Lesson 1Thermal behaviour and overheating causes during charge: internal resistance, ventilation, charger profiles, ambient temperature effectsLooks at how traction batteries heat up while charging, key factors like internal resistance, charger settings, airflow, and room temperature. Stresses spotting unusual heat patterns and setting safe limits to avoid damage or fire risks in busy warehouses.
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. refurbishmentCovers tracking batteries from start to end using serial numbers, logs, and software. Explains recording faults, filing warranty claims, planning swaps, and weighing costs of new batteries against fixing old ones for better value.
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 indicatorsGives a simple daily and shift inspection routine for traction batteries. Checks visuals, terminals, vent caps, electrolyte if needed, cables, and casings to spot damage or leaks early before they cause breakdowns or accidents.
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 common traction battery types in forklifts like flooded lead-acid, AGM, gel, and lithium-ion. Compares voltages, capacities, discharge patterns, and uses, noting strengths, weaknesses, and safety tips for Kenyan conditions.
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 everyday battery maintenance jobs and timings. Includes watering, cleaning terminals, tightening bolts, logging charges, and comparing time-based vs. use-based plans to make batteries last longer and cut unexpected stops.
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 strategiesTeaches spotting overheating and charge problems via sensors, displays, and codes. Covers quick safe steps, lockouts, and cooling methods to safeguard batteries and gear in hot Kenyan workshops.
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 battery specs on forklift labels and sheets, like C-rate, Ah, SoC, DoD. Shows how to figure runtime and pick batteries matching your truck's daily workload.
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 rulesDetails safe battery handling with PPE, lifting, moving. Handles acid spills, lithium leaks, cleanup, and following Kenyan hazardous waste rules for disposal.
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 routingCovers setting up safe charging spots with good airflow, signs, fire gear, spacing, earthing, and cable paths to keep sparks away in crowded sites.
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 bulletinsReviews key rules for battery rooms and charging. Checks manuals, OSHA/NFPA guides, safety notices, and how to find and use them on your 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 criteriaDeals with short runtime and fading power. Checks sulfation, uneven cells, drain loads, end-life signs, linking tests to 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 practices: charger types, charge algorithms, float vs. fast charge, equalization chargingExplains forklift chargers like standard, quick, fast types. Covers charge methods, equalising, float modes, safe habits to stop overcharge, gas, early wear.
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 loadDescribes regular and deep battery tests like gravity, conductance, capacity, load voltage. Interprets to find weak cells, imbalance, 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
