Complete Analysis of Forklift Load Capacity Differences

I. Light-duty Forklifts (0.5-3 tons): Flexible for Indoor Light-load Operations

Core Distinguishing Features

• Structural Design: Compact body with a small turning radius (usually able to complete flexible steering within 2.5 meters). The frame and mast adopt a lightweight design while meeting the strength requirements for light loads; the forks are relatively short (mostly 1.0-1.2 meters), suitable for standard light-duty pallets.

• Power Configuration: Mainly electric (48V/80V voltage), with small motor power and low power consumption, and the battery life can meet 8-10 hours of high-frequency short-distance indoor operations; some small models of 0.5-1 ton are manual hydraulic type without power drive, suitable for ultra-narrow spaces (such as convenience store warehouses).

• Key Parameters: The load center distance is mostly 500mm (standard light-load configuration), the maximum lifting height is usually 3-5 meters, the self-weight is light (1-3 tons), and the requirement for ground bearing capacity is low (no need for special ground reinforcement).

• Application Scenarios: E-commerce warehouses, retail distribution centers, small factory workshops, used for handling lightweight goods such as electronic products, daily necessities, and food. Typical operations include low-level shelf replenishment and short-distance pallet transfer.

II. Medium-duty Forklifts (3-5 tons): Main Models Balancing Efficiency and Strength

Core Distinguishing Features

• Structural Design: The chassis and mast are reinforced (for example, the mast of 3.8-ton models is mostly equipped with 18 reinforcing rods, compared with 16 rods for 3-ton models). The self-weight increases significantly (3.5-5 tons), and the body length is slightly extended, but it still maintains a certain degree of flexibility (turning radius 2.8-3.5 meters); the fork length is 1.2-1.5 meters, which can be adapted to large pallets or irregular medium-sized goods.

• Power Configuration: Both electric and internal combustion are available — electric models (above 80V voltage) are suitable for indoor/ventilated semi-indoor environments, environmentally friendly and noiseless, with low long-term operating costs; internal combustion models (diesel/LPG power) are suitable for outdoor/high-intensity operations, with stronger power and can operate continuously under heavy load for more than 12 hours.

• Key Parameters: The load center distance is still mainly 500mm, but some 5-ton models can be extended to 600mm; the maximum lifting height is 3-8 meters (reach trucks can reach 10 meters), which has certain requirements for ground bearing capacity (need a solid and flat ground to avoid collapse).

• Application Scenarios: Auto parts factories, home appliance manufacturing plants, regional logistics hubs, used for handling molds, semi-finished products, short-distance loading and unloading of containers and other operations. It can not only cope with medium and heavy goods but also adapt to mixed indoor and outdoor scenarios.

III. Heavy-duty Forklifts (5-10 tons): "Powerhouse" for Heavy-load Operations

Core Distinguishing Features

• Structural Design: Adopt reinforced frame, thickened mast and large tires (mostly heavy-duty pneumatic tires), large body (length above 3.5 meters), turning radius above 4 meters, reduced flexibility but extremely strong stability; the forks are heavy-duty special types, length 1.5-2.0 meters, and some can be equipped with attachments (such as paper roll clamps, rotators).

• Power Configuration: Mainly diesel internal combustion power, the motor power is much higher than that of small and medium-sized models (usually above 80V high-voltage motor), equipped with large-capacity lithium batteries or heavy-duty engines, with strong traction and lifting force, which can cope with continuous heavy-load operations.

• Key Parameters: The load center distance is 600-1000mm, the maximum lifting height is 3-6 meters (focus on load-bearing rather than high-level stacking), the self-weight is 8-15 tons, and the requirement for ground bearing capacity is high (need foundation reinforcement, bearing capacity ≥20 tons/㎡).

• Application Scenarios: Building materials markets, heavy machinery factories, wood processing factories, used for handling heavy goods such as steel, large castings, and construction materials. Typical operations include outdoor yard cargo loading and unloading, short-distance transfer of heavy equipment.

IV. Extra-heavy Forklifts (above 10 tons): Exclusive Equipment for Extreme Heavy-load

This type of forklift is a special customized equipment. The rated lifting capacity ranges from 10 tons to dozens of tons (for example, container reach stackers can reach more than 40 tons). It is specially designed to cope with extreme heavy-load scenarios, with high technical threshold and high operating cost.

Core Distinguishing Features

• Structural Design: The entire body is customized and reinforced. The chassis adopts thickened steel plates and multi-axis support. The mast is a heavy-duty telescopic structure, equipped with special counterweights and large off-road tires. Some models (such as side forklifts) adopt lateral operation design to adapt to long goods.

• Power Configuration: All are high-power diesel engines or special high-voltage electric systems, equipped with efficient heat dissipation and stable control systems. Some large-scale equipment needs external power supply or independent generator sets.

• Key Parameters: The load center distance is more than 1000mm, the maximum lifting height is customized according to the scenario (container stacking can reach more than 12 meters), the self-weight is 20-100 tons, and the operating site needs special planning (no obstacles in the air, ground bearing capacity ≥50 tons/㎡).

• Application Scenarios: Ports and terminals, steel plants, shipyards, used for loading and unloading containers, large ship components, steel coils and other extra-heavy goods. Operators must hold special qualification certificates.

V. Core Summary Table of Load Capacity Differences