When warehouse space is at a premium, the difference between a 118″ and 127″ aisle could mean thousands of lost pallet positions over time. Choosing the right reach truck affects not only forklift performance but also how tightly you can design your racking layout. In this article, we compare Raymond and Crown reach truck aisle requirements using consistent assumptions: a top beam height of 384”, standard 40×48″ pallets, and straddle-style reach trucks operating in roll-formed rack with a 96” beam span.
Quick Comparison Table of Reach Truck Aisle Dimensions
| Brand | Model | Battery Compartment | Headlength | Engineered Aisle (in) | Min Rack-to-Rack Aisle | Recommended Aisle |
|---|---|---|---|---|---|---|
| Raymond | 7520-R45TT (3613) | 18.12” | 62.2” | 106” | 118” | 124” |
| Raymond | 7520-R45TT (3609) | 21.12” | 65.2” | 106” (+3”) | 121” | 127” |
| Crown | RM 6025-45TT-400 | 18.12” | 60.4” | 108.4” | 120.4” | 126.4” |
| Crown | RR5725-45TT-380 | 18.12” | 58.04” | 106.04” | 118.04” | 124.04” |
Key Takeaways for Warehouse Layout Design for Reach Trucks and Aisle Dimensions
1. Raymond’s 21″ Battery Option Comes with a Cost
The 7520-R45TT with the 21.12” battery compartment (code 3609) adds 3″ to the minimum clear aisle. That bump moves the rack-to-rack aisle from 118″ to 121″, and the recommended aisle to 127”. If your warehouse is designed around a 10’ aisle grid, that change can break the layout.
✅ Tip: Unless the extended battery runtime is essential, the 18” compartment version is the better fit for space-sensitive applications.
2. Crown’s RR5725 Is the Tightest Turning Option
At just 58.04″ headlength, the Crown RR5725 is the most compact of the group. It matches Raymond’s narrower model with a recommended rack-to-rack aisle of 124.04”—a key metric for deep aisle density designs. Headlength is the distance from the back of the truck to the front of the load back-rest. This dimension is important and impacts reach truck aisle dimensions significantly.
🏆 Best for high-density layouts with moderate lift height (≤ 380″)
3. Fork Elevation and Extended Height Matter
Raymond offers the highest lift at 444″ fork elevation and 480″ extended mast height. If you’re topping out rack beams near 32 feet (384″), the Raymond 7520-R45TT (3609) ensures safe margin above load height.
⚠️ Watch the collapsed height too: at 184″, it may limit entry into some dock doors or tunnels.
4. Crown’s RM 6025 Offers Stability, But Needs More Room
While slightly heavier and with a longer engineered aisle of 108.4”, the RM 6025 may offer smoother vertical movement and a more robust feel—but it requires 126.4” recommended aisle, slightly wider than the Raymond 18” option.
What’s the Real Impact of 6 Inches?
On a 10-aisle, 20-deep racking design, increasing aisle width by 6 inches costs:
- 10 aisles × 6″ = 60″ (5 feet)
- Over 100,000 square feet, this could eliminate 4-5 pallet positions per aisle, or 40–50 total—impacting storage and revenue.
📌 Conclusion
When selecting reach trucks for a new or existing facility, always match your rack layout, lift height requirements, and aisle targets with the truck’s engineered clearances. Here’s a summary:
| Use Case | Best Fit |
|---|---|
| Max aisle density | Crown RR5725 or Raymond 7520 (18″) |
| Max lift height (≥ 32′) | Raymond 7520 (21″ battery) |
| Tightest headlength | Crown RR5725 (58.04”) |
| Balance of reach and load capacity | Raymond 7520 (18”) – 3,250 lb @ 400” |
💬 Need Help Specifying the Right Truck?
At Lean Material Handling, we help design aisle-efficient warehouses with optimized equipment for your operation. Reach out to request a pallet rack layout analysis or forklift spec review.
📞 1-888-310-0008 | 📧 info@leanracking.com
www.LeanMH.com