What to check before buying a used forklift

A good used forklift can give you years of work for a fraction of the price of a new one. A bad one can cost you more in repairs than you paid for it. The difference is usually visible if you know where to look. Here’s what to check, in order.

1. Make sure it suits the job

Before you look at condition, make sure the machine is right for the work:

• Capacity. Check the capacity plate (data plate). It shows the rated capacity at a set load centre, often 500 mm on common counterbalance forklifts. Long or bulky loads, high lifts and attachments all reduce what the forklift can safely lift.
• Lift height. Measure your highest racking beam and allow clearance.
• Mast type. A container mast lets you lift inside a shipping container or under a low roof without the mast hitting the top.
• Fuel. LPG for outdoor and mixed work, electric for indoors. See LPG vs electric forklifts.
• Attachments. Side shift, fork positioner or anything else your loads need.
• Type. Working in narrow aisles with high racking? Compare a reach truck with a counterbalance forklift.

2. Hours on the meter, and whether they add up

The hour meter is the forklift’s odometer. Lower is generally better, but hours only tell part of the story. A well-serviced machine with higher hours can be a better buy than a neglected one with low hours. Make sure the wear you can see matches the hours: worn pedal rubbers, a shiny steering wheel and a tired seat on a “low hours” machine are a warning sign.

3. Forks

• Look for cracks, especially at the heel (the bend) and around the hooks.
• Check for wear at the heel. A widely used rule of thumb is that forks worn more than 10% of their original thickness should be replaced.
• Check both forks are straight, level at the tips, and that the locking pins work.

4. Mast and chains

• Raise the mast to full height and lower it, with and without a load. It should move smoothly, without jerking, binding or noise.
• Check the lift chains for rust, kinks, stiff links and stretch, and that they’re lubricated.
• Look at the mast rollers and channels for heavy wear.
• Lift a load, stop, and watch the mast and tilt for a few minutes. If it creeps down or tilts forward, the hydraulic cylinders may need work.

5. Hydraulics

Look for oil on the mast, cylinders, hoses and floor under the machine. Check hoses for cracks and bulges. Small leaks are often cheap fixes; big ones, or leaks from cylinders, can be expensive.

6. Engine and gas system (LPG forklifts)

• Start it from cold. It should start easily and idle smoothly.
• Watch the exhaust for smoke and listen for knocking.
• Check for any gas smell around the cylinder, hoses and regulator.
• Check the gas compliance plate, which shows when the system was tested and by whom.

7. Battery and charger (electric forklifts)

The battery is the most expensive single part on an electric forklift, so look closely:

• Ask how old the battery is and check its condition: corrosion, damaged cells, swelling, or acid around the top.
• On lead-acid batteries, check the water levels.
• Make sure a charger is included, and that it suits the battery’s voltage and your site’s power supply (single or three phase).
• If you can, run it under load for a while to see how it holds its charge.

8. Brakes, steering, tyres and safety gear

• Test the service brake and park brake on a slope if possible.
• Steering should be smooth with no excessive play.
• Check the tyres for wear, chunks missing, and flat spots.
• Check the seatbelt, horn, lights, reversing beeper, mirrors and overhead guard all work and aren’t damaged.
• Make sure the capacity plate is fitted, readable, and matches any attachments on the machine.

9. Test drive it with a load

Drive forward and back, turn in both directions, lift and tilt with a typical load. Listen for clunks, whines and grinding. A forklift that drives fine empty can behave very differently with a full pallet on the forks.

10. Paperwork

• Ask for the service history.
• Check the serial number on the data plate matches the paperwork.
• If you’re buying privately, search the serial number on the Personal Property Securities Register (PPSR) to check there’s no finance owing on it.

Quick checklist

• Suits the job: capacity, lift height, mast, fuel, attachments
• Hours: wear matches the hours
• Forks: no cracks, heel wear under 10%, straight and level
• Mast and chains: smooth, no creep, chains not stretched or rusted
• Hydraulics: no significant leaks, hoses in good condition
• LPG system: easy start, no smoke, no gas smell, compliance plate
• Electric: battery condition, water levels, matching charger
• Brakes, steering, tyres: all working, no excessive wear
• Safety gear: seatbelt, horn, lights, guard, readable capacity plate
• Paperwork: service history, serial matches, PPSR clear

Buying from Damoli

Every forklift we sell comes with a 3-year warranty, and finance is available. Our stock is mainly Toyota, and each listing shows the model, capacity, lift height, mast, fuel, attachments and hours. Come and look over the machine at our Werribee yard, Unit 2/76 Riverside Ave, Werribee VIC 3030, Monday to Friday 8am–4pm, or at the weekend by appointment. We deliver across Melbourne and regional Victoria, and offer same-day on-site servicing after the sale. Can’t find what you need? We’ll source it.

See our used forklifts in stock, hire before you buy, or book an inspection. Call 1300 326 654. We reply within 1 hour during business hours.