Reach Truck: The Ultimate FAQs Guide

What is a reach truck?

A reach truck is a lifting machine used widely in narrow aisles; it is also known as a right-angle, narrow-aisle stacking truck. It is used for handling the load unit with a rack interface. They are purposely built for narrow-aisle operations, and the design of this machine is comfortable for operators to store and retrieve pallets in racks.  

Reach trucks can lift to a heavy load to a very long height; that makes some tasks easier to do.

Standard lifting trucks can’t move and operate in the narrow aisle. Still, the reach truck is specially designed to store heavy loads into racks in narrow aisles.  

Pantograph mechanism has been used in reach trucks to extract, pick the pallet, retract the forks to the same over the forks, and minimize the effort of driving the truck into narrow aisles.

Where is the reach truck used?

Reach truck is the class 2 category in lifting trucks, mainly used in material handling and transporting goods. It is advantageous in narrow aisles, where no other machine can perform such perfectly other than forklifts. Lifting machines are the assets of the warehouses, and a reach truck is one of them which is now used as one of the essential equipment in the warehouse. Reach trucks are used to load and unload trucks, retrieve and outrage, and transport the goods at warehouses. It is designed for handling unit load with a rack interface. Reach are the most functions and most used in warehouses because it got some features like extending forks, reaching the load in the narrow aisles. Reach trucks can maximize the capacity of unit loads because of their pantograph mechanism.

Having the reach truck at the warehouse increases the productivity and minimize the time and effort you are going to invest especially following cases matches:

• If your significant operations at warehouses revolve around handling the unit load
• If you want to increase the productivity
• If you want to impose two-way traffic at the warehouse
• If you’re going to utilize all the space of your warehouse

What are the benefits of using a reach truck?

There are many benefits of using reach truck at the warehouses; some of them are as follows:

• By using it, you can save the extra storage space at your warehouse
• You can organize your load better and in a manageable format
• The reach truck requires more minor operating and maintenance cost, so you can save your dollars
• It is easily be operated on higher storage racks in narrow aisles.
• You can save the time and effort of the labor by using a reach truck
• You can minimize the risk by using a reach truck instead of using other stackers that can’t perform well in inconvenient places.
• Less noise because of electric operation and mast technology which reduce operating noise.

What are the new features of the reach truck?

Reach trucks come up with a lot of features that make the job of workers easier. These features are introduced to maximize convenience and save time and energy. A few new features are as follows:

• Reach truck provides a platform to stand on and move with the truck. If your workers work all day on standard stackers or lifting machines, they probably get tired quickly; However, they are just moving, but still, they are putting in some effort. Reach truck even minimize that effort; now the worker just has to stand on and move the control hand and steering to navigate the car. Some models provide the seat to sit on and operate, which is even better.
• The most helpful feature of the reach truck is extending and retracting the forks of the machine. This feature is highly demandable in narrow aisle usage. You can easily lift and lower the load in a narrow aisle by extending the forks. So, no need for an extra counterbalanced truck for such tasks. Keep in mind that this feature is not available in all models and types of reach trucks.
• The reach truck provides a clear view of forks and supports legs through the mast for precise and quick pallet handling. The side-seat position gives the operator clear visibility. In some models, the cab can ever tilt a little to provide clear vision. Others are already designed with the open overhead guard as a solution.
• 3600 turning radius provides a comfortable movement of the machine in the warehouse. You can easily maneuver the machine in the narrow aisle. Smooth steering reduces sensitivity as speed increases; provides better stability when cornering.
• Triplet mast is available in this machine, allowing the operator to utilize the maximum vertical area of the warehouse.
• The reach truck provides a comfortable cabin with a pedal to stand on and an ergonomic handle to control.
• They are quiet, rapid, and smooth lifting, lowering, tilting, and side-shift functions are available.
• Overhead guard is provided to ensure safety. In case the load drops from the top of the mast on the operator, the overhead guard protects the operator.

What is the maximum lifting height of the reach truck?

Normal stackers and other lifting machines have one or two masts, but the reach truck comes up with the capability of triplet mast. Which makes the machine able to reach up to ever higher place; these masts are strong enough to lift a heavyweight and place it with perfection.

This feature varies with each model; some models can lift up to 12000, while some can lift up to 8000 only. So, choose wisely at the time of buying according to your needs. If you want to utilize your warehouse’s vertical area, you can go for the reach truck with the most lifting height.

What is the maximum load capacity of the reach truck?

Load capacity varies with the model; you can get a 1000 kg load capacity machine and a 2500 kg machine. So that totally depends on what you need and what your company’s requirement. If you have a small company; where the lifting machines will not lift heavy loads, 1000 kg load capacity reach truck would be better. Suppose you have a huge company and the transformation of heavy loads is part of daily work routine. In that case, it is highly recommended to buy a reach truck with a 2500 lifting capacity. Make sure don’t put heavier weight than its maximum limit; these machines are assets of your company; use your assets wisely.

What is the minimum lifting height for a reach truck?

There are different models with different sizes; some models have a minimum lifting height of 3000mm. Some models have even 0mm minimum height means you should move to lower the load completely during traveling. But always make sure that the load should be at the minimum lifting height; that somehow puts less pressure on the motor, and your machine will last even longer.

What type of power source is required to operate the reach truck?

AC power source is required to operate heavy machines like reach truck.

What are the benefits of having your own reach truck?

Many companies either buy the reach truck or rent. The significant advantage of having your own machine is that you can train your operators on that machine and get familiar with that machine. They will be using that specific machine in every task. Continuity in operating the same machine will make them expert in managing it. This is how the risk can be minimized, and productivity can be maximized. You will not wait for a rent machine to arrive; If you have your own machine, you can save your time as well. But there are many models and sizes of reach trucks; each one has the same features but different capacities. So, make sure you know the companies needs and buy accordingly. Few essential elements you must understand as follows:

• Determine the size and type of the load; make sure that the material can be carried in terms of size, shape, and dimension.
• Determine the load capacity; you must know how much weight you need to lift?
• Calculate the job site weight; do make sure that the forklifts can endure the lifting machines like reach truck.
• Ensure the height of the space: you should know the reach you are going to use in your warehouse. If you are going to buy a reach truck and don’t have sufficient height at your warehouse to use this machine, you shouldn’t waste your money. So better you determine the height of space that you want to utilize.
• Select the fuel type; do you want a battery or gas as a power source.
• Analyze the landscape; determine the surface of the warehouse if smooth or uneven.
• Driving speed: Decide according to the requirement regarding the traffic and the driving speed of the warehouse.

How to operate the reach truck?

Reach truck have been used widely in many industries; reach truck has become one of the most important equipments of warehouses and industries. They are used in many material handling operations. You can lift and transport efficiently, smoothly, and effortlessly in narrow aisles by using a reach truck. However, there is a high risk of any damage or failure; if the operation is not done in a safe manner. Any incident resulting in injury and property damage can occur while safe operating practices are not followed. So, what is the correct way of functioning way? Let’s know that by categorizing the whole operations.

Getting on/off and starting:

First of all, ensure that the truck’s forks are in the proper position according to the pallet and the type of load. The width between the forks should be ½ to ⅔ of the width of the pallets. Adjust the position of the forks and set them to the center of the reach truck. Beware of getting your hands caught while adjusting the forks.

Before getting on the truck, make sure there is no anyone, any object, or any hurdle surroundings.

Then you can get on the reach truck. Adjust the rear-view mirror to establish optimum visibility. Keep in mind that you can only get on and off the reach truck and set the pads while the truck is stationary. Don’t jump on and off, or grasp the steering wheel or controlling handle while getting on or of.

You have provided an LCD that displays machine status. A steering wheel is there to navigate the machine; in some models, the control handle consists of buttons that control the machine’s maneuverability. In some models, three lever handles are given to manage.

After inserting and turning the key switch to the on position, ensure that the LCD meter is lighted. Grasp the steering wheel with your left hand and the controlling handle with your right handle. Lift the forks five to ten cm above the top surface of the straddle arms and tilt the forks fully backward. To move forward, fully depressed the brake pedal and move forward by shifting the accelerator lever forward.

Right-angle turns (forward / reversal):

For the right angle, turn in forward; drive to the center of the aisle, and approach the corner of aisle.

when the front wheels reach the corner, turn the steering wheel. When the middle section of the truck arrives at the center of the aisle you’re entering or returning, turn the truck to the straight position.

For the right angle, go in reverse and drive backward to teh center of the aisle. Keep going until the distance between front wheel and corner remains one meter and then turn. When the middle section of reach truck arrives at the center of aisle you are entering or returnning, steer the truck to the straight position; make sure if the load blocks vision, drive backward or steer accordingly.

Loading and unloading:

Proceed towards the load and square up the load. Take you foot off teh pedal to stop the truck at about twenty to thirty cm before the load.

Shift the accelerator lever into neutral, level the forks, lift the forks to the height of pallet openings. Press the brake pedal to move forward slowly by shifting the accelerator lever forward. Reach out and insert forks into the pallets entirely by either moving mast or extending forks depends on the type of reach truck you are using. Take your left foot off the brake pedal, shift the accelerator level into neutral, lift the pallets about 10cm above the pallet stand. The load should be balanced, stable, and within the load capacity. Move truck backward, stop the reach truck when the distance between the reach truck and the pallets stand reamins about twenty to thirty cm. Take your foot off the brake, shift accelerator level into neutral, slowly lower the forks about 5 to 10 cm above the top of straddle arms. Tilt the forks fully backward, and then you can drive the machine to the predesignated area. For unloading, do the same method into the reversal.

Parking / Getting off:

Take your foot off the pedal and stop the reach truck. Lower the forks until fully resting on the ground, turn the key switch off, disconnect the battery plug, remove the key and store it in a secure location. Don’t execute any abrupt operation such as harsh acceleration, brake, or turning. Process of the moving the mast or extending the forks while the reach truck is moving is strictly prohibited.

What is the fork width of the reach truck?

Forks are manufactured with solid material in proper dimensions to lift heavy loads up to a considerable height. These forks are designed in a way to provide an appropriate balance and protection. The width of forks varies between 100mm to 680mm, depending on the model.

What is the length of reach truck’s forks?

There are different models with different sizes; every factor depends on its model, but the length of forks is the same in most models. Its length s 1070mm, which is quite reasonable to approach pallets and lift them comfortably with providing balance and protection.

How much weight can extract forks lift?

Extracted forks can lift the safe weight as they can lift being retracted. If a machine can lift 1500kg on its retracted forks, it can lift 1500kg on extended forks.

Is it safe to move a reach truck with extracted forks?

Yes, forks and the body are very much strong even if the splits are extended. You can lift and move your load with extended forks. Still, one thing to always remember is that those should be perfectly inserted when you insert your forks into the pallets. When you lift the weight, don’t forget to tilt it back to minimize the risk. You can travel with the extended forks, but you should retract back the forks and lower them down to the recommended travel height to be safe.

What is the maximum driving speed of a reach truck?

Some models have 8.5 km/h maximum driving speed while driving some models up to 10 km/h.

What is the maximum lifting speed of a reach truck?

The lifting capacity depends on the condition that either the forks are loaded or unloaded. The lifting speed varies between 200 to 260 mm/s for loaded and 300 to 360 for unloading. But you should always be patient while lifting and lowering the load; However, this machine is very safe to use. Still, the employee’s health is the primary concern of any company, so avoid reaching maximum lifting height to prevent any mishap, especially when lifting hefty and huge loads.

What is the turning radius in reach trucks?

It is different for different models; it varies from 1760 to 1950mm.

What wheel type used in the reach truck?

PU wheel type is used in reach trucks.

What is the operation type in reach trucks?

Some models provide a seat for the operator to sit on and operate. Others have a pedal; the operator has to stand on it to work.

What is the distance between forks’ arms?

It varies with the model; the distance between forks in the reach truck always lies between 200 and 680mm.

What ground clearance required for the reach truck to drive on?

80-100 mm of ground clearance is required for the reach truck to drive on.

How does the mast of the reach truck tilt?

The function of moving mast is available in few new models. In contrast, the feature of moving and tilting forks is available in most models. In few new models, the mast can move in a forward or backward direction. The forks can move a little to the right and left side; the forks can tilt upward and downward to adjust the load and provide balance and protection. Complex operations in narrow aisles can be done by using this feature easily.

What is the battery capacity of the reach truck?

Batteries are used according to the motor and other attributes of the motor. If the machine is designed to lift high loads, it requires a strong motor that requires a high voltage battery and vice versa. Most batteries need 40-48v and 270-560 AH to charge, depends on the model.

Is there any certificate of training required for operating the reach truck?

Training of all lifting machines is mandatory, primarily electrically operated machines like reach trucks. The operators are supposed to use these machines daily. If operators don’t know any function correctly, they can work smartly and effectively. OSHA instructs that all reach truck operators must receive the proper training. Every new reach truck comes with a new specification and new features; the company and OSHA also keep changing their safety guidelines regarding new models. In that case, the operator has to stay up to date. Through the reach truck training, the operators can build their skillset and avoid the risk. The certification shows that your company prioritizes the health and safety of workers. The training gives knowledge and confidence to the workers, knowing how they can safely work with a heavy load at height and how they can travel on inclines and other workplace practices. That training pays off as a maximum production and minimum risk.

What includes the training for operating the reach truck?

Specific training for employees is required to teach proper guidance and instruction to follow in the warehouse. The exercise highlights the reach truck safety matters; that training also encourages the workers to share their own tactics regarding safety and concern questions. The training makes the workers able to accomplish all safety guidelines and requirements by the company and OSHA. There are few important topics which should be highly considered while training.

Different truck categories:

There are many other reach trucks; each one has a slight difference. The operator should be qualified for operating all sorts. Many operators think that all the classes are similar, but that not the case. Getting training for one category will make the operator qualified for all the categories, but that’s not the case. The operation must be prepared for all the types like seated, standing, or truck with greater lift height.

Working at height:

There are different heights of racks in reach truck operations. Since the reach truck is operated for higher altitudes, operators of reach trucks have to be trained for taller heights than the operators of counterbalanced forklifts and other lifting machines. An increment in racking height means greater risk, so the operators must be adequately trained to work safely, accurately, and effectively at height. They should know about all possible risks by the drive-through and drive-in racking system.

Traveling on inclines:

One of the most challenging jobs for a reach truck driver is operating on a slope; the rise is the most considerable risk for the truck and the operator. The operator must be trained accordingly; he/she should know the proper methods of operating the machines on the inclines. A well-trained operator must identify the possible risks of the slope and the solutions to those risks. He should have a strong command of the drive and brake system while traveling, no matter the truck is loaded or unloaded. If the truck is loaded, the operator must use the tilt feature to ensure the load doesn’t fall off.

Assistive technology:

Nowadays, technology has evolved; cameras and LCD are installed everywhere for safety and monitoring purposes. These devices have been used at warehouses for the same reasons. However, these devices are very useful to enhance safety, efficiency and the owner will always look at the workers. But real reach truck training should not be replaced with these devices because if the technology or device fails, the operator must operate safely without that technology and device.

Stability:

The reach truck’s stability and center of gravity differ from counterbalanced and other lifting machines because the reach trucks have features of extended reach and extended forks. The center of gravity and stability keep varying as the operator moves the load at the height. The operator must be trained for that scenarios when the center of gravity and stability fluctuate in their positions.

Steering and operating position:

Steering and operating position might be a little bit tricky for beginner operators because, unlike another lifting machine, the reach truck has a side stand, the mast is on the right side of the operator. The operator is not supposed to only look in the direction of the travel but he/she has to be aware of all around. He/She should have an eye on every activity happening in the surrounding and all additional blind spots. These blind spots could be caused by the loaded mast, overhead guard, or improper operating position in narrow aisles.

Reach mechanism and reach-legs:

The mechanism of every machine is different, so every machine is best for specific operations. Same as the reach truck is the best lifting machine for narrow aisles operation, and the truck operator must be trained according to its mechanism and reach-legs. Even different types and models of reach trucks have different mechanisms; the operator should know that all these mechanisms are other and which machine is suitable for operation. This makes the job easier for the workers. The owner will get surety of maintaining a level of excellence around the warehouse.

What maintenance does the reach truck require?

Machines need maintenance. Suppose you want longevity of your machines, maximum performance, and avoid costly downtime. In that case, you should follow all the maintenance steps to ensure your reach truck’s long life. For some machines, regular maintenance is required, while monthly or annual maintenance is recommended. But essential maintenance daily and performing advance maintenance monthly and annually is the recommended practice. To keep all things organized, you should always follow the checklist of reach truck maintenance to ensure you are hitting all your benchmarks. First of all, let’s see what is required in daily care, which is primarily one of the essential practices given by the company.

Most warehouses are pretty familiar with the most critical lifting machine preventive maintenance protocols because OSHA requires daily inspection. So according to OSHA, all machines should be examined before and after each shift. The operator is supposed to key off and  have a pre-operation visual check of all the machine components. Then he should turn on the engine of the truck and perform an operational inspection. If any damage or fault is found, the machine should be replaced or repaired immediately.

The operator should follow the industry’s standard for monthly maintenance and are closely aligned with manufacturer recommendations. Monthly maintenance is a little advance than daily maintenance; sometimes, it requires diagnostic equipment. The monthly maintenance checkup requires a vast collection of actions involving all aspects of the machine, including all lubricating and electrical components, mast-carriage platform, tension rod locknuts, chains and anchors, forks-pallet-platform, and all general operations.

Annual maintenance is mainly tied to warranty protection; it follows the manufacturer’s recommendation. For yearly maintenance, you require a skilled and certified professional technician; who thoroughly checks the equipment that might need any potential repairs and ensures optimum performance and durability.

What are the differences between reach trucks vs. forklifts?

There are a few similarities and differences between reach trucks and forklifts. Let see a few of them:

Visibility:

Forklift features forward-facing cabs; the operator can see the load upfront with his or her eyes, while heavyweights can be an obstacle to seeing. The forklift features a proper sitting seat for the operator. In contrast, the reach truck features many stance options in which the sideway-facing cab is the most popular. In some models, the operator has to stand on the pedal. In some models, a sitting seat is available in the cab. In the reach truck, the operator can either see the operation through innovative mast design or making the process visible by tilting the cab or using the video screen.

Lifting capacity:

There is a huge difference when it comes to the lifting capacity. The lifting capacity of the reach truck is 3,000 to 5,500 pounds depending on the model. At the same time, most forklifts have higher ability. Normal forklifts can lift 3000 to 19000 pounds; forklifts of exceptional cases are built to lift even heavier, ranging from 28,000 to 100,000 pounds.

Turn radius:

The turning radius depends on the size of the machine, and the reach truck has a 35% smaller turning radius than forklifts, which means it needs a smaller area to turn completely than forklifts. This makes reach trucks even better for operation in narrow aisles. Some reach trucks are too small that can even operate in 8-foot-wide aisles, while at least 12 feet wide aisle is required for the smallest forklift to turn and function properly.

Height Capacity:

The primary purpose of designing a reach truck is to lift the load up to an extended height. Here in this category, the reach truck got an edge over the forklifts; the reach trucks can lift the load up to 19 feet of height, meanwhile, some of the reach trucks can even extend up to 41 feet of height depends on their model and type.

Forks:

Both machines use the forks to lift the load; the forks of both machines are built up by the strong material and are strong enough to lift, tilt and balance the heavy load. Different models have forks of various dimensions in reach trucks and forklifts. The reach truck has some extra features regarding forks. In some reach trucks, the forks can be extended forward and tilt to balance the load. Extra height with different lengths of forks makes the reach truck a perfect machine for some operations. Apart from performance, safety has also been considered in reach trucks.

Approaching the load:

The counterbalanced truck can come closer to lift the load and move it. While the reach truck is designed to pick up from one place and store the load in racking or storage.

Types:

The counterbalanced forklift comes in three- and four-wheel variety, while the reach truck comes with two types: the moving mast reach truck and pantograph reach trucks. Some reach trucks have a tilt mechanism in which the operator can tilt his/her cab to clear the view of the load. Some models have an open overhead guard to adjust the driver’s view. Even cameras are installed in some models, the operator can see the load through the screen.

Usage:

The counterbalanced is designed for indoor and outdoor operations. The reach truck can be used outdoor; unlike counterbalanced, it is designed for only indoor operations.

Power source:

All reach truck is operated on 36-volt electric battery, but there are many power sources for forklifts. You can choose diesel, gasoline, LPG, or electric battery as your fuel source.

How many types are there in reach trucks?

All reach truck is designed to a primary goal: lift loads at a height. Still, in different warehouses and scenarios, typical machines with the primary goals and extra features can perform that specific task. There are other models with different sizes, but all reach trucks are categorized into two; let’s see what are those two types of reach trucks and what are their extra features?

Pantograph Reach trucks:

A pantograph reach truck provides an extra feature of extending the lifting forks forward. This type uses scissor technology and allows the operator to easily lift and place the load into racks with either single or a double reach configuration design. These reach trucks directly go into the racking and lift the pallets, making sure that there is no bar at the bottom level with bottom pallets. Another configuration of raking could be using a small wheel with a slightly higher bottom bar; that could help the reach truck to move forward.

The pantograph reach truck can also lift heavy weights up to the long height when fully extended at double deep-reaching.

Moving Mast Reach Truck:

Moving mast reach trucks have the capability of moving the mast forward. The mast is based on the rails that allow it to move forward by a hydraulic system. Moving mast reach truck doesn’t need any fork extension attachment to handle double deep racking. These trucks come up with wheels of large diameter, that help them in ground clearance,  which also helps the truck to operate on the dockside and narrow aisles.

Straddle truck:

Another type of truck is the straddle truck; the legs of the straddle truck are set aside wider so that the portions of the truck can surround the pallet. This is useless in most scenarios, especially in narrow aisle operations. The pallets can’t be stacked as close; if they do so, it will take a lot of storage area.

What are the critical elements of a reach truck to focus on when buying the machine?

Many reach truck models, types, and sizes in the market; many variations in models and sizes can confuse customers about buying a suitable machine. There are three main elements you should focus on when purchasing the machine.

Stability:

stability in lifting machines is called the area under the machine’s body; it is responsible for maintaining the center of gravity to prevent the vehicle from falling over.

Load center:

It is the distance from the forks to the center of gravity of the load.

The load center depends on the weight of the load, the lifting, and the tilting angle. The operator doesn’t have to worry about it if they work according to the listed weight capacity and keep the load balanced.

Lift capacity:

Lift capacity is the amount of weight the machine can carry; it is the maximum lifting limit. This element plays a vital role in the lift of the machine and stability. If you want to keep your machine run for a long time, you must not carry more weight than its maximum limit. While lifting up the load, put pressure on the whole machine body vertically.

Which class of the forklifts does the reach truck belong to?

There are seven classes of forklifts; the reach truck belongs to the second class. The second class consists of all machines which are highly useful in narrow-aisles operations.

Can reach truck be used outside of warehouse?

Reach trucks are designed for indoor operations; they are not suitable for outside tasks. They are built low, they have little under-carriage clearance. If you use it out of a warehouse on a rough and uneven road, it can cause problems. Even the uneven surface in the warehouse is not satisfactory. An uneven surface can cause any collision of the surface and the machinery, leading to damage in the system and expensive repairs. So, it is highly recommended to keep the reach truck indoors.