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Section 4 - ADJUSTMENT & REPAIR
WARNING
DO NOT OVERFILL! DO NOT attempt to service or
charge the battery while it is installed on the
machine. DO NOT use “BOOST” chargers on the
battery.
4.5.5. BATTERY
TESTING
There are two types of battery tests: Unloaded and
Loaded. The unloaded test is the procedure that will
be discussed. It’s the simplest and most commonly
used. An unloaded test is made on a battery without
discharging current. To perform unloaded testing,
check charge condition using either a hydrometer or
voltmeter.
1.
Using a voltmeter, voltage readings appear
instantly to show the state of charge. Remember to
hook the positive lead to the battery’s positive
terminal, and the negative lead to the negative
terminal.
2.
A hydrometer measures the specific gravity of
each cell. The specific gravity tells the degree of
charge; generally, a specific gravity of about 1.265 to
1.280 indicates full charge. A reading of 1.230 to
1.260 indicates the battery should be charged. The
Battery Condition chart shows the charge level as
measured by syringe float hydrometer, digital
voltmeter and five ball hydrometer.
4.5.6
NEW BATTERY PREPARATION
1.
Remove battery from carton.
2.
Place battery in a well ventilated area on a level
non-concrete surface.
3.
Remove battery cell caps. Fill cells as required
with electrolyte (purchased separately) to proper
level. Filling battery with electrolyte will bring the
battery to 80% charged state.
4.
With cell caps removed, connect battery charger to
battery terminals; RED to positive (+) and BLACK to
negative (-) terminal.
IMPORTANT:
DO NOT place anything in battery other than
specified electrolyte.
5.
Slow charge the battery at 1 amp for 2 hours to
bring the battery to full charge.
6.
After charging, check level of electrolyte and add
as needed to bring fluid to proper level.
7.
Reinstall cell caps.
8.
Slide battery partially into battery housing.
9.
Connect positive (+) cable (red) first, from
wiring harness to the positive terminal (+) on
battery using bolt and nut provided in hardware
bag. Connect negative (-) cable (black) last, to
negative terminal (-) on battery using bolt and nut.
Apply a small amount of grease over terminals to
prevent corrosion.
10.
Insert battery completely into battery housing.
11.
Reinstall seat assembly.
WARNING
Shield the positive terminal with terminal cover
located on battery harness. This prevents metal from
touching the positive terminal, which could cause
sparks. Cables must be connected to battery
terminals in the proper position. RED (Positive) cable
must go to the ( + ) terminal. BLACK (Negative) cable
must go to the ( - ) terminal.
4.5.7. BATTERY TESTING
Battery Condition Chart
State of Charge
Syringe Hydrometer
Digital Voltmeter
Five Ball Hydrometer
100% Charged w/ Sulfate Stop
1.280
12.80v
Five Balls Floating
100% Charged
1.265
12.60v
Four Balls Floating
75% Charged
1.210
12.40v
Three Balls Floating
50% Charged
1.160
12.10v
Two Balls Floating
25% Charged
1.120
11.90v
One Ball Floating
0% Charged
Less than 1.100
Less than 11.80v
Zero Balls Floating
