Below is the precise procedure in simple steps, for filling new battery with electrolyte.
a) Ensure the area is well ventilated.
b) Lift new battery out of box and place on 2 blocks of wood or board.
c) Remove the temporary caps from the new battery.
d) Wear appropriate PPE, i.e. face visor, chemical apron and rubber gloves.
e) No Smoking. No open flam Sign Posted
f) Eye wash to be close to hand. Check expiry date. Sign Posted.
g) Ensure the electrolyte is checked by using a hydrometer, refer to service manual specification.
h) Use electrolyte pump to fill the battery.
i) Fill electrolyte into the new battery to the maximum level mark.
j) Fit permanent caps.
k) Wash with water any spilled electrolyte from the battery and floor. Then dry battery before handling.
Standard Procedure for the safe charging and changing batteries
Battery Charging Method
Must be well ventilated to prevent gas vapour accumulating long sleeve.
Wear appropriate PPE, i.e. face visor, chemical apron and rubber gloves.
No Smoking / No Open Flam Sign posted.
Eye wash arrangement to be close to hand. Check expiry date. Sign posted.
Put the battery on 2 blocks of wood or board.
Open the caps and make sure the electrolyte level is appropriate.
Leave the caps loose or released.
Ensure the battery charger is in the off position before connecting the cables.
Ensure terminal battery positive (+) and negative (-) are clean.
Install the red cable clip to the positive battery terminal (+) and black cable clip to the negative battery terminal (-).
Ensure all the connectors are firm.
Activate the charger and check that the needle voltage indicator is suitable with the battery charge requirement.
Battery Changing Procedure
Park the vehicle/unit on a flat and safe area. Place the Lock-out machine as per the Lock out Tag out procedure.
Switch off disconnect switch.
Open the battery cover. Clean battery and box.
Release battery cables and battery binder.
Lift out the old battery, store on the safe position.
Place the new battery and install the battery binder.
Clean terminal cables from rust and corrosion. Use gloves (Acid proof).
Install battery cables make sure red cable for positive (+) and black cable for negative (-)
Ensure terminal cables are correctly tightened up.
Spray on terminal battery protector.
Ensure all tools have been removed.
Activate disconnect switch and start the engine.
Re close the battery box.
Remove Lock-out facility.
Report vehicle ready for use to the Supervisor.