Reach Truck Guide: How It Works and What to Check Before You Buy
A reach truck is an electric forklift built for narrow-aisle warehouses and high racking: its forks reach forward to pick up or set down a pallet, then retract between its outriggers so the truck can travel. With no heavy counterweight at the back, it is shorter than a standard forklift and turns in a much tighter space. The trade-off: it needs a smooth floor and isn’t made for outdoor work. Browse our used reach trucks for examples of what’s available.
How does a reach truck work?
The truck travels with its load pulled back between two wheeled outriggers, then pushes the forks forward over the rack location to set down or pick up the pallet. Because the load sits between the outriggers while moving, the truck doesn’t need a heavy counterweight to stay stable. That makes it shorter and more maneuverable than an electric counterbalance forklift.
There are two main designs. On most North American models, the forks move forward on a scissor mechanism called a pantograph. On others, the whole mast slides forward on rails. For the operator the result is the same: the load moves out to pick up, then back in to travel.
Some models are double-deep: their forks reach far enough to get a second pallet stored behind the first. Raymond models marked DR are one example. They’re used in warehouses with double-deep racking, which saves floor space by cutting the number of aisles.
Reach truck or counterbalance forklift: which one do you need?
Choose a reach truck if you stack high in narrow aisles on a smooth concrete floor, and a counterbalance forklift if you load trucks, go out to the yard or drive on mixed surfaces. Many warehouses run both: the counterbalance truck at the dock and the reach truck in the aisles.
| Criterion | Reach truck | Counterbalance forklift |
|---|---|---|
| Aisle width | Narrow, often around 8 to 10 feet depending on model and pallet | Wider, often around 11 to 13 feet |
| Lift height | High, often more than 20 feet | Usually lower |
| Surface | Smooth, level concrete, indoors only | Indoors, and outdoors for pneumatic-tire models |
| Operator position | Usually standing, facing sideways | Usually seated |
| Truck loading | Not well suited | Well suited |
| Typical use | High-bay storage, distribution centers, order picking | Docks, yards, general material handling |
The aisle widths above are ballpark figures. The exact width depends on the model, the pallet length and your safety margin: check the manufacturer’s spec sheet before installing or changing racking.
Which specs should you check before buying?
Start from your racking: the height of the top beam, the weight of your heaviest pallets at that height and the width of your aisles point you to the right model. Those three numbers quickly rule out the trucks that won’t work.
- Lift height: it must clear the top beam, with room to raise the pallet over the beam.
- Lowered height: the height of the collapsed mast. It has to fit under your doors, mezzanines and sprinklers.
- Residual capacity: a 4,000 lb truck won’t necessarily lift 4,000 lb at full height. The data plate gives the real capacity at each height.
- Reach and double-deep: check the reach distance if you use double-deep racking.
- Battery voltage: it depends on the model. Battery and charger must match the truck.
- Options: side shift, fork tilt, and a camera or height indicator for high lifts.
If your pallets stay under roughly 12 feet and space is tight, an electric pallet stacker may be enough and costs less. A reach truck makes the most sense when you lift higher or work all day.
What floor and work environment does it need?
A reach truck needs a flat, smooth, clean concrete floor, indoors. Its polyurethane wheels are small and hard: they pass every bump up to the mast, which matters a lot when the load is high.
- Cracks and joints: a broken slab joint or a pothole makes a raised mast sway. Repair the floor in the aisles where you lift high.
- Ramps and docks: ground clearance is low. Slopes must stay within the manufacturer’s limits.
- Outdoors: avoid gravel, broken asphalt, snow and ice. For the yard, a pneumatic-tire forklift is the right tool.
- Cold storage: some models come in a cold-rated version. Ask for this option if you work in a cooler or freezer.
What maintenance does a reach truck need?
Maintenance combines what any electric forklift needs, the battery above all, with the parts that work hard on this type of truck: the reach mechanism, mast chains, load wheels and hydraulic hoses. The exact schedule is set by the manufacturer, based on operating hours.
- Battery: full charges, water level and cleanliness for a lead-acid battery. Our forklift battery guide covers the best practices.
- Reach mechanism: play in the pantograph pins or mast rails, worn slides, lubrication.
- Chains and mast: chain stretch, roller wear, adjustment. A mast that drifts down under load should be checked right away.
- Wheels: polyurethane load wheels wear and can separate from the hub. A damaged wheel makes the whole truck vibrate.
- Daily inspection: before every shift, the operator checks brakes, horn, steering, chains, leaks and the battery gauge.
What should you check on a used reach truck?
Focus on the battery, the reach mechanism and a lift test at full height with a representative load. The table below lists the checks specific to this type of truck.
| Item | What to check | Warning sign |
|---|---|---|
| Battery | Age, case condition, run time over a shift | Swollen case, corrosion, power loss when lifting |
| Reach mechanism | Smooth reach in and out, no jerks | Heavy play, metallic noise, leak on the reach cylinder |
| Mast and chains | Full lift to maximum height under load | Mast drifting down, stretched or rusty chains |
| Wheels | Load wheels, drive wheel, caster wheels | Cracked, separated or badly worn polyurethane |
| Data plate | Present and readable, capacity at each height | Missing plate, or one that doesn’t match the installed mast |
| Controls and safety | Brakes, operator presence system, horn, lights | Weak brake, presence system disabled |
For the full list, including forks, hydraulics and the documents to ask for, see our used forklift inspection checklist.
Frequently asked questions about reach trucks
What’s the difference between a reach truck and an electric forklift?
Both run on a battery. A standard electric forklift carries the load in front of its front wheels and offsets it with a counterweight at the back. A reach truck carries the load between its outriggers, which makes it shorter and lets it work in narrower aisles and lift higher.
Can you use a reach truck outdoors?
No, not on a regular basis. Its polyurethane wheels and low ground clearance are designed for smooth, dry concrete. For yards, asphalt or winter work, choose a pneumatic-tire forklift.
Do operators need specific training for a reach truck?
Yes. Operators must be trained and evaluated on the type of truck they drive, and stand-up operation and high lifting have their own rules. In Quebec, the CSA B335 standard covers forklift safety and the CNESST sets out employer obligations. A1 Machinery can refer you to operator training partners.
How wide should the aisles be?
Often around 8 to 10 feet, but the exact figure depends on the model, your pallet length and your safety margin. Manufacturers publish an aisle width for each model: use that figure to plan your racking.
Is a used reach truck a good buy?
Yes, if it has been inspected and its battery is in good shape. It’s a durable machine when it runs on a good floor. At A1 Machinery, every unit is inspected and certified by our mechanics and sold with a parts and labor warranty.
Where do you start?
Measure the height of your top beam, the width of your aisles and the weight of your heaviest pallets. With those three numbers, an advisor can suggest the right units from our inventory.
- Used reach trucks: for narrow aisles and high racking
- Electric forklifts: for docks and general indoor handling
- Electric stackers: for small spaces and lower lift heights
- A1 Machinery’s full forklift inventory
Since 1991, A1 Machinery has sold and rented new and used forklifts, including Raymond, Yale, Toyota and Hyster reach trucks. Every unit is inspected and certified by our mechanics, and lease financing is available. Contact an A1 Machinery advisor or call (450) 467-2224. We’re located at 3225 rue de l’Industrie in Saint-Mathieu-de-Beloeil, Quebec.