Mothballing Lift Trucks

\t OU DON'T have to be in the I Navy or the merchant fleet to become involved with equiPment mothballing. It can haPPen to anybody, particularly if slowdowns and temporary closings are at hand.

Many industrial lift truck users mothball equipment regularly, res- ponding to seasonal cYcles as in farm products and food Processing industries. Others react to problems peculiar to their industry or operation. Consequently, manY material handling managers, industrial engineers, maintenance managers and top management Personnel are concerned with mothballing.

Mothballing as an industrial technique is definitely increasing. Because lift trucks are carefullY specified for their tasks, managers want availability, despite production ups and downs. In addition, the trend toward small oPerations employing lift trucks, and to economically-priced, job-matched new trucks makes possession practical.

Everybody wants to keeP a good thing ready to go again lift trucks, direct production equiPment, backup oPerations.

However, field service reports indicate there have been Problems in the mothballing of lift trucks. Why trouble? No PreParation before storage. no in-storage service, no startup preparation.

Mothballing can be Profitable, if planned and executed carefully. It also must be weighed against alternatives such as leasing equiPment for seasonal work, renting lift trucks as needed, or renting Your trucks to someone else during slack periods. This profit appears as savings. Consequently, a most imPortant question for You to consider before mothballing is: "Will storing my lift trucks be less exPensive than just parking them?"

I propose to show that merelY parking unused equipment is the most expensive method of allowing it to be idle and to answer this question: "What is the least exPensive method of long-term storage?"

Mothballing is not exclusivelY a semi-permanent condition. Any lift truck'which is out of operation for more than 30 daYs should be Put in "mothballs" for very imPortant economic and operational reasons.

Planning for mothballing considers (1) duration of the idle period; (2) effects ofgeography and climate, (3) type of equipment, i.e., large, small, engine Powered, electric. etc.: (4) available storage facilitiesl (5) desirable maintenance during storage, and (6) availability of equipment when needed. Each factor influences other factors, as does the reason for mothballing. For examPle, storage facilities will dictate to some extent the maintenance required while equipment is in mothballs. Now, for details on these factors.

Duration is different in each case, but as a rule of thumb, the longer lift trucks are to be idle, the more thorough the mothballing required.

Idle time is the enemy of machinery. A certain amount of deterioration will result, even with the best maintenance. The longer equipment is idle, the more pronounced will be dry rotting, cracking, hardening, rusting and corroding of various components. But this gradual deterioration can be minimized.

The type of storage facilities required is influenced by duration; short periods do not require such substantial facilities as do longer periods because harmful situations do not have as much time to develop.

What kind of facilities are readily available to you? In some cases, inside space may become free due to general shutdown and so can be used for storage with minimum preparation. Sometimes only outside storage may be available, which requires more extensive protection arrangements than does inside storage.

Storage requires use of light canvas or plastic draped over the entire machine wherever long duration is involved. Dirt and dust are always present. Some short storage will permit partial coverage, general conditions permitting. Where full covering is involved, you may economically cover two or more trucks with a single cover. But whatever type of cover you choose, arrange access for service. This means the covering must be easily removed for regular maintenance. Large equipment may require sectionalized covers.

In all cases. however. it is important that you recognize potential hazards and special conditions created by climatic conditions. security problems, ambient dirt and the like. No situation is free from potential hazards so you must anticipate adverse conditions and plan to accommodate them. Whatever you do, your arrangements must consider duration of storage, number and type of units to be stored, your available maintenance service and security limitations and the effect of hazards on these factors.

Outdoor storage exposes vehicles to weather extremes. causing condensation. deterioration of rubber and synthetic parts, and accelerated rusting and corrosion. Wildlife, particularly rodents, birds, and often snakes. are nuisances and can cause damage. Rodents will often gnaw wiring. Therefore, use a fitted cover for maximum protection.

Similar problems are encountered indoors. You can usually avoid wind. rain, snow and sun, but not condensation due to temperature changes. Therefore, be sure to permit adequate ventilation, anticipate incursions by wildlife, plus effects of heat and humidity.

If we agree that mothballing expense must be moderate, the type and degree of planned maintenance must be considered in light of cost. While putting a lift truck in cosmoline is impractical, it's the only way to mothball equipment without periodic maintenance. Alternatively, plan your mothballing in 30-day increments with an extension of periods as needed. Maintenance cycles of 30 days are recommended. This allows optimum availability with economical ratio between maintenance and extended storage. Case in point: an expected storage time was six weeks, but the unexpected occurred and the mothballs stayed on for an additional nine weeks.

All maintenance programs nlust start with plans flor easy access to the vehicles and sufficient room to operate them as required for tire service and lubrication. Service personnel must be given clear instructions and a checklist for each unit covering preparation. nraintenance and de-mothballing. They should be instructed to do repair work before mothballing, because time is then available, not during the rush of getting back into production.

Pre-Mothball Maintenance For Electric-Powered Trucks:

(l) Clean each unit - steam, high pressure water, etc. Protect sensitive items from water and steam, such as electrical components, air cleaner (dry type), and transistorized com ponents.

(2) Clean and paint bare metal. Remove rust and repaint.

(3) Inspect electrical wiring for chafes, crackes, and other signs of deterioration. Repair and/or replace as necessary. The entire electrical system should be working properly.

(4) Check the hydraulic system for proper operation, leaky fittings, snug hose and pipe clamps, incipient hose ruptures. Repair or replace as necessary. Drain and flush the system. Refrll with a hydraulic oil suitable for storage. After reassembly of parts, operate all controls and retract all cvlinders. if oossible.

(5) Drain and flush cooling system. Refill with a proper mixture of water and glycol, usually 50/ 50. Run engine until it reaches normal operating temperatures, allowing antifreeze to mix thoroughly in order to allow thorough, uniform coating of water passage walls. thus reducing heat transfler.

(6) Tune the engine so that maintenance during storage and demothballing cleanup will be simplified. Pay particular attention to spark plugs, ignition points, timing adjustment, cleaning, and resetting of nozzles on diesels. Drain engine oil. refill with an oil suitable for the unit, temperature and storage. Replace the filter. Disconnect fuel lines from the engine. With the engine cold, spray an atomized preservative into the air intake while cranking it. Approximately three to eight

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Preface To Checklist

All needed repairs should be .made prior to storage.

::,,CHECKLIST FOR f,LECTRIC TRUCKS

(l) Elecrrical checkout

(2) Remove battery a. Electr_olyte level b. Specific gravity c. Outside clean

(3) Clean and spot paint rusty or corrosive spots

(4) di;;; control boards (PwM)

(5) Clean control panel (SCR)

(6) Clean power switch (PWM)

(7) Clean contactor panel

(8) Clean pump motors til iiei" hi'"d motors

(10) Check condition ofall wires and cables

CHECKLIST

For Internal Combustion Trucks

(l) Engine oil change

(2) Engine oil filter change

(3) Coolant leaks

(4) Coolant level

(5) Anri-freeze

(6) Battery electrolyte level

(7) Battery specific gravity

(8) Battery cleanliness iti i;;;;'Gon'ollna filter change

(10) Fuel systenr cleaned

( I | ) Fuel and fuel filters changed

(12) Air cleaner and hoses inspected

(13) Electrical wiring inspected

Checklist For General Service

jl) Hvdraulic oil leaks

(2) Hydraulic oil change

(3) Differential oil changed

(4) Lubrication of wheel bearings

(5) Lubrication of all linkage

(6) Tire air pressure corrected

(7) Brake fluid leaks

(8) Brake fluid level

(9) Rusting or corrosive spots cleaned and spot painted

(10) Exposed metal lubricated (cylindei rods) '..:l

(l l) Weight removed from sieei wheels