A double reach truck is a specialized type of electric narrow-aisle forklift designed to handle pallets stored two positions deep in high-density racking systems. It is a subtype of the Class II reach truck, distinguished by its ability to extend its forks into the second pallet position, a feature that can increase warehouse storage density by up to 30-40% compared to single-deep racking. Unlike a standard reach truck, which can only access a single pallet position, a double reach truck has a pantograph mechanism that extends the forks further, allowing the operator to retrieve or deposit pallets from the second row of racking.
What Is a Double Reach Truck?
A double reach truck is an electric, stand-up rider forklift designed for warehouse operations. Its key defining feature is a pantograph mechanism with two (or more) stages of extension, allowing the forks to reach into the second pallet position in a double-deep racking system. This design enables a significant increase in storage density because aisles only need to be wide enough for the truck to maneuver and extend its forks, rather than requiring space for a counterbalanced forklift to turn around. Double reach trucks typically have capacities ranging from 2,500 to 4,500 lbs and can reach lift heights of over 40 feet.
Double Reach Truck vs. Standard Reach Truck
Feature Standard Reach Truck Double Reach Truck
Racking Depth Single-deep (one pallet position) Double-deep (two pallet positions)
Storage Density Standard Up to 30-40% higher
Pantograph Extension Single stage Two-stage (or more)
Aisle Width Narrower (typically 8-9 ft) Wider (typically 10-12 ft)
Fork Length Standard Extended (to reach second position)
Operator Visibility Better More challenging (second row is harder to see)
Cost Lower Higher (more complex mechanism)
Leading Brands and Models
Several major manufacturers produce double reach trucks, each offering different configurations and specifications.
Brand Notable Models Key Specifications
Crown RD 5200 Series 3,000-4,500 lb capacity, up to 41 ft lift height, AC drive and hydraulic systems
Toyota 8BR Series 3,000-4,500 lb capacity, up to 40 ft lift height, System of Active Stability (SAS)
Raymond 7000 Series 3,000-4,500 lb capacity, up to 41 ft lift height, ACR system for reduced energy consumption
Yale MRA Series 3,000-4,500 lb capacity, up to 41 ft lift height, eLoP (electronic on-demand power steering)
Hyster R2.0-3.5HD 4,000-8,000 lb capacity, up to 40 ft lift height, heavy-duty applications
Mitsubishi RBE Series 3,000-4,500 lb capacity, up to 41 ft lift height, AC drive system
Key Specifications
Specification Typical Range Notes
Load Capacity 2,500 – 4,500 lbs (1.1 – 2.0 tonnes) Varies by model and lift height
Maximum Lift Height 30 – 41 ft (9 – 12.5 m) Triple-stage masts are common
Aisle Width 10 – 12 ft (3.0 – 3.7 m) Wider than standard reach trucks
Voltage 24V, 36V, or 48V Electric battery-powered
Tire Type Polyurethane or cushion Designed for smooth indoor surfaces
Operator Position Stand-up For improved visibility and maneuverability
Advantages of Double Reach Trucks
Maximized Storage Density: By storing pallets two positions deep, a double reach truck can increase warehouse storage capacity by up to 40% compared to single-deep racking, without expanding the facility’s footprint.
Reduced Operating Costs: Higher storage density means fewer aisles and less wasted space, which can lower overall building and operating costs per pallet stored.
Efficient for High-Bay Warehousing: Double reach trucks are designed for very narrow aisles (VNAs) and can operate in spaces as narrow as 10 feet, making them ideal for high-density, high-bay warehouses.
Versatile: They can handle a wide range of pallet types and sizes, making them suitable for various warehouse applications.
Disadvantages and Challenges
Reduced Operator Visibility: The extended forks and double-deep racking make it harder for operators to see the second pallet position, which can increase the risk of product damage or accidents.
Higher Initial Cost: Double reach trucks are more expensive than standard reach trucks due to their more complex pantograph mechanism and extended forks.
Wider Aisle Requirement: They require wider aisles than single-deep reach trucks, typically 10-12 feet, which can offset some of the space-saving benefits.
Specialized Training Required: Operators need additional training to safely handle the extended reach and reduced visibility.
Heavier and Bulkier: The extended forks and pantograph mechanism make the truck heavier, which can increase wear on floors and batteries.
Applications and Industries
Double reach trucks are best suited for warehouses and distribution centers that require high-density storage and operate with high bay heights.
E-commerce and Fulfillment Centers: High-volume, fast-moving inventory that benefits from dense storage.
Cold Storage: Maximizing storage capacity in expensive refrigerated spaces.
Manufacturing Warehouses: Storing raw materials and finished goods in a compact footprint.
Retail Distribution: High-turnover, palletized goods that can be stored two deep.
Food and Beverage: High-density storage of dry or refrigerated goods.
Buying Considerations
When purchasing a double reach truck, consider the following:
Racking Configuration: Ensure your racking system is designed for double-deep storage and is compatible with the truck's reach capabilities.
Aisle Width: Verify that your aisles are wide enough to accommodate the truck and its extended forks.
Lift Height and Capacity: Match the truck's lift height and load capacity to your specific racking and pallet requirements.
Operator Training and Safety: Invest in comprehensive operator training and consider safety features like cameras or sensors to improve visibility.
Total Cost of Ownership: Factor in the higher initial cost against the long-term savings from increased storage density and reduced building costs.
Brand and Dealer Support: Choose a reputable brand with a strong dealer network for parts and service.
Summary
A double reach truck is a specialized electric forklift designed to access pallets stored two positions deep in high-density racking systems. It offers significant storage density advantages (up to 40% more) compared to single-deep reach trucks but comes with higher costs, wider aisle requirements, and reduced operator visibility. Leading brands include Crown, Toyota, Raymond, and Yale, with capacities ranging from 2,500 to 4,500 lbs and lift heights up to 41 feet. Double reach trucks are ideal for e-commerce, cold storage, and high-turnover distribution centers where maximizing storage capacity is critical. When selecting a double reach truck, carefully evaluate your racking configuration, aisle width, and total cost of ownership.