A maintenance planner is replacing a worn lead-acid battery with lithium on a counterbalance truck. The old battery is still in the truck, the manual is missing, and the supplier asks for the compartment size, not the battery size.
Measure the compartment, not the old battery, at three points per axis, and record length, width, usable height, door or hood clearance, lifting points, connector position and the data plate. Add the truck’s minimum battery weight from the manufacturer, and photograph the tray with a tape in frame. Send the sheet to the supplier with the truck make, model and serial number so a pack can be proposed or built to fit.
The measuring sheet
- Data plate. Truck make, model, serial number, rated voltage, rated capacity, and the stated battery weight range.
- Length and width. Measure inside the compartment at three points each, because trays can be bent. Record the smallest value.
- Height. Measure to the underside of the seat, hood or cover with it closed. Add the clearance needed for cables.
- Entry. Side-pull or top-lift, roller bed or fixed tray, and the width of any opening the pack has to pass.
- Lifting points. Eyes, hooks or fork pockets, and the lifting equipment you will use. Redway’s handling and changing page lists equipment types.
- Electrical. Connector type, cable length, polarity, and any gauge or interface wiring to the truck.
- Weight. Counterbalance weight the truck needs, from the maker, and the floor load where the truck works.
Compare with real pack sizes
Redway’s tables show the scale of the task: a 48V 304Ah pack is 940 x 260 x 520 mm at about 164 kg, while a 48V 560Ah pack is 810 x 630 x 600 mm at about 352 kg. Capacity, shape and weight all change together, so choose capacity from your runtime plan, then check fit. Our custom pack and tray article covers the next step if no standard size fits.
What to do with the result
Compare your measurements with the supplier’s drawing before the order, and ask the supplier to confirm in writing the clearances on each side. If the pack is within a few millimetres of the limit, ask for a smaller outline or a spacer plan. Keep your measuring sheet with the purchase order as the fitment record.
Risk limits
Do not assume an old battery’s weight or size is right for the truck. Ask the truck maker for the permitted battery range, and do not fit a heavier or lighter battery without confirmation. Measurements taken from a worn tray may need an allowance. This article is general guidance for maintenance teams.
Additional perspectives
Measure twice on different days and have a second person verify the numbers. Record the truck’s hour meter and serial number on the sheet so you can link the measurements to the right asset.
Redway Tech Editorial Team – Maintenance planner perspective
Check whether the old battery is secured by a hold-down bar, straps or side stops, and whether that hardware fits a pack with a different outline. A good fit still needs a good restraint.
Redway Tech Editorial Team – Truck technician perspective
The most useful attachments are a dimensioned sketch, five photographs and the data plate. With those I can tell in an hour whether a standard pack fits or a custom one is needed.
Redway Tech Editorial Team – Supplier engineer 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
- 48V 300Ah 304Ah Forklift Lithium Battery
- 48V 210Ah 200Ah Forklift Lithium Battery
- 48V 460Ah 450Ah Forklift Lithium Battery
- 48V 560Ah 550Ah Forklift Lithium Battery
- 24V 280Ah 300Ah Forklift Lithium Battery
Related topics
- Forklift Battery Voltage & Capacity
- Forklift Battery Replacement & Conversion
- Forklift Brands, Models & Battery Fitment
- Forklift Models, Specifications & Technical Guides
- Forklift Battery Handling & Changing Equipment
- High-Capacity Forklift Batteries & Ah Sizing
- Sizing Methods & Load Audits
- Forklift Battery Runtime & Shift Planning
- Pallet Jack, Reach Truck & Warehouse Batteries
- 24V Forklift Battery Systems
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