| Step | Potential Hazard | Control |
|---|---|---|
| Inspect work area and gather tools | Trip hazards, poor lighting, missing tools | Clear workspace, ensure proper lighting, gather correct wrenches and lifting tools |
| Identify battery type and check for damage | Acid leaks, cracked case, corroded terminals | Look for bulging, cracks, or leaking acid, neutralize corrosion with baking soda solution, replace damaged batteries |
| Shut off engine and secure vehicle | Electrical shock, unexpected movement | Turn off ignition, set parking brake, ensure keys are removed |
| Disconnect negative terminal first | Sparks, short circuits, burns | Remove negative cable before positive to reduce risk of shorting, use insulated tools, avoid contacting metal surfaces |
| Disconnect positive terminal | Sparks, arc flash, cable movement | Keep tool contact controlled, secure cable away from battery posts to prevent accidental reconnection |
| Remove battery hold down and lift battery | Back strain, crushed fingers, dropped battery | Use proper lifting technique or mechanical lift, keep hands on sides of battery, avoid tilting battery to prevent spills |
| Inspect battery tray and cables | Corrosion, sharp edges | Clean tray, neutralize corrosion, replace damaged cables or terminals |
| Install new or charged battery | Pinch points, incorrect polarity, dropped battery | Align battery correctly, follow proper orientation, lower battery gently into tray |
| Connect positive terminal first | Arc flash, sparks | Secure positive cable before negative, tighten connections without over torquing |
| Connect negative terminal | Shock risk, loose connection | Attach cable securely, verify all tools are clear from engine compartment |
| Apply protective spray or grease to terminals | Chemical exposure, contamination | Use small amount of terminal protector, avoid overspray |
| Test electrical system | Unexpected movement, electrical faults | Ensure vehicle is in park or neutral with brake set, start engine and check for proper operation |
| Clean work area and dispose of old battery | Acid residue, environmental hazards | Wipe tools, remove corrosion residue, place old battery in approved recycling container |
Safety glasses or face shield
Mechanic gloves or chemical resistant gloves
Steel toe boots
High visibility vest when working in fleet bays or outdoors
Long sleeves to protect against acid splashes
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 work area and gather tools | Trip hazards, poor lighting, missing tools | Clear workspace, ensure proper lighting, gather correct wrenches and lifting tools |
| Identify battery type and check for damage | Acid leaks, cracked case, corroded terminals | Look for bulging, cracks, or leaking acid, neutralize corrosion with baking soda solution, replace damaged batteries |
| Shut off engine and secure vehicle | Electrical shock, unexpected movement | Turn off ignition, set parking brake, ensure keys are removed |
| Disconnect negative terminal first | Sparks, short circuits, burns | Remove negative cable before positive to reduce risk of shorting, use insulated tools, avoid contacting metal surfaces |
| Disconnect positive terminal | Sparks, arc flash, cable movement | Keep tool contact controlled, secure cable away from battery posts to prevent accidental reconnection |
| Remove battery hold down and lift battery | Back strain, crushed fingers, dropped battery | Use proper lifting technique or mechanical lift, keep hands on sides of battery, avoid tilting battery to prevent spills |
| Inspect battery tray and cables | Corrosion, sharp edges | Clean tray, neutralize corrosion, replace damaged cables or terminals |
| Install new or charged battery | Pinch points, incorrect polarity, dropped battery | Align battery correctly, follow proper orientation, lower battery gently into tray |
| Connect positive terminal first | Arc flash, sparks | Secure positive cable before negative, tighten connections without over torquing |
| Connect negative terminal | Shock risk, loose connection | Attach cable securely, verify all tools are clear from engine compartment |
| Apply protective spray or grease to terminals | Chemical exposure, contamination | Use small amount of terminal protector, avoid overspray |
| Test electrical system | Unexpected movement, electrical faults | Ensure vehicle is in park or neutral with brake set, start engine and check for proper operation |
| Clean work area and dispose of old battery | Acid residue, environmental hazards | Wipe tools, remove corrosion residue, place old battery in approved recycling container |
Safety glasses or face shield
Mechanic gloves or chemical resistant gloves
Steel toe boots
High visibility vest when working in fleet bays or outdoors
Long sleeves to protect against acid splashes