By the Power Forklifts team, with technical input from Rohit Jaswal, Service Technician at Power Forklifts. Updated November 2026.
A used forklift can be great value, but some of the most expensive faults are the hardest to spot on a quick look. These are the five problems our service team finds most often on used forklifts, what each one costs to fix, and how to check for it before you buy.
Costs are rough New Zealand guides from our workshop. They vary with the make, model and size of the machine.
1. Worn mast chains: about $1,500 or less
The lift chains carry the whole load. Over time they stretch, rust and lose lubrication, and a chain failure under load is a serious safety risk.
How to check: look for rust, stiff or kinked links, and uneven chain tension between the left and right chains. Ask when the chains were last inspected or replaced.
2. Worn solid tyres: about $3,000 for a full set, fitted
Solid tyres wear down, chunk and crack, especially on rough concrete or outdoors. As an example, a full set of solid tyres supplied and fitted on a 2-tonne LPG forklift recently came to about $3,050 excl GST. Bigger machines with bigger tyres cost more.
How to check: look for chunks missing, cracks, flat spots and the wear line. Worn tyres reduce stability and braking, and replacing them is often a sign the machine has done a lot of work.
3. A weak lead-acid battery: about $1,000 a cell, or up to about $10,000 for a full replacement
On a used electric forklift, the battery is often the single biggest cost. A battery that has been under-watered, left flat or charged badly loses capacity, and it may only run for part of a shift. One failed cell can sometimes be replaced for about $1,000. A full replacement battery can cost up to about $10,000, depending on its size.
“9,000–13,000 hours is possible with proper maintenance, but not guaranteed. It depends on how well operators look after it,” says Rohit Jaswal, Service Technician at Power Forklifts.
How to check: ask how old the battery is and how many hours it has done. Look for corrosion, low electrolyte or a swollen case. Ideally, have each cell tested. A battery check costs far less than a surprise replacement.
4. Hydraulic cylinder leaks: about $500 for a seal repair
Leaking lift or tilt cylinders let the mast creep down under load and leave oil on the floor. Replacing the seals in a cylinder costs about $500 including labour. It costs more if the cylinder rod is scored or bent.
How to check: lift a load to height and watch whether the forks creep down. Look for oil on the cylinders, hoses and floor, and pitting or rust on the chrome rods.
5. Electrical faults: about $3,000 for a new controller and motor
Intermittent faults in the controller, wiring or motors can be hard to find and expensive to fix. Replacing a controller and motor can cost about $3,000.
How to check: watch the dashboard for fault codes or warning lights. Drive the forklift and use every function, forwards and backwards, under load. Hesitation, jerky movement or cutting out are warning signs.
What about used lithium forklifts?
Lithium batteries need much less routine maintenance than lead-acid. The key part is the battery management system (BMS) inside the pack. From Rohit’s experience repairing lithium battery management systems, a BMS controller repair typically took 5–6 hours of labour and cost about $4,500 in total. Prices vary by manufacturer. Ask for the battery’s history and buy from a dealer who can support it.
Used forklift checklist
- Service history and hour meter reading. Do the hours match the wear?
- Mast chains, rollers and forks: wear, rust and cracks
- Tyres: chunking and the wear line
- Battery: age, hours, a cell test, and any corrosion or low water
- Hydraulics: leaks, and whether the mast creeps down under load
- Brakes, steering, horn and lights
- Dashboard fault codes, and a test drive using every function
- The load plate: does the capacity at your lift height suit your loads?
- LPG and diesel: starting, smoke and exhaust
Before you buy, also make sure the machine suits your site: capacity at your racking height, mast height for your doorways, and aisle width. See 6 forklift buying mistakes to avoid.
Buying used from a dealer
Buying from a forklift dealer instead of privately means the machine should have been inspected by a technician, problems fixed or disclosed before sale, and parts and service available afterwards. Always ask what warranty comes with the machine and what the pre-delivery check covers.
Frequently asked questions
What should I check when buying a used forklift?
Mast chains, tyres, the battery (on electric models), hydraulic leaks and electrical faults are the five most common hidden problems. Ask for the service history, and test drive the forklift under load.
How much does it cost to replace forklift tyres in NZ?
As a guide, a full set of solid tyres supplied and fitted on a 2-tonne forklift costs about $3,000 excl GST. Larger forklifts cost more.
How long does a forklift battery last?
A well-maintained lead-acid forklift battery can last 9,000–13,000 hours, but that depends heavily on charging and watering habits.
Find a used forklift
Browse our used forklifts for sale and new forklifts in stock, or call 09 838 0023. For servicing, see our guide to forklift service intervals. Comparing power types? Read LPG vs diesel vs electric vs lithium forklifts.
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