Lesson 1Thermal behaviour and overheating causes during charge: internal resistance, ventilation, charger profiles, ambient temperature effectsExplores how traction batteries heat during charging, focusing on internal resistance, charger profiles, airflow, and ambient temperature. Emphasises recognising abnormal heating trends and setting safe limits to prevent damage or thermal events.
Internal resistance and heat generationInfluence of charger current profilesRole of ventilation and airflow pathsAmbient temperature and seasonal effectsRecognising abnormal temperature riseLesson 2Record-keeping and battery lifecycle management: serial tracking, warranty claims, replacement planning, and ROI for battery replacement vs. refurbishmentAddresses tracking batteries through their lifecycle using serial numbers, logs, and software. Explains documenting failures, supporting warranty claims, planning replacements, and comparing cost and ROI of new batteries versus refurbishment.
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 indicatorsProvides a practical daily and shift-level inspection routine for traction batteries. Covers visual checks, terminals, vent caps, electrolyte levels, cables, and housings, helping catch damage or leaks before they cause failures or injuries.
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 characteristicsIntroduces main traction battery chemistries used in forklifts, including flooded lead-acid, AGM, gel, and lithium-ion. Compares nominal voltages, capacities, discharge curves, and typical applications, highlighting pros, cons, and safety needs.
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 maintenanceOutlines routine traction battery maintenance tasks and schedules. Includes watering, cleaning, torque checks, and logging charge cycles, comparing calendar-based and cycle-based plans to extend life and reduce unplanned downtime.
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 strategiesCovers detection of overheating and charge faults using sensors, charger displays, and fault codes. Details immediate safe responses, lockout steps, and practical thermal management and cooling methods to protect batteries and nearby equipment.
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 calculationsExplains key battery ratings used on forklift nameplates and datasheets, including C-rate, ampere-hours, state of charge, and depth of discharge. Shows how to estimate expected runtime and match batteries to truck duty cycles.
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, neutralisation, spill containment, and local hazardous waste rulesDetails safe handling of traction batteries, including PPE, lifting, and transport. Covers acid and electrolyte spills, lithium leaks, neutralisation, containment, cleanup, and compliance with local hazardous waste and recycling regulations.
Required PPE for acid and lithium risksSafe lifting, moving, and storageAcid spill neutralisation proceduresContainment and cleanup materialsDisposal and recycling regulationsLesson 9Charging area layout and safety rules: ventilation, signage, fire suppression considerations, separation distances, grounding and cable routingCovers safe design and operation of charging areas, including ventilation, signage, fire protection, and separation distances. Addresses grounding, cable routing, eyewash and shower placement, and keeping ignition sources away.
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 bulletinsSummarises key standards and guidance affecting traction battery rooms and charging areas. Reviews manufacturer manuals, OSHA and NFPA expectations, and safety bulletins, showing how to locate, interpret, and apply them on site.
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 criteriaFocuses on diagnosing short runtime and capacity loss in traction batteries. Reviews sulfation, cell imbalance, parasitic loads, and end-of-life indicators, linking test data to practical decisions on repair, reconditioning, or replacement.
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, equalisation chargingExplains forklift battery charging systems, including conventional, opportunity, and fast chargers. Reviews charge algorithms, equalisation, float modes, and safe practices that prevent overcharge, gassing, and premature battery wear.
Conventional, opportunity, and fast chargersCharge stages and control algorithmsEqualisation 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 loadDescribes routine and advanced traction battery tests, including specific gravity, conductance, impedance, and capacity checks. Explains voltage under load and how to interpret results to spot weak cells, imbalance, or hidden defects early.
Safe sampling for specific gravity testsOpen-circuit and loaded voltage checksConductance and impedance test basicsFull capacity and discharge testingInterpreting test trends over time
