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Technical Document: Customization of Electric Forklift Dimensions

2025-12-31 Visits:

Technical Document: Customization of Electric Forklift Dimensions

The dimensions of electric forklifts can be customized. Mainstream manufacturers offer full-process services ranging from light customization (minor adjustments based on standard models) to in-depth non-standard customization (brand-new structural design). The core objective is to adapt the equipment to the site conditions, load requirements, and operational scenarios, which requires a comprehensive evaluation of technical feasibility, costs, and delivery lead times.

I. Core Customizable Dimension Categories

Dimension 

Category

Customization Range

Typical Application 

Scenarios

Technical Boundaries
Fork System

Length: 600–3000 mm;

Width: 680–1200 mm; 

Thickness: 30–80 mm; 

Customization of 

adjustable-width forks, 

rotating forks, 

and narrow forks

Narrow aisles, 

long material handling, 

heavy-duty pallet operations

Must match the load center 

distance to avoid 

structural overload

Mast Height

Closed height: 1800–2500 mm;

Lifting height: 3000–12000 mm; 

Customization of low masts,

triple-stage masts, 

and telescopic masts

Cold storage with low ceilings, 

high-level racking systems, 

container operations

Affects stability and 

operator visibility; 

structural strength 

verification is required

Overall Length

/Width/Height

Width: 800–1500 mm;

 Length: 2000–4000 mm; 

Overhead guard height: 

1900–2400 mm

Low-clearance workshops, 

ultra-narrow aisles, 

special passageways

Restricted by chassis, 

battery, 

and steering mechanism; 

cannot be adjusted indefinitely

Wheelbase and

 Track Width

Wheelbase adjustment: 

±100–300 mm;

 Track width adjustment: 

±50–200 mm

Off-road operating conditions,

 turning radius optimization

Directly impacts stability

 and passability; 

requires recalibration

Stacking/

Operational 

Dimensions

Outer turning radius,

 aisle width, 

minimum ground clearance: 

50–200 mm

Automated warehouses, 

AGV docking, 

uneven ground sites

Must be designed 

in conjunction with 

operational processes 

and rack spacing

II. Customization Modes and Processes

Light Customization (Minor Adjustments to Standard Models)

  • Applicability: Only adjust fork length, mast height, overhead guard height, track width, etc., based on the modification of existing chassis, masts, and battery packs.
  • Delivery Lead Time: 2–4 weeks; Cost increase: 10%–30%; Supports small batches (1–5 units).
  • Cases: Low masts for cold storage (closed height ≤2000 mm), narrow-body forklifts for narrow aisles (width ≤900 mm).

In-depth Non-standard Customization (Brand-new Development)

  • Applicability: Brand-new wheelbase/frame design, special attachments (clamps, push-pull devices, rotating platforms), extreme dimensions (ultra-short, ultra-narrow, ultra-high).
  • Process: Demand Confirmation → Scheme Design → Strength Simulation → Prototype Testing → Mass Production.
  • Delivery Lead Time: 8–16 weeks; Cost increase: 50%–200%; Minimum order quantity of ≥10 units is recommended.
  • Cases: Forklifts for transporting semiconductor ingots (platform length 7000 mm), mold-changing forklifts for the automotive industry (custom platform dimensions).

III. Key Customization Constraints and Precautions

Technical Constraints

All customizations must comply with GB/T 5141–2021 Safety Code for Industrial Vehicles. Core components (motor, controller, battery) must maintain compatibility to prevent negative impacts on stability or safety performance caused by modifications.

Costs and Delivery Lead Times

Light customization offers a high cost-performance ratio. In-depth customization requires bearing engineering development and mold costs, leading to significantly extended delivery lead times; the larger the batch size, the lower the unit cost.

Risk Control

  1. 1.Provide accurate operational parameters (site dimensions, load capacity, aisle width, rack spacing) to avoid design deviations.
  2. 2.Require manufacturers to issue finite element analysis reports and load test reports to ensure compliance and safety.
  3. 3.Clarify after-sales terms: spare parts supply cycle for non-standard components and maintenance response time.

IV. Quick Decision Checklist

  1. 1.Clarify core demands: Is it to resolve dimension conflicts (e.g., insufficient clearance height) or improve operational efficiency (e.g., long material handling)?
  2. 2.Define precise boundaries: Minimum site width/height, maximum material dimensions, minimum turning radius, load center distance.
  3. 3.Balance costs and delivery lead times: Prioritize light customization; avoid in-depth development unless necessary.
  4. 4.Ensure compliance and safety: All modifications must meet national and industry standards, and technical documents should be retained.


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