Lesson 1Thermal behaviour and causes of overheating during charge: internal resistance, ventilation, charger profiles, ambient temperature effectsDis part go explore how traction batteries get hot during charging, focusing on internal resistance, charger profiles, airflow, and ambient temperature. E go stress recognizing abnormal heating and setting safe limits to avoid damage or thermal problems.
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. refurbishmentDis go address tracking batteries through dia life using serial numbers, logs, and software. E go explain documenting failures, supporting warranty claims, planning replacements, and comparing cost and ROI of new batteries versus refurbishment.
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 indicatorsDis provide practical daily and shift-level inspection routine for traction batteries. E cover visual checks, terminals, vent caps, electrolyte levels, cables, and housings, helping to catch damage or leaks before dem cause failures 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 used in forklifts (lead-acid, AGM, gel, lithium-ion): chemistry, nominal voltages, capacities, and discharge characteristicsDis introduce main traction battery chemistries used in forklifts, including flooded lead-acid, AGM, gel, and lithium-ion. E compare nominal voltages, capacities, discharge curves, and typical applications, highlighting pros, cons, 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 maintenance tasks and schedules: watering, cleaning terminals, torqueing connections, charge cycle logging, calendar vs. cycle maintenanceDis outline routine traction battery maintenance tasks and schedules. E include watering, cleaning, torque checks, and logging charge cycles, comparing calendar-based and cycle-based plans to extend life and reduce unplanned downtime.
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 strategiesDis cover detection of overheating and charge faults using sensors, charger displays, and fault codes. E detail immediate safe responses, lockout steps, and practical thermal management and cooling methods to protect batteries and nearby equipment.
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 calculationsDis explain key battery ratings used on forklift nameplates and datasheets, including C-rate, ampere-hours, state of charge, and depth of discharge. E show how to estimate expected runtime and match batteries to truck duty 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: PPE for acid and lithium incidents, neutralization, spill containment, and local hazardous waste rulesDis detail safe handling of traction batteries, including PPE, lifting, and transport. E cover acid and electrolyte spills, lithium leaks, neutralization, containment, cleanup, and compliance wid local hazardous waste and recycling regulations.
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 routingDis cover safe design and operation of charging areas, including ventilation, signage, fire protection, and separation distances. E address grounding, cable routing, eyewash and shower placement, and keeping ignition sources 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: manufacturer battery manuals, OSHA/NFPA guidance for battery rooms, and battery manufacturer safety bulletinsDis summarize key standards and guidance affecting traction battery rooms and charging areas. E review manufacturer manuals, OSHA and NFPA expectations, and safety bulletins, showing how to locate, interpret, and apply dem on 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 criteriaDis focus on diagnosing short runtime and capacity loss in traction batteries. E review sulfation, cell imbalance, parasitic loads, and end-of-life indicators, linking test data to practical decisions on repair, reconditioning, or replacement.
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 chargingDis explain forklift battery charging systems, including conventional, opportunity, and fast chargers. E review charge algorithms, equalization, float modes, and safe practices dat prevent overcharge, gassing, and premature battery 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 loadDis describe routine and advanced traction battery tests, including specific gravity, conductance, impedance, and capacity checks. E explain voltage under load and how to interpret results to spot weak cells, imbalance, or hidden defects early.
Safe sampling for specific gravity testsOpen-circuit and loaded voltage checksConductance and impedance test basicsFull capacity and discharge testingInterpreting test trends over time
