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Walk through almost any modern distribution centre in Sydney and you will see reach trucks working the aisles. They are purpose-built for one environment: high racking, narrow aisles, and fast, efficient pallet movement at height.
If your warehouse has racking above around 4–5 metres, or aisles narrower than what a standard counterbalance forklift can comfortably operate in, a reach truck is often not just helpful—it becomes the most efficient solution for that part of your operation.
Mars Forklifts supplies reach trucks across Sydney and the East Coast, with flexible hire options and delivery available to keep warehouse operations moving. This guide explains how reach trucks work, where they perform best, and when they should be part of your fleet.
What Is a Reach Truck?
A reach truck is an electric warehouse forklift designed specifically for narrow-aisle and high-racking environments. Unlike a counterbalance forklift, which carries the load in front of the machine, a reach truck uses an extending mast or carriage system to move the forks forward into the racking.
Once the pallet is lifted, the carriage retracts, bringing the load back within the wheelbase of the machine. This design is what allows reach trucks to operate in much narrower aisles while maintaining stability at height.
💡 How the reach mechanism works:
The operator positions the machine in front of the racking, extends the forks forward into the pallet, lifts the load, and then retracts the mast so the load sits within the machine’s wheelbase for travel. This allows stable movement even at elevated lift heights in tight warehouse aisles.
Key Specifications of a Reach Truck
| Specification | Typical Range |
| Lift height | 5 to 12 metres (some models higher) |
| Load capacity | 1,000 to 2,500 kg |
| Aisle width | 3.0 to 3.3 metres |
| Power source | Electric (lead-acid) |
| Operating surface | Smooth indoor warehouse floors |
| Operator position | Seated cab with mast-facing visibility |
| Tyres | Solid/cushion tyres |
These figures vary between models, but they reflect typical warehouse reach truck performance.
When Should You Use a Reach Truck?
A reach truck is typically the right solution when your warehouse has:
- Racking above 4.5–5 metres requiring regular access
- Narrow aisles below 3.5 metres
- High-density storage where maximising vertical space is a priority
- Smooth indoor flooring with no outdoor travel requirements
- Standard pallet loads within typical warehouse weight ranges
- A need to improve storage capacity without expanding floor space
In many modern warehouses, reach trucks are the key to increasing storage density without needing to relocate or expand facilities.
When a Counterbalance Forklift Is Still the Better Option
While reach trucks are highly efficient in the right environment, they are not suitable for every operation.
A counterbalance forklift is generally preferred when:
- Loads regularly exceed 2,500 kg
- Outdoor yard or loading dock work is required
- Floors are uneven or include ramps and gradients
- Container loading or heavy industrial handling is involved
- Wide aisles already exist and vertical storage is not required
Many operations use both: reach trucks for narrow-aisle high-bay work and counterbalance forklifts for outdoor, loading dock and heavy-duty tasks.
Mars Forklifts supports both machine types across its hire fleet, allowing businesses to run a mixed fleet matched to each task.
Why Reach Trucks Improve Warehouse Efficiency
Reach trucks allow businesses to rethink how warehouse space is used. By operating in narrower aisles and reaching higher racking levels, they make it possible to store more stock within the same footprint.
This often reduces unnecessary travel time, improves picking efficiency and helps streamline warehouse layouts without requiring structural expansion.
Hiring a Reach Truck with Mars Forklifts
For many businesses, hiring a reach truck is the most flexible way to scale warehouse capacity without committing to long-term asset ownership. Equipment can be introduced as needed, upgraded as operations grow, and supported with full maintenance and servicing throughout the hire period.
Mars Forklifts provides reach trucks across Sydney and the East Coast with fast deployment options to keep warehouse operations moving.
Frequently Asked Questions
Do reach trucks require a different licence to counterbalance forklifts?
No. Both reach trucks and counterbalance forklifts fall under the LF High Risk Work Licence in NSW. However, operators should still receive familiarisation training specific to reach trucks before use.
How high can a reach truck lift?
Most warehouse reach trucks lift between 8 and 10 metres, with some specialist models exceeding 12 metres. The required lift height should always match your racking configuration.
Can reach trucks be used in cold storage?
Yes, but only if they are specified for cold storage environments. Standard reach trucks are not designed for sustained sub-zero operation and require specialised components for cold-room use.
What maintenance does a reach truck require?
Reach trucks require regular servicing at set operating hour intervals, daily pre-start checks, and proper battery management. Electric drive systems also require correct charging practices to maintain performance and battery life over time.
