Go behind the scenes at Forklift Exchange as our technicians transform a non operational 2005 Versa Lift 40/60 into a fully refurbished forklift through a complete mechanical and cosmetic restoration. Follow the entire process from initial inspection and major mechanical repairs to final testing, customer delivery, and a return to service.
This Versa Lift 40/60 refurbishment documents the complete transformation of a non operational 2005 forklift into a fully refurbished machine, from initial inspection through customer delivery.
When most people looked at this 2005 Versa Lift 40/60, they saw a forklift that had reached the end of its service life. It had been sitting unused for several years at a company in the Chicago area after a failed lift cylinder left it non operational. The hour meter no longer worked, hydraulic oil coated the lift cylinder, and years of inactivity had taken their toll on the machine’s appearance.
We saw something different.
Our family’s experience in the high capacity forklift industry dates back to the 1980s. As extendable counterweight forklifts emerged in the late 1990s and became the preferred solution for machinery movers and rigging companies, we focused our expertise on these highly specialized machines. Over the years, we’ve bought, sold, serviced, and refurbished hundreds of extendable counterweight forklifts, giving us the experience to look beyond faded paint and cosmetic wear to evaluate what really matters: the structural integrity, drivetrain, hydraulic systems, and long term serviceability of the machine.
The opportunity came to us through our longtime partner, Revelation Machinery, who had been working with the company that owned the forklift. After learning the machine was available for sale, they contacted us to determine whether it was a good candidate for refurbishment.
Before making an offer, we traveled to inspect the forklift in person. These initial inspections are not intended to identify every repair a machine may need. Instead, they allow us to evaluate the overall condition of the truck, identify major repairs, and determine whether it has the right foundation for a complete refurbishment.
Although the forklift looked rough cosmetically, two details immediately stood out.
First, it was equipped with the proven GM 3.0L industrial engine, a platform known for its reliability and long term parts availability. Versa Lift also used the Zephyr Winds 2.4L engine in some older machines, and replacement parts for those engines have become increasingly difficult to source. Finding a truck equipped with the GM engine immediately increased its long term serviceability.
Second, the boom showed remarkably little wear.
After inspecting the boom structure, wear pads, and hydraulic cylinders, it became clear that although the truck had spent years out of service, it likely had not accumulated the heavy use its appearance suggested.
Those observations gave us confidence that this was more than just an old forklift.
It was a solid machine that deserved a second life.
Once the purchase was complete, the forklift was transported to our Bedford Park, Illinois facility, where a six week refurbishment began. What followed was not simply a repaint. It was a complete mechanical and cosmetic restoration that transformed a non operational forklift into a dependable machine built specifically for its new owner, Midwest Crane Services of Tulsa, Oklahoma.
As part of the transaction, Midwest Crane Services traded in their 2002 Royal T350C as they expanded their rigging capabilities and returned to operating a 40/60 extendable counterweight forklift.
This is that story.
Machine: 2005 Versa Lift 40/60
🏗️ Machine:
2005 Versa Lift 40/60
📍 Customer:
Midwest Crane Services
Tulsa, Oklahoma
🏢 Refurbishment Facility:
Forklift Exchange
Bedford Park, Illinois
📅 Project Timeline:
May 13, 2026 through June 24, 2026
🔍 Initial Condition:
• Non operational
• Lift cylinder failure
• Unknown hours due to inoperative hour meter
• Machine had been sitting unused for several years
⭐ Customer Requested Upgrades:
• Custom paint color
• Rear view backup camera
• Boom mounted lifting ring
🔧 Major Mechanical Repairs:
• Complete lift cylinder rebuild
✅ Testing Performed:
• Complete operational inspection
• Full capacity load test
• Successfully tested at 60,000 pounds with a 36 inch load center
🛡️ Warranty:
12 Month Powertrain Warranty
One of the biggest misconceptions about refurbished equipment is that every used forklift is a good candidate for rebuilding.
That simply is not true.
A successful refurbishment begins long before the first wrench is turned. It starts with selecting the right machine.
When Revelation Machinery contacted us about this Versa Lift, we knew it would require significant work before it could return to service. The failed lift cylinder had sidelined the truck, and years of inactivity had left it looking tired and neglected.
However, cosmetic appearance has never been our primary concern.
During our inspection, we focus on the components that truly determine whether a machine is worth rebuilding.
Is the frame structurally sound?
How much wear is present in the boom?
What engine does it have?
Are replacement parts readily available?
Does the machine have a solid foundation that justifies the investment required for a complete refurbishment?
Those questions are far more important than faded paint or surface rust.
In this case, the answers gave us confidence to move forward.
The GM 3.0L engine provided an excellent foundation, the boom showed minimal wear, and the truck had the characteristics we look for when investing in a major refurbishment.
Years of experience have taught us that not every forklift deserves a second life.
This one did.
Once the forklift arrived at our Bedford Park facility, the detailed inspection began.
The purpose of this inspection is not simply to identify broken parts.
It is to develop a complete understanding of the machine before work begins.
Every major system is evaluated, including:
The inspection confirmed that the lift cylinder represented the most significant mechanical issue.
Hydraulic oil covered the outside of the cylinder, indicating the internal seals had failed. Because the lift cylinder is responsible for raising and lowering the mast under load, it is one of the most important hydraulic components on the forklift.
Rather than attempting a temporary repair, we made the decision to remove the cylinder completely and send it to a specialized hydraulic repair facility for a full rebuild.
Fortunately, the inspection also confirmed what we had hoped to find.
The engine was in excellent condition and required only our complete 2,000 hour preventive maintenance service along with several updates to the LP fuel system.
Likewise, the boom structure, wear pads, and boom cylinders all inspected well and required very little corrective work.
That combination is exactly what we hope to find during a refurbishment.
Address the major mechanical issues while preserving the components that have already stood the test of time.
Every forklift tells a story.
Knowing how to read that story comes from experience.
Our family’s history in the high capacity forklift industry spans more than four decades. Since extendable counterweight forklifts became a preferred solution for machinery movers and rigging companies in the late 1990s, we’ve focused on buying, selling, servicing, and rebuilding these specialized machines.
That experience allows us to recognize details that others may overlook.
It tells us which engines have proven themselves over time.
Which components deserve extra attention.
Which repairs should never be postponed.
And perhaps most importantly, it tells us when a machine is truly worth saving.
That experience also extends to the technicians performing the work.
The team assigned to this project has more than 20 years of experience building new Hoist FR forklifts while servicing and refurbishing Versa Lift, Royal, Toyota, and other extendable counterweight forklifts.
One of those technicians, Sergio, handled all of the electrical work throughout the project. His ability to diagnose and repair complex electrical systems is the result of decades spent working on specialized material handling equipment.
Experience like that cannot be replaced by a service manual.
It is earned one forklift at a time.
Once the inspection was complete, it was time to develop a detailed refurbishment plan.
Every forklift that enters our Bedford Park facility is different. Some require extensive drivetrain work, while others may need hydraulic repairs, structural work, or cosmetic restoration. No two refurbishment projects are exactly alike, which is why every machine receives its own scope of work based on its condition.
For this Versa Lift 40/60, the failed lift cylinder became the primary focus, but it was far from the only item addressed during the project.
Our technicians developed a comprehensive refurbishment plan that included mechanical repairs, preventive maintenance, operator compartment improvements, electrical updates, cosmetic restoration, and final testing.
The work performed included:
By the time the project was complete, more than $54,000 had been invested in parts, labor, and specialized outside services, demonstrating our commitment to restoring the machine properly rather than simply preparing it for resale.
That investment reflects our philosophy toward refurbishment. We don’t simply repair enough to make a forklift operational. We restore the machine so it can provide dependable service for years to come.
One of the biggest misconceptions about refurbished equipment is that the process begins in the paint booth.
For us, it begins underneath the paint.
Before any cosmetic work was performed, our technicians concentrated on restoring the forklift mechanically.
The first priority was removing the failed lift cylinder.
Hydraulic oil had coated the outside of the cylinder, indicating the internal seals had failed. Because the lift cylinder is responsible for raising and lowering the mast under load, it is one of the most important hydraulic components on the entire forklift.
Rather than attempting a temporary repair, the cylinder was removed and sent to a hydraulic repair specialist for a complete rebuild.
Only after it was fully rebuilt did it return to our shop for installation.
With the lift cylinder removed, our technicians continued inspecting and servicing the remainder of the hydraulic system while performing the complete preventive maintenance required throughout the truck.
At the same time, the GM 3.0L engine underwent our complete 2,000 hour preventive maintenance service.
During the inspection we confirmed that the engine itself remained in excellent condition. Instead of requiring major mechanical repairs, it received fresh filters, fluids, routine maintenance, and updates to portions of the LP fuel system to ensure dependable operation.
Finding an engine in this condition reinforced what we had seen during the initial inspection.
Although the forklift looked rough cosmetically, its foundation remained remarkably solid.
One of the advantages of rebuilding hundreds of extendable counterweight forklifts is knowing where to look.
While the failed lift cylinder required immediate attention, our inspection of the boom revealed a pleasant surprise.
Despite the truck’s appearance, the boom itself showed very little wear.
The wear pads remained in good condition, the boom cylinders inspected well, and the structure showed none of the excessive wear commonly found on heavily used machines.
That discovery confirmed what we had suspected during the initial inspection.
This forklift had spent years sitting idle, but it likely had not accumulated the heavy operating hours that many people would have assumed simply by looking at it.
That is exactly why experience matters.
The appearance of a forklift rarely tells the entire story.
Knowing how to evaluate what cannot immediately be seen is what separates a quality refurbishment from simply preparing a used machine for sale.
One of the unique aspects of this project was that the forklift had already been sold before the refurbishment began.
Midwest Crane Services of Tulsa, Oklahoma purchased the Versa Lift knowing it would undergo a complete mechanical and cosmetic refurbishment before delivery.
Every customer has different operating requirements. Because this truck was sold before the refurbishment began, we were able to work directly with Midwest Crane throughout the restoration process to configure the forklift specifically for the way they intended to use it.
For many years, Midwest Crane had operated Versa Lift forklifts as part of their rigging fleet. As their business evolved, those machines were eventually replaced.
As the company expanded its rigging capabilities once again, they knew they wanted another 40/60 extendable counterweight forklift.
Just as importantly, they specifically wanted an older Versa Lift.
Like many experienced machinery movers, they appreciate the simplicity of the earlier Versa Lift models. With fewer electronics, proven components, and straightforward serviceability, these machines remain a popular choice for companies that value reliability and ease of maintenance.
Rather than restoring the truck in its original colors, Midwest Crane selected a custom gray and black paint scheme that reflected their company’s preferences.
They also requested two practical upgrades.
A rear view backup camera was installed to improve visibility while maneuvering on busy jobsites.
A boom mounted lifting ring was added to provide an additional lifting point for handling suspended loads.
The result was more than a refurbished forklift.
It was a machine mechanically restored, customized, and prepared specifically for Midwest Crane Services, ready to return to work on day one.
Only after the mechanical work was complete did the cosmetic restoration begin.
Every body panel was removed, inspected, repaired where necessary, and carefully prepared for paint.
The chassis, mast, boom, carriage, counterweights, and sheet metal were refinished before receiving an entirely new set of decals.
To many people, this stage represents the transformation of the project.
The faded, worn forklift that arrived at our shop now looked like an entirely different machine.
While the visual transformation is certainly satisfying, we believe it represents something much more important.
The fresh paint is simply the final reflection of the work already completed underneath it.
A professionally painted forklift that still suffers from mechanical issues isn’t truly refurbished.
By completing the mechanical work first, we know the finished appearance accurately represents the quality of the machine beneath it.
One aspect of our refurbishment process often goes unnoticed, but it plays a significant role in the quality of the finished product.
Whenever possible, the same technicians who disassemble the forklift remain with the project through mechanical repairs and final reassembly.
That consistency matters.
The people reinstalling every hose, wire, bracket, and hydraulic component are the same people who originally removed them.
It eliminates unnecessary guesswork, improves quality control, and helps ensure that small details aren’t overlooked during reassembly.
Like every other part of our refurbishment process, it reflects a simple philosophy.
Do the job once.
Do it correctly.
Build a forklift we’re proud to stand behind.
As the refurbishment neared completion, the focus shifted from rebuilding the forklift to verifying that every system performed as intended.
Every major function of the machine was inspected and tested before it was approved for delivery. Hydraulic functions, steering, brakes, electrical systems, safety equipment, and operator controls were all checked to ensure the forklift operated the way it was designed to.
With the rebuilt lift cylinder reinstalled, the truck successfully completed a full capacity load test at 60,000 pounds with a 36 inch load center. This final test confirmed that the hydraulic system performed properly under load and gave both our team and our customer confidence that the forklift was ready to return to service.
Testing is one of the most important steps in any refurbishment.
Replacing parts is only part of the process. Verifying that every repair performs correctly before the forklift leaves our shop is equally important.
Only after every inspection and test was complete was this Versa Lift approved for shipment.
With the refurbishment complete, the forklift was carefully prepared for transportation to Midwest Crane Services in Tulsa, Oklahoma.
Protective coverings were installed where needed, the operator compartment was secured, and the machine was professionally loaded and tied down for the journey south.
Although the refurbishment had taken nearly six weeks, we understand that every customer is eager to put their new equipment to work. Taking the time to properly prepare the forklift for transportation helps ensure it arrives in the same condition it left our facility.
Attention to detail doesn’t end when the repairs are finished.
It continues until the machine reaches its new owner.
One of the most rewarding moments in any refurbishment project is seeing the machine unloaded at the customer’s facility.
After weeks of planning, repairs, testing, and preparation, this Versa Lift 40/60 was delivered to Midwest Crane Services, where it immediately became part of their expanding rigging fleet.
For Midwest Crane, the purchase represented more than simply adding another forklift.
It marked their return to operating a 40/60 extendable counterweight forklift as they continued growing their rigging capabilities.
Their familiarity with older Versa Lift models made this refurbishment an ideal fit. They appreciated the simplicity of these machines, their proven reliability, and the ease of servicing compared to more electronically complex equipment.
Since delivery, the forklift has performed exactly as intended.
Perhaps the best compliment we can receive is that the customer has already told us they plan to purchase another refurbished forklift from us when the right machine becomes available.
To us, repeat customers are the strongest indication that we’ve done our job well.
One of the biggest misconceptions about refurbished equipment is that refurbishment is primarily cosmetic.
Nothing could be further from the truth.
Fresh paint may be the most noticeable part of the project, but it’s also the last step.
The real work happens long before the forklift enters the paint booth.
It happens during the inspection that determines whether a machine is worth rebuilding.
It happens while diagnosing hydraulic problems.
It happens while rebuilding critical components.
It happens while performing preventive maintenance, testing electrical systems, replacing worn parts, and verifying that every function performs properly before delivery.
That’s the difference between restoring a forklift and simply making one look newer.
At Forklift Exchange, our goal has never been to build the cheapest refurbished forklift.
Our goal is to build one we’re proud to put our name behind.
Completing the refurbishment and delivering the forklift isn’t the end of the project. It’s the beginning of the relationship.
Every major refurbishment we complete is backed by our 12 Month Powertrain Warranty, but we’ve always believed our responsibility extends well beyond the warranty period.
Mechanical equipment is just that… mechanical. Even the best maintained forklifts occasionally need service, technical advice, replacement parts, or simply someone to answer a question.
When that happens, we want our customers to know we’re still here.
Our family’s reputation has been built on supporting customers long after the sale is complete. Many of the companies we work with have been doing business with us for years, and some for decades. Those long term relationships weren’t built by simply selling forklifts.
They were built by standing behind every machine we sell and every customer we serve.
Midwest Crane is a great example. Since taking delivery of this Versa Lift 40/60, the forklift has performed exactly as intended, and we’ve received no reports of mechanical issues. More importantly, they’ve already told us they’ll be back when the next opportunity comes along.
To us, that’s the greatest compliment we can receive.
When this 2005 Versa Lift 40/60 arrived at our Bedford Park facility, many people would have seen an old forklift that had reached the end of its useful life.
We saw a machine with the right foundation, the right engine, and the potential to return to productive service.
Six weeks later, that’s exactly what happened.
Through careful inspection, mechanical repairs, preventive maintenance, customization, cosmetic restoration, and extensive testing, the forklift was transformed into a dependable machine built specifically for Midwest Crane Services.
Projects like this are the reason we enjoy what we do.
Every forklift has a story.
Sometimes, all it needs is the right team to write the next chapter.
One of the reasons we document projects like this is simple.
Anyone can advertise a refurbished forklift.
Very few companies are willing to show exactly how that refurbishment was completed.
By sharing the process from initial inspection through final delivery, we hope our customers gain a better understanding of the work, experience, and attention to detail that goes into every major refurbishment completed at Forklift Exchange.
Purchasing a professionally refurbished Versa Lift can provide significant cost savings compared to buying new while maintaining the lifting performance and reliability required by machinery movers, riggers, steel fabricators, and industrial contractors. Every refurbishment performed by Forklift Exchange is tailored to the customer’s requirements and thoroughly inspected before delivery.
Whether you’re searching for a refurbished Versa Lift, Hoist, Royal, Toyota, or another extendable counterweight forklift, our team can help you find the right machine for your application. We stock both refurbished and new forklifts and can recommend the best solution based on your lifting requirements, budget, and delivery timeline.
Every refurbishment begins with selecting the right candidate, performing a comprehensive inspection, developing a detailed repair plan, and restoring the machine to dependable operating condition. Before delivery, every forklift undergoes operational testing and a full capacity load test to verify performance.
If you’re considering adding an extendable counterweight forklift to your fleet, we’d be happy to discuss your application, your budget, and whether a refurbished machine is the right fit for your operation.
Contact Forklift Exchange today to discuss your application, request current inventory, or learn more about our forklift refurbishment program.
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