These precautions can help technicians stay safe when handling, working on and charging vehicle batteries.
- Technicians need to be thoroughly trained in battery maintenance procedures, first aid, personal protective equipment (PPE) and precautions and hazards of battery maintenance operations.
- Consult the vehicle and battery owner’s manuals for instructions and safety precautions.
- Before handling a battery, remove any jewelry and personal metal items such as rings, bracelets, necklaces and watches, especially when working with a lead-acid battery. These batteries can produce a short circuit current high enough to weld a ring or the like to metal, causing a severe burn.
- Always wear the appropriate personal protective equipment (PPE) – such as gloves, safety glasses, goggles or face shield – and the proper clothing to protect the body. An apron must be worn when handling leaking batteries or electrolytes.
- Avoid touching eyes while working on a battery.
- Have plenty of fresh water and soap nearby in case battery acid contacts the skin, clothing or eyes. If it does, wash immediately with soap and water. If acid enters eyes, immediately flood the eyes with running cold water for at least 10 minutes and get medical attention immediately.
- Have someone within range to hear a call for help or close enough to come to provide aid when a technician is working with a lead-acid battery.
- Make sure the work area is well-ventilated.
- Never lean over a battery when working on it. Place the battery at eye-level.
- Never smoke or allow flames, sparks and other ignition sources in the vicinity of a battery, as they could cause the battery to catch fire or explode.
- The same tools and materials must not be used between battery chemistries.
-Color code tools for added precaution.
- Be extra cautious when working with metallic tools or conductors to prevent sparks and short circuits of the battery or other electrical parts, as this could possibly cause an explosion.
- Never charge a frozen or visibly damaged battery.
- Do not charge, use booster cables or adjust post connections without proper instructions and training.
- Make sure that the charger leads to the battery are not broken, frayed or loose.
- Never allow the charger clamps to touch together or contact the same piece of metal to prevent arcing when the charger is plugged in.
- Always turn the charger “Off” before removing charger leads from the battery to avoid dangerous sparks.
- Do not force batteries into equipment as this can make them hard or dangerous to remove, possibly causing personal injury and/or damaging the equipment and battery.
- Do not mix new and old batteries in equipment. Doing so could result in the charging of old batteries by new batteries. This could force the old batteries into voltage reversal and a violent venting.
Source: Compiled from battery and automotive service equipment manufacturers and the U.S. Army.
