Lesson 1Heat during charging and causes of overheating: inside resistance, air flow, charger settings, room temperature effectsLooks at how traction batteries get hot when charging, focusing on inside resistance, charger settings, air flow, and room temperature. Stresses spotting unusual heat patterns and setting safe limits to avoid damage or heat problems.
Internal resistance and heat generationInfluence of charger current profilesRole of ventilation and airflow pathsAmbient temperature and seasonal effectsRecognizing abnormal temperature riseLesson 2Keeping records and managing battery life: tracking serial numbers, warranty claims, planning replacements, and value for new vs. fixing batteriesDeals with tracking batteries through their life using serial numbers, logs, and software. Explains noting failures, backing warranty claims, planning replacements, and comparing costs and value of new batteries versus fixing.
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 battery check list: looking checks, terminal state, vent covers, electrolyte level (if needed), and signs of physical damageGives a practical daily and shift check routine for traction batteries. Covers looking checks, terminals, vent covers, electrolyte levels, cables, and casings, helping find damage or leaks before they cause breakdowns 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 in forklifts (lead-acid, AGM, gel, lithium-ion): chemistry, usual voltages, capacities, and discharge featuresIntroduces main traction battery types used in forklifts, like flooded lead-acid, AGM, gel, and lithium-ion. Compares usual voltages, capacities, discharge patterns, and common uses, pointing out good and bad sides, 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 upkeep tasks and schedules: adding water, cleaning terminals, tightening connections, logging charge cycles, time-based vs. cycle upkeepOutlines regular traction battery upkeep tasks and schedules. Includes adding water, cleaning, torque checks, and logging charge cycles, comparing time-based and cycle-based plans to lengthen life and cut unexpected stoppages.
Watering intervals and safe methodsCleaning cases, tops, and terminalsTorque checks on lugs and busbarsLogging charge and discharge cyclesCalendar versus cycle‑based planningLesson 6Handling overheating and charging problems: spotting, quick actions, charger error codes, heat management, and cooling waysCovers spotting overheating and charge problems using sensors, charger screens, and error codes. Details quick safe responses, lockout steps, and practical heat management and cooling methods to protect batteries and nearby gear.
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 specs and ratings: C-rate, ampere-hour (Ah), charge state (SoC), discharge depth (DoD), and expected run time calculationsExplains key battery ratings on forklift plates 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 impact on runtimeAmpere‑hour capacity and sizingState of charge and depth of dischargeRuntime estimation for duty cyclesLesson 8Safe handling, spill/leak response and disposal: gear for acid and lithium problems, neutralizing, spill holding, and local waste rulesDetails safe handling of traction batteries, including gear, lifting, and moving. Covers acid and electrolyte spills, lithium leaks, neutralizing, holding, cleanup, and following local hazardous waste and recycling rules.
Required PPE for acid and lithium risksSafe lifting, moving, and storageAcid spill neutralization proceduresContainment and cleanup materialsDisposal and recycling regulationsLesson 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.
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: maker battery guides, OSHA/NFPA rules for battery rooms, and battery maker safety noticesSums up key standards and guidance for traction battery rooms and charging areas. Reviews maker guides, OSHA and NFPA rules, and safety notices, showing how to find, understand, and use them on site.
Using manufacturer battery manualsOSHA rules for charging operationsNFPA guidance for battery roomsLocating safety bulletins and updatesDocumenting site compliance stepsLesson 11Handling short run time and capacity loss: checking sulfation, cell imbalance, extra loads, and end-of-life signsFocuses on checking short run time and capacity loss 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.
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 ways: charger types, charge methods, float vs. quick charge, equalizing chargingExplains forklift battery charging systems, including usual, chance, and quick chargers. Reviews charge methods, equalizing, float modes, and safe ways that stop overcharge, gassing, and early battery wear.
Conventional, opportunity, and fast chargersCharge stages and control algorithmsEqualization charge goals and timingFloat charging and storage practicesPreventing overcharge and gassingLesson 13Regular battery testing and checks: 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 read 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 testingInterpreting test trends over time
