Lesson 1Heat buildup and causes of overheating while charging: internal resistance, airflow, charger settings, and room temperature effectsLooks at how traction batteries get hot during charging, paying attention to internal resistance, charger settings, air flow, and room temperature. It stresses spotting unusual heat patterns and setting safe boundaries to avoid damage or heat incidents.
Internal resistance and heat buildupCharger current settings influenceAirflow and ventilation rolesRoom temperature and weather effectsSpotting unusual temperature increasesLesson 2Record keeping and battery life management: tracking serial numbers, warranty claims, replacement plans, and value for money in replacing vs fixing batteriesDeals with following batteries through their life using serial numbers, logs, and computer systems. It explains noting down failures, backing warranty claims, planning replacements, and comparing costs and value of new batteries against fixing old ones.
Serial number and asset trackingLogging faults, tests, and fixesBacking warranty and service claimsPlanning replacements and spare setsValue of replacement vs fixingLesson 3Daily and shift-level battery check list: visual looks, terminal state, vent covers, electrolyte level (if needed), and signs of physical damageGives a practical daily and shift-level check routine for traction batteries. It covers visual checks, terminals, vent covers, electrolyte levels, cables, and casings, to spot damage or leaks before they lead to breakdowns or injuries.
Pre-shift visual walk-around stepsChecking terminals and connectionsLooking at vent covers and traysSafely checking electrolyte levelsSpotting 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 good and bad points, and safety needs.
Flooded lead-acid basic buildAGM and gel sealed battery traitsLithium-ion packs and safety systemsVoltage, capacity, and pack setupsDischarge patterns and usesLesson 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 schedules. Includes adding water, cleaning, torque checks, and logging charge cycles, comparing time-based and cycle-based plans to lengthen life and cut unexpected stoppages.
Water adding times and safe waysCleaning cases, tops, and terminalsTorque checks on lugs and barsLogging charge and discharge cyclesTime vs cycle-based planningLesson 6Handling overheating and charging problems: spotting, quick actions, charger error codes, heat control, and cooling plansCovers spotting overheating and charge problems using sensors, charger screens, and error codes. Details quick safe responses, lockout steps, and practical heat control and cooling ways to protect batteries and nearby gear.
Common charger and battery problem signsReading and understanding charger error codesQuick shutdown and lockout actionsUsing fans, space, and cool-down timesWhen to take a battery out of useLesson 7Battery specs and ratings: C-rate, ampere-hour (Ah), charge level (SoC), discharge depth (DoD), and expected run time calculationsExplains key battery ratings on forklift labels and sheets, including C-rate, ampere-hours, charge level, and discharge depth. Shows how to guess expected run time and match batteries to truck work cycles.
Reading battery labels and platesC-rate and its run time effectAmpere-hour capacity and sizingCharge level and discharge depthRun time guess for work cyclesLesson 8Safe handling, spill/leak response and disposal: gear for acid and lithium incidents, neutralising, spill holding, and local waste rulesDetails safe handling of traction batteries, including gear, lifting, and moving. Covers acid and electrolyte spills, lithium leaks, neutralising, holding, cleanup, and following local hazardous waste and recycling rules.
Needed gear for acid and lithium risksSafe lifting, moving, and storageAcid spill neutralising stepsHolding and cleanup materialsDisposal and recycling rulesLesson 9Charging area setup and safety rules: airflow, signs, fire control thoughts, separation spaces, grounding and cable pathsCovers safe setup and running of charging areas, including airflow, signs, fire protection, and separation spaces. Addresses grounding, cable paths, eye wash and shower spots, and keeping fire starters away.
Airflow and gas dilution needsNeeded signs and access controlFire control and extinguisher typesSeparation from offices and trafficGrounding, cabling, and trip risksLesson 10Key standards and sources: maker battery guides, OSHA/NFPA advice for battery rooms, and battery maker safety noticesSums up key standards and advice for traction battery rooms and charging areas. Reviews maker guides, OSHA and NFPA rules, and safety notices, showing how to find, understand, and use them on site.
Using maker battery guidesOSHA rules for charging workNFPA advice for battery roomsFinding safety notices and updatesNoting site rule stepsLesson 11Handling short run time and capacity loss: checking sulfation, cell imbalance, extra loads, and end-of-life signsFocuses on checking short run time and capacity drop in traction batteries. Reviews sulfation, cell imbalance, extra loads, and end-of-life signs, linking test info to real choices on fixing, reconditioning, or replacing.
Gathering run time and charge historySpotting sulfation and low charge patternsFinding weak or unbalanced cellsSpotting extra loads on parked trucksEnd-of-life signs and replacement needsLesson 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 overcharge, gas buildup, and early battery wear.
Standard, chance, and quick chargersCharge stages and control methodsBalancing charge goals and timingFloat charging and storage waysStopping overcharge and gas buildupLesson 13Regular battery testing and checks: specific gravity/hydrometer tests, conductance/impedance tests, capacity tests, voltage under loadDescribes regular and advanced traction battery tests, including specific gravity, conductance, impedance, and capacity checks. Explains voltage under load and how to read results to spot 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 testingReading test patterns over time
