Lesson 1Heat buildup and overheating reasons during charging: internal resistance, airflow, charger settings, and room temperature impactsLooks at how traction batteries warm up while charging, zeroing in on internal resistance, charger settings, ventilation, and surrounding temperature. Stresses spotting unusual heat patterns and setting safe boundaries to avoid harm or heat incidents.
Internal resistance and heat generationInfluence of charger current profilesRole of ventilation and airflow pathsAmbient temperature and seasonal effectsRecognizing abnormal temperature riseLesson 2Record-keeping and battery life management: serial number tracking, warranty claims, replacement planning, and value for money on new vs. refurbished batteriesDeals with following batteries through their life using serial numbers, logs, and software. Covers noting down faults, backing warranty claims, planning swaps, and weighing costs and returns of new batteries against refurbishing.
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 check list: visual looks, terminal state, vent covers, electrolyte level (if needed), and signs of physical damageGives a hands-on daily and shift check routine for traction batteries. Includes visual inspections, terminals, vent caps, electrolyte levels, cables, and casings, to spot damage or leaks before they lead to 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 in forklifts (lead-acid, AGM, gel, lithium-ion): chemistry, standard voltages, capacities, and discharge traitsIntroduces main traction battery types used in forklifts, like flooded lead-acid, AGM, gel, and lithium-ion. Compares standard voltages, capacities, discharge patterns, and common uses, pointing out advantages, drawbacks, and safety requirements.
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-based upkeepOutlines regular traction battery upkeep tasks and timelines. Includes watering, cleaning, torque checks, and recording 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 6Dealing with overheating and charging problems: spotting, quick steps, charger error codes, heat control, and cooling methodsCovers spotting overheating and charge issues using sensors, charger screens, and error codes. Details safe immediate actions, lockout steps, and practical heat management and cooling ways to safeguard 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 level (SoC), discharge depth (DoD), and expected run time estimatesExplains main battery ratings on forklift labels and sheets, including C-rate, ampere-hours, charge state, and discharge depth. Shows how to figure 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 events, neutralising, spill holding, and local waste rulesDetails safe handling of traction batteries, including protective gear, lifting, and moving. Covers acid and electrolyte spills, lithium leaks, neutralising, containing, cleaning up, 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: ventilation, signs, fire control thoughts, separation spaces, grounding and cable pathsCovers safe setup and running of charging areas, including ventilation, signs, fire protection, and separation spaces. Addresses grounding, cable paths, eyewash 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 10Key standards and sources: maker battery guides, OSHA/NFPA tips for battery rooms, and battery maker safety noticesSums up main standards and tips for traction battery rooms and charging spots. 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 drop: diagnosing sulfation, cell imbalance, drain loads, and end-of-life signsFocuses on spotting short run time and capacity loss in traction batteries. Reviews sulfation, cell imbalance, drain loads, and end-of-life signs, connecting test info to real choices on fixing, reconditioning, or replacing.
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 setups and safe charging ways: charger types, charge methods, float vs. quick charge, balancing chargingExplains forklift battery charging setups, including standard, chance, and quick chargers. Reviews charge methods, balancing, float modes, and safe ways that stop overcharging, 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 diagnostics: specific gravity/hydrometer checks, 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 read results to find 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
