A warehouse operator runs electric pallet jacks and a few reach trucks on 24V lead-acid batteries. Space in the battery compartments is tight, and the fleet manager wants to know which lithium capacity range fits and what else must be checked before ordering.
Start with three limits from each truck: compartment dimensions, the minimum battery weight on the data plate, and the controller’s current. Then choose capacity from measured energy use per shift. Redway lists 24V packs from 50Ah to 560Ah; for example, the 24V 280Ah pack is 25.6V nominal and 7.16 kWh, measures 630 x 251 x 450 mm and weighs about 60 kg without counterweight.
The checks, in order
- Space. Measure the compartment, not the old battery, and note cable exits and the lid. Our compartment measuring guide gives a method.
- Weight. Reach trucks and some stackers rely on battery mass for stability. If the lithium pack is lighter than the minimum battery weight on the truck’s data plate, ballast is needed, built in and approved, not added loose.
- Current. The 24V 280Ah pack lists 300A continuous and 800A peak (5 s) discharge. Compare these figures with the truck controller’s rating.
- Charging. The same pack accepts up to 200A continuous charge, from 0 to 55 degrees C. The charger must have a lithium profile for 8 cells in series (25.6V nominal, 29.2V maximum).
- Connectors and data. It lists a Rema 160A charging connector, an Anderson 175A discharge connector, RS485 and CAN-bus, and cloud monitoring over 4G.
Choosing the capacity
Log energy per truck per shift for two weeks. Pallet jacks with short runs may suit a smaller pack with opportunity charging, while a reach truck lifting to height all shift usually needs more. See Redway’s pallet jack and reach truck page and the 24V systems page.
Mixed fleets
If your fleet mixes pallet jacks, stackers and reach trucks, try to standardise on two or three pack sizes and one connector type. Fewer variants mean fewer spare packs and chargers, and technicians learn one set of BMS screens. Check that each truck still meets its weight and current limits before you standardise.
Risk limits
Never run a truck below its rated battery weight, and do not modify the compartment without the truck maker’s approval. Figures above come from Redway product pages as of October 2026; confirm the current specification and fit for your truck model.
Additional perspectives
Make a table of truck model, compartment size, minimum battery weight and controller current before you request quotes. One table usually shows that two or three pack sizes cover the whole fleet.
Redway Tech Editorial Team – Fleet engineer perspective
Treat the data-plate battery weight as a hard limit. A lighter pack changes stability on reach trucks, and the truck maker’s rules on ballast and capacity plates apply.
Redway Tech Editorial Team – Safety officer perspective
Ask the supplier to quote each truck type separately with the ballast, connector and charger included. A low pack price is not useful if each truck then needs custom work on site.
Redway Tech Editorial Team – Procurement perspective
Specifications are taken from Redway product pages as of October 2026. Where a figure isn’t published, this article says so. Confirm current specifications for your model with Redway before ordering. This article is general guidance, not a site-specific engineering assessment.
Related products
- 24V 280Ah 300Ah Forklift Lithium Battery
- 24V 200Ah 210Ah Forklift Lithium Battery
- 24V 560Ah 550Ah 500Ah Forklift Lithium Battery Factory
- 24V 160Ah 150Ah Lithium Forklift Battery Factory
- 24V 50Ah Forklift Lithium Battery OEM
Related topics
- Pallet Jack, Reach Truck & Warehouse Batteries
- 24V Forklift Battery Systems
- Forklift Battery Voltage & Capacity
- High-Capacity Forklift Batteries & Ah Sizing
- Forklift Battery Runtime & Shift Planning
- Forklift Brands, Models & Battery Fitment
- Forklift Battery Replacement & Conversion
- Forklift Battery Parts, Connectors & Accessories
- Forklift Battery Charging
- Lithium vs Lead-Acid Forklift Batteries
Continue learning
Forklift Batteries
Related reading
