Lesson 1Thermal behaviour and overheating causes during charge: internal resistance, ventilation, charger profiles, ambient temperature effectsThis lesson examines how traction batteries heat up during charging, emphasizing internal resistance, charger profiles, airflow, and ambient temperature influences. It highlights identifying unusual heating patterns and establishing safe limits to avoid damage or thermal incidents in Canadian environments.
Internal resistance and heat generationInfluence of charger current profilesRole of ventilation and airflow pathsAmbient temperature and seasonal effectsRecognizing abnormal temperature riseLesson 2Recordkeeping and battery lifecycle management: serial tracking, warranty claims, replacement planning, and ROI for battery replacement vs. refurbishmentThis lesson discusses tracking batteries throughout their lifecycle using serial numbers, logs, and software. It covers documenting failures, supporting warranty claims, planning replacements, and evaluating costs and ROI for new batteries versus refurbishment under Canadian regulations.
Serial number and asset ID trackingLogging faults, tests, and repairsSupporting warranty and service claimsPlanning replacements and spare poolsROI of replacement versus refurbishmentLesson 3Daily and shift-level battery inspection checklist: visual checks, terminal condition, vent caps, electrolyte level (if applicable), and physical damage indicatorsThis lesson provides a practical daily and shift-level inspection routine for traction batteries. It includes visual checks, terminals, vent caps, electrolyte levels, cables, and housings to detect damage or leaks early, preventing failures or injuries in line with Canadian safety guidelines.
Pre-shift visual walk-around stepsChecking terminals and connectorsInspecting vent caps and traysVerifying electrolyte levels safelyIdentifying leaks and case damageLesson 4Types of traction batteries used in forklifts (lead-acid, AGM, gel, lithium-ion): chemistry, nominal voltages, capacities, and discharge characteristicsThis lesson introduces primary traction battery chemistries in forklifts, such as flooded lead-acid, AGM, gel, and lithium-ion. It compares voltages, capacities, discharge curves, and applications, noting pros, cons, and safety requirements relevant to Canadian operations.
Flooded lead-acid construction basicsAGM and gel sealed battery featuresLithium-ion modules and BMS roleVoltage, capacity, and pack layoutsDischarge curves and use casesLesson 5Battery maintenance tasks and schedules: watering, cleaning terminals, torqueing connections, charge cycle logging, calendar vs. cycle maintenanceThis lesson outlines routine traction battery maintenance tasks and schedules. It includes watering, cleaning, torque checks, and logging charge cycles, comparing calendar-based and cycle-based plans to prolong life and minimize downtime in Canadian facilities.
Watering intervals and safe methodsCleaning cases, tops, and terminalsTorque checks on lugs and busbarsLogging charge and discharge cyclesCalendar versus cycle-based planningLesson 6Managing overheating and charging faults: detection, immediate actions, charger fault codes, thermal management, and cooling strategiesThis lesson addresses detecting overheating and charge faults via sensors, charger displays, and codes. It details immediate responses, lockout procedures, and thermal management methods to safeguard batteries and equipment in compliance with Canadian standards.
Typical charger and battery fault symptomsReading and interpreting charger fault codesImmediate shutdown and lockout actionsUsing fans, spacing, and cooldown periodsWhen to remove a battery from serviceLesson 7Battery specifications and ratings: C-rate, ampere-hour (Ah), state of charge (SoC), depth of discharge (DoD), and expected runtime calculationsThis lesson explains key battery ratings on forklift nameplates and datasheets, including C-rate, ampere-hours, state of charge, and depth of discharge. It demonstrates estimating runtime and matching batteries to truck duty cycles for Canadian use.
Reading battery labels and nameplatesC-rate and its impact on runtimeAmpere-hour capacity and sizingState of charge and depth of dischargeRuntime estimation for duty cyclesLesson 8Safe handling, spill/leak response and disposal: PPE for acid and lithium incidents, neutralization, spill containment, and local hazardous waste rulesThis lesson details safe handling of traction batteries, including PPE, lifting, and transport. It covers spills, leaks, neutralization, containment, cleanup, and adherence to Canadian hazardous waste and recycling regulations.
Required PPE for acid and lithium risksSafe lifting, moving, and storageAcid spill neutralization proceduresContainment and cleanup materialsDisposal and recycling regulationsLesson 9Charging area layout and safety rules: ventilation, signage, fire suppression considerations, separation distances, grounding and cable routingThis lesson covers designing and operating charging areas safely, including ventilation, signage, fire protection, and separation. It addresses grounding, cable routing, eyewash placement, and keeping ignition sources distant per Canadian codes.
Ventilation and hydrogen dilution needsRequired signage and access controlFire suppression and extinguisher typesSeparation from offices and trafficGrounding, cabling, and trip hazardsLesson 10Relevant standards and sources: manufacturer battery manuals, OSHA/NFPA guidance for battery rooms, and battery manufacturer safety bulletinsThis lesson summarizes key standards for traction battery rooms and charging areas. It reviews manufacturer manuals, OSHA and NFPA guidelines, and safety bulletins, teaching how to apply them on-site in Canada.
Using manufacturer battery manualsOSHA rules for charging operationsNFPA guidance for battery roomsLocating safety bulletins and updatesDocumenting site compliance stepsLesson 11Handling low runtime and capacity fade: diagnosing sulfation, cell imbalance, parasitic loads, and end-of-life criteriaThis lesson focuses on diagnosing reduced runtime and capacity loss in traction batteries. It reviews sulfation, cell imbalance, parasitic loads, and end-of-life signs, connecting tests to decisions on repair or replacement in Canadian settings.
Collecting runtime and charge historyIdentifying sulfation and undercharge patternsDetecting weak or imbalanced cellsFinding parasitic loads on parked trucksEnd-of-life criteria and replacement callsLesson 12Battery charging systems and safe charging practices: charger types, charge algorithms, float vs. fast charge, equalization chargingThis lesson explains forklift battery charging systems, including conventional, opportunity, and fast chargers. It reviews algorithms, equalization, float modes, and safe practices to prevent overcharge and wear, aligned with Canadian safety.
Conventional, opportunity, and fast chargersCharge stages and control algorithmsEqualization charge goals and timingFloat charging and storage practicesPreventing overcharge and gassingLesson 13Periodic battery testing and diagnostics: specific gravity/hydrometer testing, conductance/impedance testing, capacity tests, voltage under loadThis lesson describes routine and advanced tests for traction batteries, including specific gravity, conductance, impedance, and capacity. It explains interpreting results to identify weak cells or defects early for Canadian compliance.
Safe sampling for specific gravity testsOpen-circuit and loaded voltage checksConductance and impedance test basicsFull capacity and discharge testingInterpreting test trends over time
