TM 10-6140-200-14
CHAPTER 4
HEALTH AND SAFETY
Section I. BATTERY HAZARDS
concentrate in an explosive mixture. If it accumulates into
4-1. General
gas pockets, as can occur within a cell, it might explode if
ignited.
A lead-acid battery can be a very useful, safe source of
electrical power. While installing, using, maintaining or
repairing a motive power battery, opportunities exist,
discharge and, while most persons cannot "feel" voltages
however, for exposure to potentially dangerous situations.
This section identifies those hazards which could result
below 35 to 40 volts, all motive power batteries should be
from improper handling or use.
regarded as potentially dangerous. A lead-acid battery is
capable of discharging at extremely high rates and, under
conditions of direct shorting, can cause much damage and
4-2. Hazards
serious injury.
a. A SULFURIC ACID solution is used as the electro-
d. THE WEIGHT of these heavy batteries can easily
lyte in lead-acid batteries and has a concentration of
cause painful strains or crushed hands or feet if improperly
approximately 37% by weight of sulfuric acid in water. In
lifted or handled. Batteries can be damaged if dropped. The
this diluted state it is not as hazardous as strong or
average motive power battery weighs more than one ton, so
concentrated sulfuric acid, but it acts as an oxidizing agent
proper equipment must be provided when changing or
and can burn the skin or eyes and destroy clothing made of
handling batteries.
many common materials such as cotton or rayon.
e. BURNS can result from contact with molten lead or
hot compound while repairing a battery. Lead can splash
is produced in a lead-acid battery while it is being charged.
when intercell connectors are being reburned and hot
The gases can combine explosively if a spark or flame is
compound can be spilled when resealing covers to jars. The
present to ignite them. Because hydrogen is so light, it
protective gear provided, if worn, will prevent such burns.
normally rises and diffuses into the air before it can
Section II. SAFETY PROCEDURES
insulated lifting beam, of adequate capacity, should always
4-3. Federal Standards
be used with overhead lifting equipment. Do not use chains
attached to a hoist at a single central point forming a
a. In 1970, Congress passed the Occupational Safety and
triangle. This procedure is unsafe and could damage the
Health Act (OSHA). This act established the minimal
steel tray.
acceptable standards for safe and healthful working condi-
tions. The safety procedures suggested in this manual have
been compiled from standards developed over the years by
hat made of a non-conducting material.
professional and technical organizations and by battery
manufacturers and users. Experience has shown them to be
c. Tools, chains and other metallic objects will be
the most effective safety standards. In all cases they exceed
kept away from the top of uncovered batteries to prevent
the minimum standards of OSHA for personal safety and
include procedures for safeguarding equipment as well.
possible short circuits.
b. The safety procedures have been grouped by functional
d. Battery operated equipment should be properly
area of most logical application or need. The applicable
positioned with switch off, brake set, and battery un-
military safety procedures must also be followed.
plugged when changing batteries or charging them while in
the equipment.
4-4. Safety Procedures While Handling Batteries
e. Personnel who work around batteries should not
a. Lift batteries with mechanical equipment only, such
wear jewelry made from a conductive material. Metal items
as an overhead hoist, crane or lift truck. A properly
can short circuit a battery and could cause severe burns.
4-1
