Lesson 1Heat during charging and causes of too much heat: inside resistance, air flow, charger ways, room temperature effectsThis lesson looks at how traction batteries get hot when charging, paying attention to inside resistance, charger ways, air movement, and room temperature. It stresses spotting unusual heat patterns and setting safe boundaries to avoid harm or heat problems in daily use.
Inside resistance and heat makingEffect of charger current waysRole of air flow and pathsRoom temperature and season effectsSpotting unusual temperature riseLesson 2Keeping records and battery life handling: serial following, warranty claims, replacement planning, and value for battery change vs. fixing upThis lesson covers following batteries through their life using serial numbers, logs, and computer tools. It explains noting down failures, helping warranty claims, planning changes, and comparing costs and value of new batteries against fixing up old ones for better choices.
Serial number and asset ID followingLogging faults, tests, and fixesHelping warranty and service claimsPlanning changes and spare groupsValue of change versus fixing upLesson 3Daily and shift-level battery check list: eye checks, terminal state, vent covers, liquid level (if needed), and body damage signsThis lesson gives a hands-on daily and shift check routine for traction batteries. It covers eye checks, terminals, vent covers, liquid levels, cables, and casings, to find damage or leaks early before they cause breakdowns or hurts.
Before-shift eye walk-around stepsChecking terminals and connectorsLooking at vent covers and traysChecking liquid levels safelyFinding leaks and case damageLesson 4Kinds of traction batteries in forklifts (lead-acid, AGM, gel, lithium-ion): makeup, normal voltages, powers, and release traitsThis lesson brings in main traction battery makeups used in forklifts, like flooded lead-acid, AGM, gel, and lithium-ion. It compares normal voltages, powers, release curves, and common uses, pointing out good points, bad points, and safety needs for safe work.
Flooded lead-acid building basicsAGM and gel sealed battery featuresLithium-ion parts and control roleVoltage, power, and pack setupsRelease curves and use casesLesson 5Battery upkeep jobs and times: adding water, cleaning terminals, tightening connections, charge cycle noting, calendar vs. cycle upkeepThis lesson outlines regular traction battery upkeep jobs and times. It includes adding water, cleaning, torque checks, and noting charge cycles, comparing time-based and cycle-based plans to make batteries last longer and cut unexpected stops.
Water adding times and safe waysCleaning cases, tops, and terminalsTorque checks on lugs and busbarsNoting charge and release cyclesCalendar versus cycle-based planningLesson 6Handling too much heat and charging faults: finding, quick actions, charger fault codes, heat handling, and cooling waysThis lesson covers finding too much heat and charge faults using sensors, charger screens, and fault codes. It details quick safe responses, lockout steps, and practical heat handling and cooling methods to guard batteries and nearby tools.
Common charger and battery fault signsReading and understanding charger fault codesQuick shutdown and lockout actionsUsing fans, spacing, and cool-down timesWhen to take a battery out of useLesson 7Battery specs and ratings: C-rate, ampere-hour (Ah), charge state (SoC), discharge depth (DoD), and expected run time countsThis lesson explains key battery ratings on forklift labels and sheets, including C-rate, ampere-hours, charge state, and discharge depth. It shows how to guess expected run time and match batteries to truck work cycles for better planning.
Reading battery labels and nameplatesC-rate and its effect on run timeAmpere-hour power and sizingCharge state and discharge depthRun time guess for work cyclesLesson 8Safe handling, spill/leak response and throwing away: gear for acid and lithium events, neutralizing, spill holding, and local danger waste rulesThis lesson details safe handling of traction batteries, including gear, lifting, and moving. It covers acid and liquid spills, lithium leaks, neutralizing, holding, cleanup, and following local danger waste and recycle rules for safety.
Needed gear for acid and lithium risksSafe lifting, moving, and storageAcid spill neutralizing stepsHolding and cleanup materialsThrowing away and recycle rulesLesson 9Charging area setup and safety rules: air flow, signs, fire putting out thoughts, separation spaces, grounding and cable pathsThis lesson covers safe setup and running of charging areas, including air flow, signs, fire guard, and separation spaces. It addresses grounding, cable paths, eye wash and shower spots, and keeping fire starters away for safe work.
Air flow and hydrogen mixing needsNeeded signs and access controlFire putting out and extinguisher kindsSeparation from offices and trafficGrounding, cabling, and trip dangersLesson 10Related rules and sources: maker battery books, OSHA/NFPA guides for battery rooms, and battery maker safety notesThis lesson sums up key rules and guides for traction battery rooms and charging areas. It reviews maker books, OSHA and NFPA hopes, and safety notes, showing how to find, understand, and use them on site for better safety.
Using maker battery booksOSHA rules for charging workNFPA guides for battery roomsFinding safety notes and updatesNoting site following stepsLesson 11Handling low run time and power fade: finding sulfation, cell unbalance, extra loads, and end-of-life signsThis lesson focuses on finding short run time and power loss in traction batteries. It reviews sulfation, cell unbalance, extra loads, and end-of-life signs, linking test info to real choices on fix, recondition, or change.
Gathering run time and charge historyFinding sulfation and undercharge patternsSpotting weak or unbalanced cellsFinding extra loads on parked trucksEnd-of-life signs and change callsLesson 12Battery charging setups and safe charging ways: charger kinds, charge plans, float vs. fast charge, equal chargeThis lesson explains forklift battery charging setups, including normal, chance, and fast chargers. It reviews charge plans, equalizing, float modes, and safe ways that stop overcharge, gas making, and early battery wear for long life.
Normal, chance, and fast chargersCharge steps and control plansEqual charge goals and timingFloat charging and storage waysStopping overcharge and gas makingLesson 13Regular battery testing and finding problems: specific weight/hydrometer testing, conductance/impedance testing, power tests, voltage under loadThis lesson describes regular and advanced traction battery tests, including specific weight, conductance, impedance, and power checks. It explains voltage under load and how to understand results to spot weak cells, unbalance, or hidden faults early.
Safe sampling for specific weight testsOpen-circuit and loaded voltage checksConductance and impedance test basicsFull power and discharge testingUnderstanding test trends over time
