Service Manual

Service and Repairs
Battery Service
The battery is the heart of the electrical system. With reg-
ular and proper service, battery life can be extend. Addi-
tionally, battery and electrical component failure can be
prevented.
CAUTION
When working with batteries, use extreme cau-
eyes. Always wear safety goggles and a face
shield when working with batteries.
tion to avoid slashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or
Electrolyte Specific Gravity
Fully charged: 1.250 – 1.280
Discharged: less than 1.240
Battery Specifications (Gasoline Engines)
BCI Group 24 Battery:
370 Amp Cranking Performance at 0 F (17
 C)
45 min. Reserve Capacity at 80 F (27C)
Battery Specifications (Diesel Engines)
BCI Group 24 Battery:
630 Amp Cranking Performance at 0 F (17
 C)
130 min. Reserve Capacity at 80 F (27C)
Removal (Fig. 14)
IMPORTANT: Be careful not to damage terminal
posts or cable connectors when removing the bat-
tery cables.
1. Remove battery cover from the frame. Loosen bat-
tery retainer securing the back of the battery to the bat-
tery support.
2. Loosen nut on ground cable (–) post first and remove
cable from battery
. This should prevent short circuiting
the battery, other components, or the operators hands.
3. Loosen nut on positive (+) cable post and remove
cable from battery
.
4. Make sure battery vent caps are on tightly.
5. Remove battery from the battery compartment to a
service area to allow better access for service.
Inspection, Maintenance, and Testing
1. Perform following inspections and maintenance:
1
Figure 14
1. Battery
Figure 15
A. Check for cracks. Replace battery if cracked or
leaking.
B. Check battery terminal posts for corrosion. Use
wire brush to clean corrosion from posts.
IMPORTANT: Before cleaning the battery, tape or
block vent holes to the filler caps and make sure the
caps are on tightly
.
C. Check for signs of wetness or leakage on the top
o
f the battery which might indicate a loose or missing
filler cap, overcharging, loose terminal post, or over-
filling. Also, check battery case for dirt and oil. Clean
t
he battery with a solution of baking soda and water,
then rinse it with clean water.
D. Check that the cover seal is not broken away
. Re-
place the battery if the seal is broken or leaking.
E. Check the electrolyte level in each cell. If the level
is below the tops of the plates in any cell, fill all cells
with distilled water between the minimum and maxi-
mum fill lines. Charge at 15 to 25 amps for 15 minutes
to allow suf
ficient mixing of the electrolyte.
Electrical System (Rev. G) Page 8 – 22 W
orkman 3000/4000 Series