Battery Safety Guidelines

Safety First

• Do wear eye protection and protective clothing when handling batteries.
• Do charge batteries in a well-ventilated area.
• Do keep batteries out of reach of children.
• Don’t leave batteries charging unattended.

Battery Maintenance Do’s and Dont’s

1. Measuring Specific Gravity

Do:

• Open vent plugs using the appropriate opening tool.
• Use a calibrated or branded hydrometer for correct readings.

Don’t:

• Never use a coin or screwdriver; it may damage the vent plug grooves.
• Never use a non-calibrated or unbranded hydrometer, as it may give wrong readings.

2. Measuring Open Circuit Voltage (OCV) of the Battery

Do:

• Use a calibrated or branded multi-meter of a suitable voltage range.

Don’t:

• Never use a non-calibrated or unbranded multi-meter; it may provide false readings.

3. Battery Terminal Cleaning

Do:

• Apply a thin smear of petroleum jelly on both the battery terminals and cable clamps.

Don’t:

• Avoid using grease or oil, as it may damage the terminals over time due to corrosion or sulphation.

4. Battery Top Cover Cleaning

Do:

• Clean the battery top cover using normal tap water.
• Ensure vent plugs are properly tightened before washing the battery top.

Don’t:

• Avoid using dirty or contaminated water.
• Do not remove or loosen the vent plugs during cleaning, as it may allow water to enter the battery.

5. Battery Removal from Vehicle

Do:

• Always remove the negative terminal first, then the positive terminal.
• Use proper size tooling for battery fastening and de-fastening activities.

Don’t:

• Don’t remove the positive terminal first; it may create a risk of short-circuiting.
• Avoid using the wrong size tools.

6. Battery Fitment

Do:

• Fit the positive terminal first, and then the negative terminal last.

Don’t:

• Do not alter the sequence; always follow the correct procedure as mentioned.

Tips for Battery Maintenance

• Check Battery Electrolyte Level:

  • Frequency: Monthly
  • Action: Remove vent caps and ensure the electrolyte level matches the MAX line without crossing it.
  • Result: Proper electrolyte level maintained.

• Top Up Battery Electrolyte:

  • Frequency: As & when required
  • Action: Top up with Battery Grade DM Water only. Do not use acid or raw water.
  • Result: Electrolyte level correctly restored.

• Battery Terminal Maintenance:

  • Frequency: Monthly
  • Action: Keep terminals tight, clean, and dry.
  • Result: Dust and corrosion-free terminals.

• Avoid Hammering Terminals:

  • Frequency: As & when fitting terminals
  • Action: Gently tighten terminals using clamps.
  • Result: Terminals secured without damage.

• Vent Plug Maintenance:

  • Frequency: Monthly
  • Action: Ensure vent plugs are clean and securely attached to the battery top.
  • Result: Proper ventilation maintained.

• Battery Top Cleaning:

  • Frequency: Monthly
  • Action: Clean the top cover with a wet cloth and dry it with a dry cloth.
  • Result: Dust-free battery surface.

• Avoid Short Circuits:

  • Frequency: As & when handling batteries
  • Action: Prevent any physical short circuit between terminals during maintenance.
  • Result: No short circuit or accident hazards.

• Battery Fitment Check:

  • Frequency: Monthly
  • Action: Ensure the battery is properly fitted in the cradle or battery box.
  • Result: Secure battery installation.

• Intended Battery Use:

  • Frequency: Daily
  • Action: Use the battery only for engine cranking.
  • Result: Extended battery life.

• Vehicle Idle Battery Care:

  • Frequency: As & when vehicle remains idle for more than 3 weeks
  • Action:
    • Remove the negative cable.
    • Ensure battery is adequately charged before removal.
    • If discharged, remove and bench charge the battery.
  • Result: Maintained battery health during vehicle downtime.

Battery Charging Safety Checklist

• Keep sparks, flames, smoking materials, and other ignition sources away from the battery at all times.
• Ensure the area is well-ventilated while handling or charging batteries.
• Always wear protective safety goggles, gloves, and an apron when working with batteries.
• If acid contacts your eyes, rinse immediately with plenty of cold water and seek medical attention.
• Neutralize any acid spills with baking soda promptly.
• Only attempt to charge batteries if you are properly trained.

Disposal of Old/Scrap Batteries

According to the Batteries Management and Handling Rules (BMHR) 2001, batteries are classified as poisonous and hazardous.

• Never dispose of batteries in regular trash.
• Store used batteries safely until they can be properly handled.
• Always sell old or scrap batteries to an authorized smelter.

Responsible disposal protects the environment and complies with legal standards.