A used forklift can give years of service for a fraction of the cost of a new truck, but forks, chains and batteries are expensive to replace and are easy to overlook on a quick look. This checklist covers what to check before buying a used forklift, whether it is a diesel or LPG counterbalance truck, an electric truck or a reach truck.
Before you view
- Capacity and load centre. The data plate shows the rated capacity at a stated load centre, usually 500mm. Capacity falls at greater lift heights and with attachments, so check the figures for the heights and loads you need.
- Mast. Ask for the maximum lift height, the closed height (important for doorways and containers), and whether it has free lift.
- Hours and age. Compare the hour meter with the general wear. A low reading on a heavily worn truck can mean a replaced meter.
- Power. Diesel and LPG trucks suit outdoor and mixed use; electric trucks suit indoor work. For an electric truck, ask the age of the battery and whether a suitable charger is included, and check whether it needs a single-phase or three-phase supply.
- Paperwork. Ask for the current LOLER thorough examination report, the service history and the serial number.
Forks and carriage
- Look for cracks, especially at the heel where the blade meets the shank, and at the hooks.
- Check the thickness at the heel. Industry practice, based on the international standard for fork arms, is to withdraw a fork when wear has reduced the heel thickness by 10%.
- Check that the blades are straight and that both tips are at the same height.
- Check the positioning locks hold the forks in place, and that the carriage and any side shift move smoothly.
Mast, chains and hydraulics
- Check the lift chains for stiff or rusted links, damaged plates and uneven stretch. Worn chains are normally replaced as a pair and checked with a chain gauge.
- Look for oil on the lift and tilt cylinders, scored chrome, and weeping hoses and fittings.
- Check the mast rollers and channels for excessive play and wear.
Truck, cab and safety equipment
- The overhead guard should be undamaged, with no cutting, drilling or welding.
- An operator restraint, normally a seat belt, should be fitted and working where there is a risk of the truck overturning.
- Check the tyres for chunking, cracking and wear. Solid tyres usually have a wear line.
- Check the lights, horn, reversing alarm and beacon, if fitted.
- Check the steering for excessive play, and test the service brake and the parking brake on a slope.
Engine or battery
- Diesel and LPG. Start from cold if possible. Look for heavy smoke, oil in the coolant, and leaks. On LPG trucks, check the gas hoses, cylinder bracket and connections, and for any smell of gas.
- Electric. The battery is often the most expensive single part of an electric truck. Look for corrosion, damaged cell connectors and low electrolyte. Ask for recent cell readings or a discharge test, and check the battery lasts a full shift.
The test drive
- Drive forwards and in reverse, and check for knocks, jerky drive and transmission slip.
- Raise the mast to full height, unloaded and with a typical load if possible, and watch for jerky movement.
- Hold a load raised for a few minutes. If it creeps down or tilts forward, the cylinder seals may be worn.
- Use the tilt, side shift and any attachments through their full range.
After you buy
Forklifts must have a LOLER thorough examination at least every 12 months, and the rest of the truck must be maintained under PUWER. If there is no current report, arrange one before use; see LOLER thorough examinations. Operators must be trained and authorised, and HSE’s Approved Code of Practice L117 sets out the training expected for rider-operated lift trucks.
Summary: buying a used forklift
Check the capacity plate against your loads, inspect the forks, chains and mast, test the brakes, steering and hydraulics, judge the engine or battery, and ask for the thorough examination report. Then browse used forklifts for sale, or read the general guide to what to check when buying used machinery.
Used forklifts for sale
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Images: Photo: Rossographer, CC BY-SA 2.0, via Wikimedia Commons (Geograph)