| Step | Potential Hazard | Control |
|---|---|---|
| Inspect charging area and equipment | Clutter, poor ventilation, damaged cables, electrical hazards | Maintain clean area, ensure adequate ventilation, inspect chargers and cords for damage before use |
| Identify battery type and condition | Acid leaks, cracked cases, damaged terminals | Check for bulging, cracks, or leaking electrolyte, do not charge damaged batteries, neutralize corrosion with baking soda solution |
| Verify charger settings | Overcharging, overheating, incorrect voltage | Select charger voltage and amperage appropriate for battery type, follow manufacturer instructions |
| Place battery in charging area | Dropped battery, back strain, acid exposure | Use proper lifting technique, keep battery upright, place on stable and non conductive surface |
| Connect charger clamps | Sparks, incorrect polarity, arc flash | Attach positive clamp first then negative clamp, verify polarity, ensure clamps have solid contact |
| Start charging cycle | Hydrogen gas release, overheating, fire | Ensure area is ventilated, keep sparks and flames away, periodically check temperature of battery and charger |
| Monitor charging process | Battery overheating, electrolyte boil over, charger failure | Check battery regularly, stop charging if battery becomes hot, emits odor, or leaks |
| End charging cycle and disconnect | Sparks, accidental contact, cable whipping | Turn off charger, disconnect negative clamp first then positive clamp, keep clamps from touching each other |
| Inspect charged battery | Acid residue, loose terminals, improper charge | Clean terminals if needed, check voltage, confirm battery is cool before handling |
| Store battery or return to equipment | Dropped battery, incorrect installation | Use proper lifting techniques, ensure battery is secured in tray and connected properly |
| Clean charging station | Acid contamination, trip hazards, damaged equipment | Neutralize spills, wipe surfaces, coil charger cables, store PPE and tools properly |
Safety glasses or face shield
Chemical resistant gloves
Steel toe boots
Long sleeves to protect against acid splashes
High visibility vest when working in active fleet areas
Always have a complete, well-stocked first aid kit available.
JSA Category: General Maintenance and Shop Operations
* The steps, hazards, and controls displayed above may be incomplete or not suit your department's needs. All job safety analyses should be a completed with frontline worker input to ensure that each potential hazard is identified and mitigated.
Please read about The Essentials Elements of a Solid Job Safety Anaylsis here.
Thank you to our primary sponsor, Roadwurx, which is a simple asset management platform for small public works and road departments.
| Step | Potential Hazard | Control |
|---|---|---|
| Inspect charging area and equipment | Clutter, poor ventilation, damaged cables, electrical hazards | Maintain clean area, ensure adequate ventilation, inspect chargers and cords for damage before use |
| Identify battery type and condition | Acid leaks, cracked cases, damaged terminals | Check for bulging, cracks, or leaking electrolyte, do not charge damaged batteries, neutralize corrosion with baking soda solution |
| Verify charger settings | Overcharging, overheating, incorrect voltage | Select charger voltage and amperage appropriate for battery type, follow manufacturer instructions |
| Place battery in charging area | Dropped battery, back strain, acid exposure | Use proper lifting technique, keep battery upright, place on stable and non conductive surface |
| Connect charger clamps | Sparks, incorrect polarity, arc flash | Attach positive clamp first then negative clamp, verify polarity, ensure clamps have solid contact |
| Start charging cycle | Hydrogen gas release, overheating, fire | Ensure area is ventilated, keep sparks and flames away, periodically check temperature of battery and charger |
| Monitor charging process | Battery overheating, electrolyte boil over, charger failure | Check battery regularly, stop charging if battery becomes hot, emits odor, or leaks |
| End charging cycle and disconnect | Sparks, accidental contact, cable whipping | Turn off charger, disconnect negative clamp first then positive clamp, keep clamps from touching each other |
| Inspect charged battery | Acid residue, loose terminals, improper charge | Clean terminals if needed, check voltage, confirm battery is cool before handling |
| Store battery or return to equipment | Dropped battery, incorrect installation | Use proper lifting techniques, ensure battery is secured in tray and connected properly |
| Clean charging station | Acid contamination, trip hazards, damaged equipment | Neutralize spills, wipe surfaces, coil charger cables, store PPE and tools properly |
Safety glasses or face shield
Chemical resistant gloves
Steel toe boots
Long sleeves to protect against acid splashes
High visibility vest when working in active fleet areas