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10/50/125/250 Amp
6V/12V Battery Charger-
Engine Starter
OPERATOR’S MANUAL
TY25862 Battery Charger- Engine
Starter
OMTY25885 Issue 16Sep04 (ENGLISH/FRENCH)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, bir
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Introduction Foreword THANK YOU for purchasing a John Deere product. WRITE PRODUCT INFORMATION in the Specification section. Accurately record all the numbers to help in READ THIS MANUAL carefully to learn how to operate tracing the battery charger- engine starter should it be and service your battery charger- engine starter stolen. Your distributor also needs these numbers correctly. Failure to do so could result in personal when you order parts. File the product information in a injury or equi
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Contents Page Safety ................................ 05-1 Assembly Instructions Assembly Parts ......................... 10-1 Assembly Tools ......................... 10-1 Assembly Procedure ..................... 10-2 Controls and Operation Preparing Battery........................ 15-1 Positioning Battery Charger ................ 15-1 Checking Battery State-of-Charge ........... 15-2 Identifying Battery Reserve Capacity (RC) Rating........................... 15-2 Estimating Battery Recharge Ti
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Contents ii 091604 PN=2
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Safety Recognize Safety Information This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. DX,ALERT –19–29SEP98–1/1 Understand Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are li
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Safety Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). DX,SPARKS –19–03MAR93–1/1 Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed in
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Safety Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. DX,WEAR2 –19–03MAR93–1/1 Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Materi
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Safety Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into Recycle Waste any water source. Air conditioning refrigerants esca
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Safety IMPORTANT SAFETY INSTRUCTIONS- SAVE THESE INSTRUCTIONS a. the pins on plug of extension cord are the same CAUTION: RISK OF EXPLOSIVE GASES. number, size, and shape as those on plug of Working in the vicinity of lead-acid batteries charger, is dangerous. Batteries generate explosive gases during normal battery operation. Read b. the extension cord is properly wired and in good this manual and follow the instructions electrical condition, and exactly EACH TIME you use this battery charger.
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Safety Personal Precautions 1. Wear complete eye protection and clothing 7. Remove personal metal items such as rings, protection. Avoid touching eyes when working near bracelets, necklaces, and watches when working batteries. near a lead-acid battery. 2. Have plenty of fresh water and soap nearby, in 8. Use the battery charger for charging LEAD-ACID case battery acid contacts skin, clothing, or eyes. batteries only. The charger is not intended to supply power to a low voltage electrical system
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Safety Safety Sign Safety Decal Location Safety Decal NOTE: Safety decal (A) is located on back of battery charger- engine starter housing. OURGP12,000010F –19–02JUN04–1/1 05-7 091604 PN=11 TYB4740 –UN–08SEP04 TYB4740A –UN–08SEP04
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Assembly Instructions Assembly Parts CAUTION: Before operating charger, wheels must be installed to ensure proper ventilation and to meet minimum UL requirements for ground clearance for sparking components. The following parts are provided for assembly. • (2) Screws, 10-32 • (2) Screws 1/4-20 • (2) Wheels • (2) Axle caps • (2) Axle brackets • (1) Axle • (1) Mounting Foot • (1) Handle OUOD006,0000119 –19–03JUN04–1/1 Assembly Tools The following tools are suggested for assembly. • Wrench, 5/16 in
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Assembly Instructions Assembly Procedure 1. Position battery charger- engine starter on its side. 2. Install mounting foot (A) with two 1/4-20 screws. A—Mounting Foot Install Mounting Foot OUOD006,000011B –19–03JUN04–1/6 3. Insert end of each axle bracket (B) in slot and fasten bracket with a 10-32 screw. B—Axle Bracket Install Axle Brackets Continued on next page OUOD006,000011B –19–03JUN04–2/6 10-2 091604 PN=13 TYB4747 –UN–08SEP04 TYB4746 –UN–08SEP04
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Assembly Instructions 4. Install axle into axle cap (C) with a hammer. 5. Slide one wheel (D) onto axle as shown. C—Axle Cap D—Wheel Install Wheel on Axle OUOD006,000011B –19–03JUN04–3/6 6. Insert axle (E) through both axle brackets. E—Axle Install Axle Continued on next page OUOD006,000011B –19–03JUN04–4/6 10-3 091604 PN=14 TYB4749 –UN–08SEP04 TYB4748 –UN–08SEP04
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Assembly Instructions 7. Position charger on opposite side. 8. Slide remaining wheel onto axle as shown and install axle cap (F) with a hammer. F—Axle Cap Install Wheel OUOD006,000011B –19–03JUN04–5/6 9. Position charger on its wheels and mounting foot. 10. Remove two top screws (G) from each side of charger. Position handle (H) as shown, and reinstall screws (G). G—Screws H—Handle Install Handle OUOD006,000011B –19–03JUN04–6/6 10-4 091604 PN=15 TYB4751 –UN–08SEP04 TYB4750 –UN–08SEP04
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Controls and Operation Preparing Battery 5. Study battery manufacturer’s specific precautions, CAUTION: A marine (boat) battery must be such as removing or not removing cell caps while removed and charged on shore. To charge it charging, and recommended rates of charge. onboard requires equipment specially designed for marine use. 6. For batteries with removable vent caps, add distilled water to each cell until battery acid reaches level 1. Make sure battery is a 6 volt or 12 volt lead-acid spec
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Controls and Operation Checking Battery State-of-Charge Use a voltmeter or hydrometer (A) to determine state-of charge. Refer to chart to obtain percent of charge. Voltmeter Reading Hydrometer Battery Test Reading Reading 12 Volt Battery* Specific Gravity Percent of Charge 12.4 or greater 1.265 100% 12.39 to 12.25 1.225 75% 12.24 to 12.10 1.190 50% 12.09 to 11.96 1.155 25% 11.95 to 0 1.120 0% * 6 volt battery voltmeter readings are one-half of 12 volt battery readings shown. CAUTION: Do NOT atte
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Controls and Operation Estimating Battery Recharge Time 1. Use table to determine time needed to completely recharge battery based on battery type, present state of charge, and charging rate (amps). 2. If recharge time cannot be estimated from the table, calculate recharge time using the following formula: Recharge capacity (minutes) x 0.6 x 1.25 ÷ charge rate (amps) = approximate hours needed to recharge a totally discharged battery. EXAMPLE: 80 x 0.6 x 1.25 ÷ 10 = 6 hours NOTE: Example uses an
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Controls and Operation Activating and Charging a Dry Battery Listed below are six steps to activate a dry-charged Charging is recommended when: battery. a. The voltage of the activated battery is below 12.4 volts, even after 15 minutes stand time. 1. Remember Safety. Always wear protective b. The battery will not be installed within the next glasses, gloves, and clothing when handling 30 days. batteries and sulfuric acid electrolyte. c. The outside temperature is below 32°F. 2. Prepare the Batte
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Controls and Operation Testing Battery Installed in Vehicle CAUTION: A marine (boat) battery must be removed and charged on shore. To charge it onboard requires equipment specially designed for marine use. Stay clear of fan blades, belts, pulleys, and other parts that can cause injury. Battery gases produced during charging can explode. Ventilate area. Keep sparks and flames away. Control Panel WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals
