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Avoid spills or contact with skin, eyes, clothing. • To prevent accidents, wear protective clothes, rubber gloves and shield eyes with safety goggles when working on or near the battery. • Neutralize acid spills with a baking soda and water solution. Neutralize electrolyte container with same solution. Then rinse with clear water. Antidote: External- Flush with water; Eyes- Flush with water for 15 minutes and get immediate medical attention. Antidote: Internal- Drink large quantity of water or milk. Follow with milk of magnesia, beaten eggs, or vegetable oil. Call a doctor immediately. 16 Assembly To Activate the Battery: WARNING Remove metal jewelry before working near the battery or near the electrical system. Failure to comply may cause a short circuit, resulting in electrical burns, a shock, or explosion of battery gases. For shipping purposes only, the unserviced battery and its hold-down clamp were installed backwards at the factory. When reinstalling the battery and hold-down clamp, be sure to turn them around so they face in the opposite direction from which they were shipped. A. Use a 7/16" wrench to remove the two l-'A" long bolts and the two 1/4" whiz nuts securing the front and rear hold-down clamp legs to the batteiy bracket (Photo 2-23). Lift off the clamp. Remove battery. Save the hardware. B. If there is a short piece of sealed plastic tubing covering the vent fitting on the negative side of the battery (see Photo 2-23), remove and discard it. C. Put the battery on a level work surface, far away from heat- or flame-producing sources like stoves, water heaters, dryers, furnaces, etc. D. Take off the six filler caps on top of the battery. Put them aside. Refer to Photo 2-24. (Battery Shown Backwards - As Shipped) Photo 2-23: Remove hold-down clamp (A). Remove the piece of clear plastic tubing (B)ifso supplied. E. Be sure you are wearing protective clothes, rubber gloves and eye protection. Fill each cell to the “Upper Level” line printed on the battery case using battery-grade electrolyte solution. (This is 1.265 specific gravity sulfuric acid.) Temperature of battery and electrolyte is ideal when between 60°F-to-80°F. Do not add water or any other liquid to the battery during this initial activation. F. Let batteiy stand for 30 minutes. Check electrolyte level in each cell. Add more electrolyte solution if needed. Don’t overfill battery—this could lead to flooding from the cells during charging. B Photo 2-24: Remove all six filler caps (A). Fill each cell up to the “Upper” level line (B). To Charge the Battery: A. Follow one of the three charging methods described next for maximum starting capacity and longest battery life. Note: The electrolyte solution within the cells is gassing freely when the surface of the electrolyte is covered with small bubbles. When checking for bubbles, always wear safety goggles to protect eyes. A flashlight makes the inspection easier. Inspect all cells. Our Recommended Method: Charge the battery at a rate of 1-to- 2 amperes until all cells gas freely. Do not exceed 24 hours charging. First Alternative Charging Method: Charge the battery at a rate of 4-to-6 amperes until all cells gas freely. Do not exceed 8 hours charging. 17 Assembly Second Alternative Charging Method: Charge the battery at a rate from 6-to-12 amperes until all cells gas freely. Do not exceed 4 hours charging time. B. Turn off the charging equipment and disconnect the charger cables from the battery terminals. C. Recheck electrolyte level in each cell. Top off any low cells with electrolyte solution up to the “Upper” level line. D. Securely replace all six filler caps. Use a baking soda and water mixture to rinse off electrolyte that may have spilled on the battery. DANGER Never jump start the battery with a vehicle battery or charging system. This may produce a battery explosion, causing acid or electrical bums. A NR DANGER To Avoid Personal Injury or Property Damage: • Batteries produce explosive gases - always keep sparks and flame away from battery. • Ventilate area when charging or using the battery. • During charging, don’t leave battery unattended. Charging time need not be continuous. • Follow safety rules and instructions supplied by battery and charger manufacturers. • Do not charge battery at a rate higher than 12 amperes to avoid generating excessive heat and gassing which could damage the battery. DANGER To Avoid Personal Injury or Property Damage: • Do not touch positive battery terminal and any surrounding metal objects with tools, jewelry or other metal items. Failure to comply could cause a short circuit leading to electrical burns or explosion of battery gases. • Never bring a gas can near the positive (+) battery termi-nal. A short circuit could occur leading to an explosion of the gasoline or the battery gases. Always fill the engine fuel tank from the front or side of the engine. STEP 2: Connect the Wire Harness Receptacle ...

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