Lithium-ion batteries have transformed the material handling industry, offering faster charging, longer run times and virtually maintenance-free operation. However, unlike traditional lead-acid batteries, lithium batteries contain a sophisticated Battery Management System (BMS) that protects the battery from damage.
One of the most common causes of lithium battery failure is allowing the battery to become too deeply discharged. In many cases, this can cause the BMS to enter protection mode, leaving the battery unable to accept a normal charge. This situation is entirely preventable with the correct charging routine.
Why Regular Charging Matters
Even when your pallet truck or stacker is not being used, the battery continues to consume a very small amount of power. Over time, this can reduce the battery voltage to a level where the BMS activates its low-voltage protection.
To maximise battery life and performance:
- ✔ Charge the battery regularly, even when the truck is not in use.
- ✔ Recharge the battery after use whenever possible.
- ✔ Never allow the battery to become fully discharged.
- ✔ During storage, recharge the battery at least once every 30 days.
Following these simple steps will help maintain battery health, reduce downtime and extend the overall service life of your equipment.
What Happens If the Battery Is Left Flat?
If the battery voltage falls below the safe operating threshold:
- The Battery Management System (BMS) may shut down.
- The battery may not accept a normal charge.
- Specialist equipment or recovery procedures may be required.
- The truck may be out of service unexpectedly.
- Damage caused by deep discharge may void the battery warranty.
Preventing this situation is far easier than recovering a battery that has entered protection mode.
Protect Your Investment
Lithium batteries represent one of the most valuable components of your pallet truck or stacker. A few minutes spent charging the battery correctly can save significant repair costs and prevent unnecessary machine downtime.
If your truck is likely to remain unused for several weeks, make sure someone is responsible for periodically charging the battery to maintain a healthy state of charge.
Our Advice
At Pallet Trucks Direct, we recommend making battery care part of your regular maintenance routine. We've even produced a dedicated Lithium Battery Care reminder sticker to help operators remember these simple but essential charging practices.
By following these guidelines, you'll:
- Extend battery life.
- Reduce the risk of unexpected breakdowns.
- Maintain maximum truck performance.
- Help protect your battery warranty.
- Avoid costly battery recovery or replacement.
Need Advice?
If you have any questions about caring for your lithium battery or you're experiencing charging issues, our technical team is here to help.
Pallet Trucks Direct
Website: pallet-trucksdirect.co.uk