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Easy Truck Material Handling
Published in: Knowledge Hub

Forklift Refurbishment Process

At Easy Truck we take pride in the refurbishment of our Toyota trucks. We truly believe it is one of many aspects of our operations that sets us apart from the rest. Our thorough process ensures you are buying equipment that is not only as visibly good as new but performs like new.

We address every aspect, from mechanical faults to aesthetic work. We take pride in only using original equipment manufacturer parts (OEM) and high-quality expert finishes. This leaves us with a truck indistinguishable from its brand-new counterpart.

Our team of engineers receive training on the brands Easy Truck specialises in, including Toyota, Bendi and Combilift, which allows them to provide the equipment with expert care and attention to ensure a high degree of quality.

Let’s follow this Forklift’s Refurbishment Process

Before:

Truck 10 Toyota Traigo 24v electric counterbalance 8FBE15T

Step 1 – Cleaning and Inspection

The first step in our refurbishment process is deep cleaning and inspection. This step removes all traces of dirt, oil, and potential leaks, prior to the truck’s refurbishment process. Our cleaning process includes spraying down the entire truck, including the undercarriage, followed by steam cleaning. This isn’t just about aesthetics; it’s crucial for ensuring the truck’s functionality and longevity.

After cleaning, our engineers conduct an inspection of the truck, identifying any issues that may have been hidden by dirt or oil. Fluid leaks, which can cause operational inefficiencies, are easier to detect on a clean machine, for example.

Our inspection goes beyond just a visual check. The Easy Truck engineers put the truck through a series of operational tests, simulating the conditions of its regular working life. This helps uncover any underlying mechanical faults, to ensure the truck will return to a high and dependable standard of performance.

Step 2 – Full Refurbishment Process

In our refurbishment process, our skilled engineers conduct a thorough inspection and replacement of parts. They identify and address common forklift faults, considering the average lifespan of a forklift and focusing on the most serious defects. This challenging phase ensures that the refurbished forklifts meet the high standards our customers expect from us.

The truck is put onto the line in our workshop and is stripped to the chassis, and the existing parts are diligently tested . A decision is then made whether to replace or refurbish parts, which can include the engine, chains, hoses, gearbox, motors, pumps, bearings, brakes, and more. Due to our confidence of the quality of our refurbished trucks we give the trucks a 12-month warranty. This warranty period is the same as most manufacturers give new equipment.
We also inspect the condition of the tyres and, based on the environment where the forklift will be used, we fit the appropriate tyres. But how do we decide which tyres are best? To find out more about our selection process, check out our article, “Introduction to Forklift Tyres”

Our expert engineer Richard, with over 20 years of industry experience, has provided us with the parts inspection and replacement process:

Properly maintained Toyota forklift trucks can continue working for 20+ years. This longevity is primarily due to preventative measures that address potential issues before they escalate, resulting in peak performance throughout its lifespan.

    • Our electric counterbalance forklifts are specially designed to withstand years of use if they are properly maintained and looked after. The battery is often the first to go if the truck is not responsibly maintained. However, with preventative maintenance such as topping up the battery acid with de-ionised water (lead acid batteries only), they have an average life of 5 years or 2000 charge cycles.
    • The engine, which is the heart of the forklift, is specially designed for longevity. Toyota industrial forklift engines in particular allow for quick acceleration and combine fuel efficiency with low maintenance and high durability. The term ‘bulletproof’ is often used to describe these engines, emphasising their robust and enduring nature.

However, these impressive lifespans are only achieved with regular maintenance and the use of OEM parts. Proper care, including regular inspection and replacement of worn parts, is vital to ensure the forklift continues to operate efficiently and safely.

As long as these necessary maintenance steps are taken, a Toyota forklift engine can deliver many years of reliable service.

Forks, chains, and brakes are some of the parts that require close attention due to the risk presented when they begin to wear and tear.

The forks bear the brunt of a forklift’s operational load. Over time, wear and tear can lead to a reduction in fork thickness. When this wear reaches 10%, it is essential to replace the forks due to the increased risk of failure, which can lead to accidents. In extreme cases, worn forks can snap rather than just bend, posing a significant safety risk.

The chains are another component requiring diligent maintenance. Faulty chains can lead to failures, leading to safety risks as well as loss of goods if the truck is in use. Regular inspections for wear, elongation, and corrosion are crucial to ensure the chains are in good working condition.

Lastly, the braking system is the forklift’s primary safety mechanism. Any defects in the brakes can lead to accidents due to the inability to stop the truck effectively. Regular inspections and replacements of brake pads and components are essential to ensure the system’s effective operation.

Refurbishment requires attention to detail, technical expertise, and a commitment to quality assurance. This careful inspection ensures the reliability of the refurbished truck, reducing field engineer workload and customer costs.

Each component is scrutinised for defects and wear, with substandard parts replaced with OEM parts. This guarantees that the refurbished truck adheres to Toyota’s original specifications and high-quality standards, ensuring peak performance and longevity.

The process is complex due to the need for thoroughness. Speed cannot compromise the integrity of the refurbishment process, as this could lead to overlooked defects and subsequently, suboptimal product performance or safety issues. It is a delicate balance requiring experienced engineers with in-depth knowledge and understanding of the equipment’s construction and performance requirements.

The commitment to delivering a product that is ‘as good as new’ is not just a company slogan but a philosophy embedded in the refurbishment process. It serves as a tribute to the dedication to quality and customer satisfaction that Easy Truck brings to every refurbishment project.

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Rich’s Background and Expertise

Rich’s journey into forklift engineering began early, inspired by his father, who was also a forklift engineer. He spent his school holidays in the garage, working on trucks as far back as he can remember. With 23 years of industrial experience, his expertise is built on a solid foundation of knowledge gained from his father.

Rich began his apprenticeship in 2001 and has dealt with every make of forklift. For Rich, the best part about working at Easy Truck is the continuous support from Toyota Material Handling UK.

The maintenance team receives significant support from Toyota, including the same training courses as undertaken by Toyota Material Handling engineers. Both in-house and service engineers receive training from Toyota Material Handling UK. This training is done regularly to ensure that the engineers stay updated with the latest technological advancements and the most current training.

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Step 3 – Paint and Bodywork

The third stage of our refurbishment process is dedicated to paint and bodywork. We focus on eliminating surface flaws like dents, chips, and scratches to restore the truck to its original aesthetic condition.

Our Bodywork Repair and Paint Specialist, Rob, applies his 30+ years of trade experience to bring the truck back to manufacturer standards. The forklift undergoes bodywork infills and a full repaint, making it look like new. Rob’s expertise, honed from his previous work in the automotive industry, ensures top-quality results.

We discussed all aspects of paint and bodywork with Rob:

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Our primary focus during the refurbishment process is the preparation of the truck’s paint and bodywork. This pivotal stage determines the quality of subsequent activities. It includes sanding, filling, and smoothing the truck’s surface until it is ready to be painted.

This stage is crucial as it sets the tone for the rest of the bodywork restoration. A poorly prepared surface can negatively affect the truck’s overall appearance and lead to premature paint failure. Therefore, we emphasise this aspect, ensuring every minute detail is addressed.

Our working process begins with a thorough inspection of the truck. This critical step ensures our meticulous sanding procedure effectively targets all problem areas. We use advanced power sanders to achieve a flat, smooth surface, eliminating rust and old paint, and setting the stage for subsequent steps.

Next, we identify and fill any surface imperfections with high-quality filler. Our detailed approach ensures the truck body has an even surface, which is essential for an exceptional paint finish.

Once the surface is ready, we begin the masking process, carefully covering areas that do not require painting. This process guarantees a professional finish. Following this, the truck body undergoes a primer coating, which provides better adhesion for the paint and adds a layer of protection.

The painting phase involves multiple layers of application to achieve a glossy, even finish. Precision is key here. Our techniques ensure the paint is uniformly distributed, avoiding runs or sags. Each layer is carefully inspected before proceeding to the next, guaranteeing a flawless outcome.

After a second thorough inspection for surface evenness, we apply three top coats. These layers not only enhance the aesthetic appeal but also strengthen the truck’s resilience against environmental factors, ensuring longevity.

Given the meticulous nature of the paint and bodywork phase in our refurbishment process, it usually takes 4 to 5 days to bring the truck back up to manufacturer standard.

I can honestly say I love what I do, I’ve been doing this since I was 11 with my dad. It makes me happy to work on something that comes in looking battered and being able to change it to look like new and knowing it is because of my work.

I find that each truck gives me a new challenge, meaning I’m always being challenged to find new ways to restore the truck back to new. The paintwork is something that keeps me engaged day in and day out as I have to keep an eye for detail and a steady hand.

For me this has become less of a job and more of a passion, it’s enjoyable watching the change of each truck and making it look like something that has just rolled off the factory floor.

Rich’s Tips for Forklift Longevity

Operating Environment:

  • Harsh conditions, like heavy salt environments, require more frequent and thorough servicing and maintenance.
  • Carefully maintained warehouses can significantly extend service life of trucks.

Regular Maintenance:

  • Conduct regular inspections and take immediate corrective actions to minimise the risk of major breakdowns.

Number of Operators:

  • Assigning a single driver to a truck ensures consistent handling, reducing wear and tear and promoting accountability for the vehicle’s condition.

Operator Care and Attention:

  • Damage to components like the overhead guard necessitates costly repairs and poses safety hazards.
  • Foster a culture of responsibility for machinery among operators to ensure longevity and safety.

After:

Forklift Refurbished

Conclusion

Our team takes pride in customer satisfaction which is why Easy Truck’s truck refurbishment process is a technical and detailed approach that ensures each truck is restored to top-notch condition. This process enhances the truck’s aesthetic appeal and secures its mechanical reliability, thereby extending its longevity. By focusing on thorough cleaning, inspection, and refurbishment, we strive to bring every truck in our possession back to an almost new condition.