Lesson 1Thermal behavior an overheating causes during charge: internal resistance, ventilation, charger profiles, ambient temperature effectsExplores how traction batteries heat up during charging, focusing pon internal resistance, charger profiles, airflow, an ambient temperature. Emphasizes recognizing abnormal heating trends an setting safe limits to prevent damage or thermal events, mi bredda.
Internal resistance an heat generationInfluence a charger current profilesRole a ventilation an airflow pathsAmbient temperature an seasonal effectsRecognizing abnormal temperature riseLesson 2Recordkeeping an battery lifecycle management: serial tracking, warranty claims, replacement planning, an ROI fi battery replacement vs. refurbishmentAddresses tracking batteries through dem lifecycle using serial numbers, logs, an software. Explains documenting failures, supporting warranty claims, planning replacements, an comparing cost an ROI a new batteries versus refurbishment, yuh know.
Serial number an asset ID trackingLogging faults, tests, an repairsSupporting warranty an service claimsPlanning replacements an spare poolsROI a replacement versus refurbishmentLesson 3Daily an shift-level battery inspection checklist: visual checks, terminal condition, vent caps, electrolyte level (if applicable), an physical damage indicatorsProvides a practical daily an shift-level inspection routine fi traction batteries. Covers visual checks, terminals, vent caps, electrolyte levels, cables, an housings, helping catch damage or leaks before dem cause failures or injuries, seen.
Pre-shift visual walk-around stepsChecking terminals an connectorsInspecting vent caps an traysVerifying electrolyte levels safelyIdentifying leaks an case damageLesson 4Types a traction batteries used inna forklifts (lead-acid, AGM, gel, lithium-ion): chemistry, nominal voltages, capacities, an discharge characteristicsIntroduces main traction battery chemistries used inna forklifts, including flooded lead-acid, AGM, gel, an lithium-ion. Compares nominal voltages, capacities, discharge curves, an typical applications, highlighting pros, cons, an safety needs, yuh zeet.
Flooded lead-acid construction basicsAGM an gel sealed battery featuresLithium-ion modules an BMS roleVoltage, capacity, an pack layoutsDischarge curves an use casesLesson 5Battery maintenance tasks an schedules: watering, cleaning terminals, torqueing connections, charge cycle logging, calendar vs. cycle maintenanceOutlines routine traction battery maintenance tasks an schedules. Includes watering, cleaning, torque checks, an logging charge cycles, comparing calendar-based an cycle-based plans to extend life an reduce unplanned downtime, mi fren.
Watering intervals an safe methodsCleaning cases, tops, an terminalsTorque checks pon lugs an busbarsLogging charge an discharge cyclesCalendar versus cycle-based planningLesson 6Managing overheating an charging faults: detection, immediate actions, charger fault codes, thermal management, an cooling strategiesCovers detection a overheating an charge faults using sensors, charger displays, an fault codes. Details immediate safe responses, lockout steps, an practical thermal management an cooling methods to protect batteries an nearby equipment, yuh hear.
Typical charger an battery fault symptomsReading an interpreting charger fault codesImmediate shutdown an lockout actionsUsing fans, spacing, an cooldown periodsWhen to remove a battery from serviceLesson 7Battery specifications an ratings: C-rate, ampere-hour (Ah), state a charge (SoC), depth a discharge (DoD), an expected runtime calculationsExplains key battery ratings used pon forklift nameplates an datasheets, including C-rate, ampere-hours, state a charge, an depth a discharge. Shows how to estimate expected runtime an match batteries to truck duty cycles, seen.
Reading battery labels an nameplatesC-rate an its impact pon runtimeAmpere-hour capacity an sizingState a charge an depth a dischargeRuntime estimation fi duty cyclesLesson 8Safe handling, spill/leak response an disposal: PPE fi acid an lithium incidents, neutralization, spill containment, an local hazardous waste rulesDetails safe handling a traction batteries, including PPE, lifting, an transport. Covers acid an electrolyte spills, lithium leaks, neutralization, containment, cleanup, an compliance wid local hazardous waste an recycling regulations, yuh know.
Required PPE fi acid an lithium risksSafe lifting, moving, an storageAcid spill neutralization proceduresContainment an cleanup materialsDisposal an recycling regulationsLesson 9Charging area layout an safety rules: ventilation, signage, fire suppression considerations, separation distances, grounding an cable routingCovers safe design an operation a charging areas, including ventilation, signage, fire protection, an separation distances. Addresses grounding, cable routing, eyewash an shower placement, an keeping ignition sources away, mi bredda.
Ventilation an hydrogen dilution needsRequired signage an access controlFire suppression an extinguisher typesSeparation from offices an trafficGrounding, cabling, an trip hazardsLesson 10Relevant standards an sources: manufacturer battery manuals, OSHA/NFPA guidance fi battery rooms, an battery manufacturer safety bulletinsSummarizes key standards an guidance affecting traction battery rooms an charging areas. Reviews manufacturer manuals, OSHA an NFPA expectations, an safety bulletins, showing how to locate, interpret, an apply dem pon site, yuh zeet.
Using manufacturer battery manualsOSHA rules fi charging operationsNFPA guidance fi battery roomsLocating safety bulletins an updatesDocumenting site compliance stepsLesson 11Handling low runtime an capacity fade: diagnosing sulfation, cell imbalance, parasitic loads, an end-of-life criteriaFocuses pon diagnosing short runtime an capacity loss inna traction batteries. Reviews sulfation, cell imbalance, parasitic loads, an end-of-life indicators, linking test data to practical decisions pon repair, reconditioning, or replacement, seen.
Collecting runtime an charge historyIdentifying sulfation an undercharge patternsDetecting weak or imbalanced cellsFinding parasitic loads pon parked trucksEnd-of-life criteria an replacement callsLesson 12Battery charging systems an safe charging practices: charger types, charge algorithms, float vs. fast charge, equalization chargingExplains forklift battery charging systems, including conventional, opportunity, an fast chargers. Reviews charge algorithms, equalization, float modes, an safe practices dat prevent overcharge, gassing, an premature battery wear, yuh hear.
Conventional, opportunity, an fast chargersCharge stages an control algorithmsEqualization charge goals an timingFloat charging an storage practicesPreventing overcharge an gassingLesson 13Periodic battery testing an diagnostics: specific gravity/hydrometer testing, conductance/impedance testing, capacity tests, voltage under loadDescribes routine an advanced traction battery tests, including specific gravity, conductance, impedance, an capacity checks. Explains voltage under load an how to interpret results to spot weak cells, imbalance, or hidden defects early, mi fren.
Safe sampling fi specific gravity testsOpen-circuit an loaded voltage checksConductance an impedance test basicsFull capacity an discharge testingInterpreting test trends over time
