install battery into vehicle with negative (-) terminal positioned toward rear of vehicle.

IMPORTANT: Avoid damage! Dirt and debris can enter engine when air cleaner canister is opened. Install cover immediately after installing battery to keep contamination of the intake system to a minimum.


3. Install air cleaner canister cover with rubber unloading valve pointing downward. Check instruction molded into canister cover for proper installation.


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4. If equipped, route rubber vent hose (A):

4x2 - Route hose through drain hole (B) in frame or over back side of frame rail (C). Make sure hose does not extend too far below vehicle where it could be pulled off by ground debris.


MX4658

6x4 - Route hose through lower hole in power lift cylinder plate (D).

5. Install battery hold-down strap.

6. Connect all red positive cables to positive (+) battery terminal first. Tighten the connections.

7. Connect all black negative cables to negative (-) battery terminal. Tighten the connections.

8. Apply petroleum jelly to battery terminals to help prevent corrosion.

9. Slide protective cover down the battery positive cable and seat it over the positive (+) terminal.

Checking Battery Electrolyte Level (Maintenance Type Batteries Only)

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.

NOTE: Do not attempt to service batteries marked "Maintenance-Free."

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.

IMPORTANT: Avoid damage! Do not fill cells to the bottom of filler neck (A). Electrolyte can overflow when battery is charged and cause damage.



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

5. Add distilled water if necessary.

6. Install battery cell caps.

7. Install battery.

Clean Battery and Terminals

c CAUTION: Avoid injury! 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.

1. Remove battery from vehicle.

2. 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.

3. Rinse the battery with plain water and dry.

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

5. Apply petroleum jelly or silicone spray to terminals to prevent corrosion.

6. 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 degrees C (60 degrees 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.


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).

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 Headlight Bulb (Non-Homologated Units Only)

1. Remove hood.


MX4661A

2. Rotate bulb/socket assembly (A) 1/3 turn and remove from housing.

3. Disconnect wire connector (B) from socket. Discard the bulb/socket assembly.

IMPORTANT: Avoid damage! Do not touch glass portion of new bulb with bare skin. Contact with oil or dirt will reduce bulb life. Handle bulb by the base or with a clean cloth or gloves.


4. Connect wiring connector to new bulb/socket assembly. Install the assembly into housing and rotate 1/3 turn to lock in place.

5. Test head lamp function.

IMPORTANT: Avoid damage! Vibration of hood against headlight housing may cause headlight lamps to fail early. Allow clearance around headlight housings when installing hood.


6. Install hood.

Replacing Headlight Bulb (Homologated Units Only)

1. Remove hood.


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2. Disconnect wiring plug (A) from light.

3. Remove rubber boot (B).


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4. Push ends (C) of wire clip together to disconnect wire clip.

5. Remove socket and bulb (D). Remove bulb from socket.

IMPORTANT: Avoid damage! Do not touch new bulb with bare skin. Contact with oils or dirt will reduce the life of the bulb. Handle only with a clean cloth or gloves.


6. Install new bulb into socket and insert into light.

7. Install rubber boot and connect wiring plug.

IMPORTANT: Avoid damage! Vibration of hood against headlight housing may cause headlight lamps to fail early. Allow clearance around headlight housings when installing hood.


8. Install hood.

Replacing Headlight Housing (Non-Homologated Units Only)

1. Remove hood.

2. Disconnect bulb socket from headlight housing.


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3. Remove screws (A) at back side of light.

4. Remove headlight housing.

5. Install new headlight housing assembly and secure with screws.

IMPORTANT: Avoid damage! Vibration of hood against headlight housing may cause headlight lamps to fail early. Allow clearance around headlight housings when installing hood.


6. Install hood.

Replacing Headlight Housing (Homologated Units Only)

1. Remove hood.

2. Disconnect wiring plug at rear of headlight housing.

3. Remove rubber boot, socket, and bulb.


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4. Remove three screws and springs (A).

5. Remove headlight housing.

6. Install new headlight housing and secure with springs and screws.

7. Install bulb, socket, and rubber boot.

8. Connect wiring plug.

IMPORTANT: Avoid damage! Vibration of hood against headlight housing may cause headlight lamps to fail early. Allow clearance around headlight housings when installing hood.


9. Install hood.

10. Adjust headlight if necessary.

Replacing Instrument Panel Bulbs


W01009

Picture Note: Hood shown removed for clarity. Removal of hood not required.

1. Reach under dash panel and remove appropriate bulb socket (A) from plastic housing.

Rotate bulb socket 1/4 turn.

Pull socket straight outward.

2. Remove bulb from socket. Discard bulb.

3. Install new bulb in socket.

4. Align and insert bulb socket into plastic housing. Turn socket 1/4 turn to lock in place.

Replacing Fuses (Homologated Units Only)

NOTE: Fuse block is located below dash on operator side of vehicle.

1. Remove fuse by pulling it from fuse block socket.


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2. Check metal element (A) in fuse window. Discard fuse if element is broken.

IMPORTANT: Avoid damage! Replace fuses with those of correct amperage or electrical system could be damaged.



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A - Hazard and Directional Lights, 15 amp

B - Brake Light, 10 amp

C - Horn, 10 amp

D - Spare, 15 amp

E - Left Headlight, 10 amp

F - Right Headlight, 10 amp

G - Right Front/Left Rear Position Lights, 10 amp

H - Left Front/Right Rear Position Lights, 10 amp

3. Install new fuse with correct amperage rating.

Replacing Directional, Brake, and Position Light Bulbs (Homologated Units Only)

IMPORTANT: Avoid damage! Do not touch glass portion of new bulb with bare skin. Contact with oils or dirt will reduce bulb life. Handle bulb by the base or with a clean cloth or gloves.


Front Lights


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1. Remove screws (A) and lens (B).


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2. Push in and turn to remove directional bulb (C).

3. Move bracket (D) to the right to remove position bulb (E).

4. Install new bulbs if necessary.

5. Install lens and secure with screws.

Rear Lights


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1. Remove lens (A) from clips (B).


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2. Push in and turn to remove position bulb (C), directional bulb (D), or brake bulb (E).

3. Install new bulbs if necessary.

4. Install lens into clips.

Replacing License Plate Light Bulb (Homologated Units Only)

IMPORTANT: Avoid damage! Do not touch glass portion of new bulb with bare skin. Contact with oils or dirt will reduce bulb life. Handle bulb by the base or with a clean cloth or gloves.



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1. Remove screw (A) and cover (B).


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2. Push in and turn to remove bulb (C).

3. Install new bulb.

4. Install cover and secure with screw.