Standard AGV specifications may not fit every warehouse.

A project may require a different fork width, modified chassis dimensions, higher lifting capacity, customized safety sensors or communication with an existing warehouse system.

For buyers importing automated forklifts from China, the difficult part is not simply asking whether a manufacturer can make the modification.

The more important questions are:

Who approves the engineering change? How is it tested? Will it affect the delivery date? And what documentation will the customer receive?

A well-managed customization process should move through a defined sequence:

Requirement → Engineering Review → Design Change → Prototype/Test → Customer Approval → Production → FAT → Shipment

Can I Change Chassis or Fork Dimensions During Production?

Potentially, but the timing of the request is critical.

Changing a dimension during the early engineering stage may be relatively straightforward.

Changing it after fabrication has started can affect:

• Mechanical drawings

• Structural calculations

• Purchased components

• Welding fixtures

• Hydraulic components

• Fork assemblies

• Safety sensor positions

• Cable routing

• Vehicle software parameters

• Testing procedures

• Production scheduling

For example, changing fork width may appear to be a simple mechanical modification.

However, the change can also affect the vehicle's ability to approach pallets, the sensing area around the forks and the software parameters used during pickup and placement.

Use an Engineering Change Request

Instead of communicating the change informally through email or messaging, ask the Chinese manufacturer to create a formal engineering change request.

The document should identify:

• Original specification

• Requested specification

• Reason for change

• Engineering impact

• Cost impact

• Schedule impact

• Safety impact

• Required testing

• Customer approval

• Final revision number

This creates a clear record of what the factory is actually manufacturing.

What Happens If I Change Fork Width Midway Through Production?

The manufacturer should first determine whether the requested width is compatible with:

• Fork carriage

• Mast structure

• Hydraulic system

• Pallet dimensions

• Vehicle stability

• Load center

• Safety sensors

• Mechanical clearances

The change may also require a new drawing revision.

For a high-lift automated forklift, the load center is particularly important.

Changing fork geometry can alter how a pallet is supported and may influence the vehicle's load-handling characteristics.

Therefore, the engineering department should approve the change before production continues.

Don't Approve Changes Based Only on a New Drawing

A revised CAD drawing confirms the intended geometry.

It does not necessarily prove that the completed AGV performs correctly.

For significant mechanical changes, require the manufacturer to identify the corresponding validation test.

How Are Custom Software Communication Patches Validated?

Software customization should be handled with the same discipline as mechanical engineering changes.

Suppose the AGV needs to communicate with a customer's:

• WMS

• ERP

• PLC

• Automatic door

• Conveyor

• Elevator

• Pallet handling equipment

A software patch may affect the communication sequence between multiple systems.

The manufacturer should first define:

Input → Processing → Output → Expected Result

For example:

WMS task → Fleet system → AGV dispatch → Pickup → Delivery → Confirmation

The test should verify not only normal operation but also abnormal conditions.

Important Software Test Cases

Include:

• Communication loss

• Duplicate task

• Invalid task

• AGV unavailable

• Emergency stop

• Device timeout

• PLC failure

• Network interruption

• Server restart

• AGV reconnection

• Task recovery

This is particularly important if the customized software will control material movement automatically.

Should Custom Software Be Tested Before Shipment?

Yes.

Ideally, the software integration should be validated before the equipment leaves China.

The manufacturer can conduct a factory integration test using:

• Simulation software

• Test servers

• PLC test equipment

• Virtual WMS interfaces

• Representative AGV hardware

The customer should receive the test results before approving shipment.

For major integrations, a useful process is:

FAT → Customer review → Issue correction → Regression test → Final sign-off → Shipment

This reduces the risk of discovering a communication problem after the equipment arrives at the destination warehouse.

Will Heavy-Lift Structural Customization Extend Production Time?

It can.

The schedule impact depends on whether the modification affects an existing standard design or requires substantial engineering work.

A relatively simple customization might involve:

• Fork dimensions

• Sensor position

• Software parameters

• Color

• Minor mounting changes

A more substantial modification could involve:

• Chassis redesign

• Higher lifting height

• Increased payload

• Mast redesign

• Counterweight changes

• Custom attachments

• Structural reinforcement

The second category may require additional engineering calculations, component procurement and testing.

Ask for a Revised Production Schedule

When approving a customization, request the manufacturer to provide:

This makes the schedule impact visible instead of leaving it as a vague statement such as “the customization may take longer.”

What CAD and Engineering Documents Should I Receive?

For a customized Chinese AGV project, documentation should be agreed upon during the procurement stage.

Depending on the customization, useful documents may include:

Mechanical Documentation

• General arrangement drawing

• Chassis drawing

• Fork dimensions

• Mast dimensions

• Load-center information

• Wheel arrangement

• Overall vehicle dimensions

• Mounting locations

Electrical Documentation

• Electrical schematic

• Wiring diagram

• I/O list

• Component list

• Safety circuit diagram

• Connector information

Software Documentation

• System architecture

• Communication protocol

• API documentation

• Interface definitions

• Network diagram

• Error-code list

• Software version information

Warehouse Integration Documentation

• AGV traffic interface

• WMS communication specification

• PLC interface

• Elevator interface

• Automatic-door interface

• Charging-station interface

The exact documentation package should match the scope of customization.

Should I Request CAD Files or Only PDF Drawings?

This depends on the customer's engineering requirements.

PDF drawings may be sufficient for maintenance records and general dimensional verification.

Native CAD files can be more useful when the customer needs to:

• Integrate the AGV into facility drawings

• Check clearance

• Design docking stations

• Design safety barriers

• Plan charging areas

• Validate rack interfaces

If native CAD files are required, specify the required format in the purchase agreement.

For example, the project may require:

• STEP

• DWG

• DXF

• SolidWorks-compatible files

The manufacturer should also identify which files are proprietary and which can be released to the customer.

How Should Engineering Changes Be Approved?

A simple approval workflow can prevent many disputes.

Step 1 — Customer Requirement

The customer submits the requested modification.

Step 2 — Engineering Review

The Chinese manufacturer's engineering team evaluates:

• Feasibility

• Safety

• Structural impact

• Software impact

• Cost

• Lead time

Step 3 — Revised Specification

The manufacturer provides updated drawings and technical specifications.

Step 4 — Customer Approval

The customer approves the revised design before manufacturing proceeds.

Step 5 — Production

The factory builds according to the approved revision.

Step 6 — Factory Testing

The modified AGV is tested against the agreed acceptance criteria.

Step 7 — FAT Sign-Off

The customer reviews the results.

Step 8 — Shipment

Only after the agreed FAT requirements are satisfied should the equipment be released for shipment.

What If the Factory Says the Modification Is “Too Late”?

This is where the production stage becomes important.

A modification requested after:

• Components have been purchased

• Welding has started

• The mast has been assembled

• Wiring has been completed

• Software has been deployed

may generate additional cost and delay.

The manufacturer should explain exactly what has already been completed and what must be rebuilt or replaced.

Ask for a written impact statement covering:

Additional Cost + Additional Lead Time + Additional Testing + New Delivery Date

This gives the buyer a factual basis for deciding whether to proceed.

Should I Accept a Verbal Engineering Change?

For significant modifications, no.

A verbal agreement can create ambiguity over:

• Final dimensions

• Software version

• Responsibility for testing

• Delivery date

• Warranty coverage

• Additional costs

All major changes should be reflected in a controlled document or revised purchase specification.

The final production unit should have a clearly identifiable revision.

What Should the Final Engineering Sign-Off Include?

Before shipment, the customer should ideally have a final technical package showing:

• Approved vehicle configuration

• Final mechanical drawings

• Final electrical configuration

• Software version

• Interface version

• Component list

• Safety configuration

• FAT results

• Outstanding issues

• Customer approval

• Final revision number

This documentation becomes valuable later when the fleet needs:

• Maintenance

• Software updates

• Replacement parts

• Additional vehicles

• Site modifications

• Troubleshooting

Without configuration records, it can become difficult to determine exactly which version of the AGV was originally delivered.

What Should I Put in the Chinese AGV Purchase Contract?

For customized vehicles, the contract or technical agreement should clearly define:

1. Final vehicle specifications

2. Custom engineering requirements

3. Approved drawings

4. Software modifications

5. Integration interfaces

6. FAT requirements

7. Documentation requirements

8. Production milestones

9. Change-control procedure

10. Additional customization costs

11. Delivery schedule

12. Warranty implications

13. Final software version

14. Final hardware configuration

15. Customer sign-off procedure

This converts customization from an informal sales promise into a measurable engineering commitment.

Treat Customization as a Controlled Engineering Project

The biggest mistake when purchasing a customized AGV from China is treating engineering modifications as simple changes to a quotation.

A change to the fork, chassis, mast, sensor configuration or software can affect other parts of the vehicle.

A more reliable process is:

Requirement → Engineering Review → Revised Design → Customer Approval → Production → Testing → FAT → Documentation → Shipment

For B2B AGV procurement, the final objective is not simply receiving a vehicle that looks like the requested configuration.

The objective is receiving a vehicle whose mechanical design, software configuration, safety functions and documentation all match the approved engineering revision.

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