Title: Module 7: Battery Safety & Environmental - Activity
Course: ASE A6 Battery Service > Section: Module 7: Battery Safety & Environmental

Q: When jump-starting a vehicle using a donor vehicle, which connection should be made **first**?
- Black cable to the engine ground on the dead vehicle
- Red cable to the dead battery positive terminal
- Red cable to the good battery positive terminal
- Black cable to the good battery negative terminal
A: Red cable to the dead battery positive terminal

Q: When disconnecting jumper cables after a successful jump-start, which connection should be removed **last**?
- Black cable from the engine ground on the dead vehicle
- Black cable from the good battery negative terminal
- Red cable from the good battery positive terminal
- Red cable from the dead battery positive terminal
A: Red cable from the dead battery positive terminal

Q: A technician is removing a battery with heavy corrosion buildup on the terminals and visible acid residue on the tray. Which PPE combination is most appropriate?
- Leather gloves and safety glasses
- Nitrile gloves, safety glasses with side shields, and a rubber apron
- Latex gloves and a dust mask
- Nitrile gloves only
A: Nitrile gloves, safety glasses with side shields, and a rubber apron

Q: What type of gas is produced during battery charging that creates an explosion risk?
- Carbon monoxide
- Nitrogen
- Hydrogen
- Methane
A: Hydrogen

Q: Which substance should be used to neutralize a sulfuric acid spill on a work surface?
- Vinegar
- Baking soda (sodium bicarbonate)
- Bleach
- Rubbing alcohol
A: Baking soda (sodium bicarbonate)

Q: Under EPA regulations (RCRA), lead-acid batteries are classified as which type of waste?
- General solid waste
- Hazardous waste requiring a manifest
- Universal Waste
- Non-regulated recyclable material
A: Universal Waste

Q: If a technician gets sulfuric acid (electrolyte) in their eye, for how long should they flush the eye with water at an eyewash station?
- 1-2 minutes
- 5 minutes
- 15-20 minutes
- 30 seconds
A: 15-20 minutes

Q: According to DOT requirements, what must be done to battery terminals before transporting used batteries?
- Terminals must be cleaned with a wire brush
- Terminals must be coated in grease
- Terminals must be protected against short circuits (caps, tape, or insulation)
- Terminals must be left exposed for inspection
A: Terminals must be protected against short circuits (caps, tape, or insulation)

Q: OSHA and EPA regulations require an eyewash station to be located within what distance of the battery work area?
- 50 feet
- A 10-second walk
- 100 feet
- The same room
A: A 10-second walk

Q: When jump-starting a vehicle, why is the final ground cable connected to an engine ground point on the dead vehicle rather than directly to the dead battery's negative terminal?
- The engine ground provides a better electrical connection
- It reduces the chance of a spark near the battery where hydrogen gas may be present
- The dead battery's negative terminal is not strong enough to carry the current
- It prevents damage to the donor vehicle's alternator
A: It reduces the chance of a spark near the battery where hydrogen gas may be present

Q: A technician needs to add distilled water to a flooded battery that finished charging 10 minutes ago. Identify all hazards present in this scenario and list the complete PPE the technician should wear. Explain why each PPE item is necessary for this specific task. Hazards include hydrogen gas still present from recent charging (explosion risk if sparked), sulfuric acid splash when removing vent caps or pouring water (electrolyte may still be bubbling), and hot electrolyte from the charging process. Required PPE: chemical splash goggles with full eye seal (not just safety glasses, because removing vent caps places the technician's eyes directly over open cells where acid can splash upward), acid-resistant gloves (nitrile or neoprene to protect hands from acid contact), and a rubber apron (to protect clothing and torso from splashes). The technician should also ensure ventilation by opening the hood and avoiding sparks, open flames, or smoking near the battery.

Q: A 2023 Toyota Camry Hybrid has a dead 12V auxiliary battery. The technician notices orange cables running through the engine bay. Explain whether the vehicle can be jump-started, describe the correct procedure, and identify the specific safety precautions related to the hybrid system. What should the technician never do in this situation? Yes, the 12V auxiliary battery can be jump-started using the standard procedure, but extra caution is required. The orange cables are part of the high-voltage system (200-350V) and must never be touched, cut, or disturbed. The technician should locate the 12V auxiliary battery (typically under the hood or in the trunk) and jump-start using the standard connection order: red cable to dead battery positive, red cable to good battery positive, black cable to good battery negative, and black cable to engine ground on the dead vehicle. If the 12V battery is in a remote location, the technician should use the remote jump-start terminals provided by the manufacturer. The technician should never attempt to interact with, disconnect, or jump-start the high-voltage hybrid battery system. Only qualified hybrid-trained technicians should work on the high-voltage components.

Q: A battery explodes while a technician is checking vent caps during charging. Acid and plastic fragments hit the technician's face and chest. Describe the complete first-aid response in the correct order of steps, and explain what responders should avoid doing. The correct first-aid response in order: (1) Call 911 immediately, as battery explosions can cause severe injuries. (2) Move the injured person away from the battery area to prevent further chemical exposure. (3) Begin flushing all affected areas (face, eyes, chest) with water immediately using the eyewash station for the eyes and a safety shower or hose for the body. (4) Continue flushing for at least 15-20 minutes without interruption. (5) Remove contaminated clothing if possible without pulling it over the face or eyes. (6) Keep the person calm and still until emergency services arrive. (7) If the person stops breathing, begin CPR. Responders should NOT attempt to remove embedded plastic or lead fragments, as this should be handled by medical personnel. They should also not apply creams, ointments, or baking soda to the skin — water flushing is the primary treatment for acid burns on the body.

Q: A new technician asks why old batteries cannot simply be thrown in the dumpster since they are "just car parts." Provide a thorough explanation covering (a) the hazardous materials in a lead-acid battery, (b) the specific federal regulations that apply, (c) the correct disposal procedure, and (d) the recycling rate and what materials are recovered. (a) Lead-acid batteries contain two hazardous materials: lead, a toxic heavy metal that causes neurological damage and contaminates soil and groundwater, and sulfuric acid, a corrosive acid that burns skin and damages the environment. (b) Under federal EPA regulations (Resource Conservation and Recovery Act / RCRA), lead-acid batteries are classified as Universal Waste. It is illegal to dispose of them in regular trash in all 50 states, with significant fines for violations. (c) The correct procedure is to collect batteries as "cores," store them in a designated area with spill containment (upright, in a ventilated space), and return them to the battery distributor or a licensed recycler. Most states require a core deposit that is refunded upon return. (d) Over 99% of lead-acid batteries in the U.S. are recycled, making them one of the most recycled consumer products. The lead is melted down and reused in new batteries, the sulfuric acid is neutralized or converted to sodium sulfate for use in detergents and textiles, and the polypropylene case material is recycled into new battery cases.

Q: A shop is setting up a new battery service area. List and explain the four items that OSHA and EPA regulations require in this area. For each item, explain its purpose and describe how it would be used in a real emergency or compliance scenario. The four required items are: (1) A designated battery storage area with spill containment — this keeps batteries organized, upright, and prevents acid leaks from reaching the shop floor or storm drains. In practice, this means acid-resistant containment pallets or trays that can hold the volume of the largest battery's electrolyte. (2) Acid-neutralizing materials (baking soda / sodium bicarbonate) readily accessible — used to neutralize sulfuric acid spills on work surfaces, floors, and battery trays. In an emergency, the technician sprinkles baking soda on the spill until the fizzing stops, indicating the acid is neutralized, then cleans up the residue. (3) An eyewash station within a 10-second walk from the battery work area — required for immediate flushing if acid contacts the eyes. The 10-second rule exists because acid damage to the eyes is progressive and every second of delay increases the severity of injury. The station must deliver at least 15 minutes of continuous flushing. (4) Safety Data Sheets (SDS) on file for sulfuric acid and lead — these documents provide emergency responders and technicians with critical information about chemical properties, health hazards, first-aid measures, and spill cleanup procedures. SDS must be accessible to all employees at all times per OSHA's Hazard Communication Standard.