Lesson 1Heat behaviour and overheating reasons during charging: internal resistance, air flow, charger settings, room temperature effectsLooks at how traction batteries get hot during charging, focusing on internal resistance, charger settings, air flow, and room temperature. Stresses spotting unusual heating patterns and setting safe boundaries to avoid damage or heat incidents.
Internal resistance and heat productionEffect of charger current settingsRole of air flow and ventilation pathsRoom temperature and seasonal changesSpotting unusual temperature increaseLesson 2Record keeping and battery life cycle handling: serial tracking, warranty claims, replacement planning, and value for battery replacement vs. fixing upDeals with tracking batteries through their life using serial numbers, logs, and software. Explains noting down faults, backing warranty claims, planning replacements, and comparing cost and value of new batteries versus fixing up.
Serial number and asset ID trackingLogging faults, tests, and fixesBacking warranty and service claimsPlanning replacements and spare setsValue of replacement versus fixing upLesson 3Daily and shift-level battery check list: visual looks, terminal state, vent covers, electrolyte level (if needed), and physical damage signsGives a practical daily and shift-level check routine for traction batteries. Covers visual looks, terminals, vent covers, electrolyte levels, cables, and casings, helping spot damage or leaks before they cause breakdowns or injuries.
Pre-shift visual walk-around stepsChecking terminals and connectorsLooking at vent covers and traysVerifying electrolyte levels safelySpotting leaks and case damageLesson 4Types of traction batteries used in forklifts (lead-acid, AGM, gel, lithium-ion): chemistry, standard voltages, capacities, and discharge featuresIntroduces main traction battery chemistries used in forklifts, including flooded lead-acid, AGM, gel, and lithium-ion. Compares standard voltages, capacities, discharge curves, and common uses, pointing out good sides, bad sides, and safety needs.
Flooded lead-acid build basicsAGM and gel sealed battery featuresLithium-ion modules and management system roleVoltage, capacity, and pack setupsDischarge curves and use casesLesson 5Battery upkeep tasks and schedules: watering, cleaning terminals, tightening connections, charge cycle noting, calendar vs. cycle upkeepOutlines regular traction battery upkeep tasks and schedules. Includes watering, cleaning, torque checks, and noting charge cycles, comparing calendar-based and cycle-based plans to lengthen life and cut unplanned stoppages.
Watering times and safe waysCleaning cases, tops, and terminalsTorque checks on lugs and busbarsNoting charge and discharge cyclesCalendar versus cycle-based planningLesson 6Handling overheating and charging faults: spotting, quick actions, charger fault codes, heat management, and cooling plansCovers spotting overheating and charge faults using sensors, charger screens, and fault codes. Details quick safe responses, lockout steps, and practical heat management and cooling methods to protect batteries and nearby gear.
Common charger and battery fault signsReading and understanding charger fault codesQuick shutdown and lockout actionsUsing fans, spacing, and cool-down timesWhen to take a battery out of serviceLesson 7Battery specs and ratings: C-rate, ampere-hour (Ah), charge state (SoC), discharge depth (DoD), and expected run time calculationsExplains key battery ratings on forklift labels and sheets, including C-rate, ampere-hours, charge state, and discharge depth. Shows how to guess expected run time and match batteries to truck work cycles.
Reading battery labels and nameplatesC-rate and its effect on run timeAmpere-hour capacity and sizingCharge state and discharge depthRun time guessing for work cyclesLesson 8Safe handling, spill/leak response and disposal: PPE for acid and lithium incidents, neutralising, spill holding, and local waste rulesDetails safe handling of traction batteries, including PPE, lifting, and moving. Covers acid and electrolyte spills, lithium leaks, neutralising, holding, cleanup, and following local hazardous waste and recycling rules.
Needed PPE for acid and lithium risksSafe lifting, moving, and storageAcid spill neutralising stepsHolding and cleanup materialsDisposal and recycling rulesLesson 9Charging area setup and safety rules: air flow, signs, fire control thoughts, separation spaces, grounding and cable pathsCovers safe setup and running of charging areas, including air flow, signs, fire protection, and separation spaces. Addresses grounding, cable paths, eye wash and shower spots, and keeping fire starters away.
Air flow and hydrogen mixing needsNeeded signs and access controlFire control and extinguisher typesSeparation from offices and trafficGrounding, cabling, and trip risksLesson 10Relevant standards and sources: maker battery guides, OSHA/NFPA advice for battery rooms, and battery maker safety noticesSums up key standards and advice affecting traction battery rooms and charging areas. Reviews maker guides, OSHA and NFPA expectations, and safety notices, showing how to find, understand, and use them on site.
Using maker battery guidesOSHA rules for charging workNFPA advice for battery roomsFinding safety notices and updatesNoting site compliance stepsLesson 11Handling short run time and capacity loss: spotting sulfation, cell imbalance, extra loads, and end-of-life signsFocuses on spotting short run time and capacity drop in traction batteries. Reviews sulfation, cell imbalance, extra loads, and end-of-life signs, linking test data to practical choices on fix, recondition, or replace.
Gathering run time and charge historySpotting sulfation and undercharge patternsFinding weak or imbalanced cellsSpotting extra loads on parked trucksEnd-of-life signs and replacement decisionsLesson 12Battery charging systems and safe charging ways: charger types, charge methods, float vs. quick charge, equalising chargingExplains forklift battery charging systems, including regular, chance, and quick chargers. Reviews charge methods, equalising, float modes, and safe ways that stop overcharge, gassing, and early battery wear.
Regular, chance, and quick chargersCharge stages and control methodsEqualising charge goals and timingFloat charging and storage waysStopping overcharge and gassingLesson 13Regular battery testing and fault finding: specific gravity/hydrometer testing, conductance/impedance testing, capacity tests, voltage under loadDescribes regular and advanced traction battery tests, including specific gravity, conductance, impedance, and capacity checks. Explains voltage under load and how to understand results to spot weak cells, imbalance, or hidden faults early.
Safe sampling for specific gravity testsOpen-circuit and loaded voltage checksConductance and impedance test basicsFull capacity and discharge testingUnderstanding test patterns over time
