Shipboard Report Style-Final 05
Contents
1. Replace B 1 6 O ring on bottom of center cylinder NOTE To remove center cylinder remove B 1 28 center cylinder snap ring Be sure oil is in the reservoir Raise the B 1 26 lift ram a couple of inches so that it is not bottomed out Then strike top of lift ram firmly with a leather or rubber mallet The back pressure will jar the center cylinder loose where it can be hand removed 10 Internal Brake Parts Drawing 3 Item Part Qty Description Item Part Qty Description 1 DM 01 1 Spindle Stop 21 DM 21 1 Cable Housing 2 DM 02 2 Clapper Plate 22 DM 22 1 Cable Stainless Steel 3 DM 03 1 Long Link 27 DM 27 1 Pivot Shoulder Screw 4 DM 04 2 Short Link 28 DM 28 2 Link Shoulder Screw 5 DM 05 1 Pivot 29 DM 29 1 Pivot Pull Shoulder 6 DM 06 2 Pivot Pull 30 DM 30 2 Roll Pin 7 DM 07 2 Heavy Duty Spring 32 DM 32 2 Clapper Plate Pin 8 DM 08 2 Clamp for Housing 11 BRAKE WHEEL PARTS Drawing 4 5 39 9 27 6 3 Be an me SE i EE OEE GE 31 x 0x te 20 NENNEN Ej 30 1 Item Part Oty Description Item Part Qty Description 1 DM 01 1 Spindle Stop 20 DM 20 1 Steer Wheel Axle 3 DM 03 1 Long Link 27 DM 27 1 Pivot Shoulder Screw 4 DM 04 2 Short Link 29 DM 29 1 Pivot Pull Shoulder 5 DM 05 1 Pivot 30 DM 30 2 Roll Pin 6 DM 06 2 Pivot Pull 31 DM 31 2 Axle Washer 9 DM 09 2 Steer Wheel 12 26 21 22 HANDLE VIEW SIDE Item 10 12. 1 12 15 21 22 23 24 26 Part DM 08 DM 10 DM 11 DM 12 DM 15 DM 21 DM 22 DM 23 SS DM 24 DM 26 N A E E E E EU N Description Clamp for Housing Brake Handle Assy Handle Pivot Pivot Cable Lock Cable Tube Cable Housing Cable Stainless Roll Pin Stainless Washer Jam Nut 13 SHIPBOARD DEADMAN BRAKE CABLE REMOVAL AND ADJ USTMENT Remove both DM 06 and DM 12 pivot pulls Loosen associated set screws in the pivot pulls Remove DM 08 short and long bolts followed by the brake cable housing and the brake ca ble Replace the DM 21 brake cable housing and DM 22 brake cable Insert the DM 22 brake cable through both the DM 08 short and long bolts Install the DM 08 long bolt into han dle tube and DM 08 short bolt in the DM 01 spindle stop Replace both the DM 06 and DM 12 onto DM 22 brake cable Insert the brake cable into the bottom of the 3 32 hole Tighten associated set screws To set the brake release the DM 10 brake handle assembly Must be in Contact with the Steer Handle when the brake is fully disengaged Ifthe handle is not making contact with the steer handle proceed as follows Turn the DM 08 long short bolts in a clockwise rotation until the DM 10 brake handle makes contact with the steering handle Ifthe brake is not releasing proceed as follows Turn DM 08 long amp short bolts in counter clockwise rotation until the brake releases with DM 10 brake handle making contact
3. 1 B6 04 SS 2 Steer Wheel Axle Pin 2 DM 01 1 Spindle Stop 3 4 DM 02 2 Clapper Plate 3 DM 03 1 Long Link 3 4 DM 04 2 Short Link 3 4 DM 05 1 Pivot 3 4 DM 06 2 Pivot Pull 3 4 DM 07 2 Heavy Duty Spring 3 DM 08 Long 2 Clamp for Housing Assembly 3 5 DM 09 2 Steer Wheel Assembly 1 4 DM 10 1 Brake Handle Assembly 5 DM 11 1 Handle Pivot 5 DM 12 1 Pivot Cable Lock 5 DM 14 2 Static Strap includes mounting hardware DM 20 1 Steer Wheel Axle 2 4 DM 21 1 Cable Housing 3 DM 22 1 Cable Stainless Steel 3 DM 23 SS 4 Roll Pin Stainless 5 DM 24 2 Washer 5 DM 26 1 Jam Nut 5 DM 27 1 Pivot Shoulder Screw 3 4 DM 28 2 Link Shoulder Screw 3 DM 29 1 Pivot Pull Shoulder 3 4 DM 30 2 Roll Pin 3 4 DM 31 2 Axle Washer 3 4 DM 32 2 Clapper Plate Pin 3
4. N e e e A e N N e N N e e me he HL Description Load Wheel Thrust Bearing Hydraulic Pump Housing Center Cylinder 10M Screw Post Load Arm Load Arm Pivot Stainless Steel Cap Screw Pump Link Assembly Roll Pin Stainless Steel Washer Stainless Steel Center Cylinder O ring Bottom Steer Wheel Bearing Load Arm Snap Ring Bleeder Valve Release Plunger Stainless Steel Release Plunger O ring Pump Piston Seal Ball Pump Piston Stainless Steel Pump Piston U Cup Plug Load Pivot Ball Lift Ram 10M Stainless Steel Lift Ram Seal Cylinder Snap Ring Center Cylinder O ring Top Low Pressure Spring Lift Ram U cup 10M High Pressure Spring Stripper Bolt Nut Low Valve Ball Spring Air Seal Restrictor Restrictor O ring Spacer Cotter Pin Stainless Steel Roll Pin Stainless Steel Lock Nut Drawing 1 1 2 N N N N 17 Parts Index Continued Part Quantity Description Drawing B1 41N 1 Lock Nut 2 B1 40SS 10 Roll Pin 1 B1 42 2 Release Guide 2 B1 43 1 Release Bar 2 B1 44A 1 Handle Release Adj Nut 2 B2 1 Frame 2 B3 01L7 Spec 1 Left Bell Crank 1 B3 01R7 Spec 1 Right Bell Crank 1 B3 02 1 Bell Crank Axle 1 B4 01T GF 2 Load Wheel Fork w Grease Fit 1 B4 02 Spec 2 Load Wheel Fork Axle 1 B4 04 XD 1 Handle Pivot 2 B4 04 SS Spec 2 Load Wheel Axle Stainless Steel 1 B4 07 OSB 8 Load Wheel Bearing 1 B5 04A 1 Release Link Assembly 2 B5 6 2 Bushing 2 B5 A 1 Hand Release 2 B5 B 1 Nut 2 B6 01 Spec 2 Push Rod 1 B6 02 4 Push Rod Axle
5. PALLET MULE SHIPBOARD PALLET TRUCK 42 27 60 XTSB PARTS SERVICE MANUAL WESLEY INTERNATIONAL 3680 Chestnut Street Scottdale GA 30079 800 241 2869 404 292 7441 404 292 8469 Fax WWW PALLETMULE COM INTRODUCTION The factory installed oil in the Shipboard Pallet Mule is automatic transmission fluid type dextron 2 The hydraulic system holds approximately one pint of fluid and operates on approximately 1 2 pint of fluid The oil level and filler plug is located on the left hand side on the pump assembly approximately 2 inches down from the top of the pump To properly fill the reservoir lower forks remove level filler plug squirt fluid from squirt type oil can into hole until oil trickles out the bottom edge of the hole This is the maximum amount of fluid neces sary to operate properly The wiper seals around the top of the pump piston and lift ram are fully functional wiper rings and do not need to be replaced unless they are damaged as both the pump piston and lift ram can be removed directly from and reinstalled through the wiper seals without their having to be removed USE OF LOCTITE WHEN NECESSARY TO INSTALL A Preparation on the B1 15 5 pump piston seal involving installation in its oversize casting bore 1 The seal and its respective casting bore must be clean and free of debris and oil To clean Spray the casting bore surface and the outer perimeter of the pump seal with Locquic Primer Cleaner grade T and
6. POUM 19918 Y P9UM 19095 DO sse urejs Uld 491100 UBI DO sse urejs Uld OH Depot dumd omnegpAH DO sse urejs Uld OY JOAId e pueH Jegeds uondripsoq el ed ed ed Cl ed ei ed NYAN B VL NA dSO dU LO TA SS 70 94 UC TNOU SS dO0v Td Cd SS dI Td Wao 10TH SS HOYT4A vo vd GETH Ved INN Tv eseerey opueH Jeg OSPAPY pmy oo INN WOT Age SUT seo py Age Jur dung Burysng pars sso ureIs JeuseM Mas de JSO MAINS MN OSPOPY pueH uondripsoq SLIed MITA duing geo aA ed ANN NAN ei M ed Cd el ei E Vvv 1d er Tad cV Td NIT Td Vv0 Gd U TvOTd 9 Gd SS MvO Td dod gd 0 Td asd VG Ved SHIPBOARD PUMP REBUILD PROCEDURE Requires B1 10M 5 8 Hydraulic Kit Remove B1 28 Snap Ring at top of pump cylinder 2 Fluid level under Lift Ram B1 26 10M SS mush have approximately 1 5 2 under Lift O ONO S R LO 11 13 Ram U cup Procedure is as follows Place shop rag around the top of the pump to prevent oil splatter Firmly strike the top of the Lift Ram with a rubber mallet The fluid back pres sure will cause the B1 01 C Center Cylinder to lift out Remove the lift ram part B1 26 10MSS Remove B1 04 R L pump straps Lift out B1 17 5SS pump piston Remove both the B1 42 release guides and B1 13SS release plunger Remove the B1 20 hydraulic plugs 4 plugs along with the B1 35 B1 33 B1 31 springs Remove B1 16 balls 3 and the B1 13 RP rele
7. SBAIO M MOA POUM PLOT c JO 110 74 Iv eers ssepurejs ueDunjgeseopeH T SS EI T4 gI 9 XV XO POUM PLOT C 9eds c0 Td GE ees uojstq dung L GC 19 LI oz poy usnd T Z0 94 LE pars sse urejs UOS dumg L SS G TTA 9r poy usnd c oeds 10 94 9 ees JY L Goe 1d SI 9 XV ywen IPA I c0 d GE dno N uojstq dung L G81T4 TL UBI Pd IU NI L oeds HIO tH VE ATEA Dee L ITA CL yuen Pd PT L ode ZTIO d VE Buuds amssalg MOT L LC 19 CL Buu O meet L dse 1d EE Buuds amsseig UDH L CC 19 TI Joen L 8 T4 c Duck TEA 9ATeA MOT L GETH OL woyog DU 0 Ipu 17u00 L 90 14 TE Ted C 14 6 WOL dno n wey Yr L WOL c 19 OE DA T 0Z 19 8 WOT DOT e L WOT 21014 6c Dog Sny 1 L UI OE VV G dot Guu JepurA E I 6cTd 9c uy peoT I 9eds 0T4 T MN C drC Td LT Buri deus Y peor L 48014 Nog Jeddins c ve Td 9c Fa SSOTUTEIS OAI WIV PEOT Z SS D 0T4 c pars SSOTUMEIS WOT wey YMI L SS WOI 97 14 GZ Ae 99uM AS c 60 Wa I uondrnpseq NO Med mont uondrpseq NO Med wy SLAVd MAIA AGIS ee ZL TL 04 MA GN EA T L N TILI MG b CE G E LT ASS Lg bees Hi F meid BEI 7 j 18 J GS TC ES c Durme1g a6eg HUMO uo ISPI SHE MOTA dumg reoy duind prmge 0 permbae s Jeq pue shurids Stadt sjeas 1essooou Je surezuoo IDT AS LX09 L7 ZP POLL 39 Ted preogdrys 103 WI Aedsy ITTNEIP H 8 C MOL TA sds oneis Dog PYM Foie uld 9 XV
8. ase plunger Keep all parts clean during the reassemble process Replace all O rings U cups Wipers Springs and Balls Reassemble pump in reverse order of part removal applying one drop of non detergent SAE 30 oil to all o rings wipers and seals Fill pump in the upright position with Dextron Type 2 Automatic Transmission Fluid Fill to the bottom of the B1 20 filler plug with the Lift Ram in the lowered position Open B1 11 Bleeder Valve 1 8 turn to remove air trapped under the pump piston Close valve when fluid runs free of air Do not over tighten Reinstall pump and adjust B1 38 Restrictor screw to set lowering speed PALLET MULE HYDRAULIC SYSTEM Schematic No 1 showing pump filling from reservoir Ness Normal Action On the up stroke of the main handle we have the intake stroke which draws oil from the reservoir into the pump piston cylinder Ball 1 is pulled off its seat allowing oil from the reservoir to be pulled up under the piston balls 2 and 3 are seated by spring pressure TROUBLE SHOOTING EFFECT Air instead of oil is pulled into the pump piston on the intake stroke resulting in aloss of pumping effort on the subsequent pump stroke CAUSE Truck may have been turned upside down allowing air to be pulled into system CORRECTION Bleed system as follows 1 Place handle in near upright position allowing room for your hand to manipulate wrench 2 Open bleeder screw P N B 1 11 with Ya inc
9. eft Bellcrank 2 B4 01T GF Load Wheel Fork 2 3 15 COMMON HARDWARE ITEMS Part Description Size Quantity B1 03B Bolt Socket Head 10 24x11 4 1 B1 04B Hex Bolt Grade 5 1 4 20 x 11 4 2 B1 34 Bolt 3 8 16 x 4 1 4 2 B1 34B Nut Nylon Lock 3 8 16 2 B1 40CPSS Cotter Pin Stainless Steel 3 16x11 4 1 B1 40RSS Roll Pin Stainless Steel 3 16x 11 2 1 B1 40SS Roll Pin Stainless Steel 3 16 x 2 10 B1 41 Shoulder Bolt 3 8 18 x1 1 2 1 B1 41N Nut Nylon Lock 5 16 1 B1 42 Bolt Hex 1 4 20x11 2 2 B5 B Nut 10 24 1 B6 04SS Roll Pin Stainless Steel 3 16x 11 2 2 DM 30 Roll Pin Stainless Steel 18x3 4 2 DM 23 Roll Pin Stainless Steel 1 8 x 3 4 2 Suggested Spare Parts Part Description Quantity A3x4 POSB Load Wheel Assembly 1 AA 30 CR Thrust Bearing 1 B1 10M 5 8 Hydraulic Repair Kit 1 B5 HRS Handle Return Spring 2 DM 02 Clapper Plate 1 DM 07 Spring for Deadman Brake 2 DM 09 Steer Wheel Assembly 1 DM 14 Static Strap Kit 2 DM 22 Brake Cable 2 DM 21 Brake Cable Housing 1 Order Parts from Wesley International Cage 56250 Part A3X4POSB AA 30 CR B10110DM B1 01C 10M B1 03B B1 03 Spec B1 03C SS B1 04B B1 04 L R B1 04R SS B1 04W B1 06 B1 07RB OSB B1 08B B1 11 B1 13 SS B1 14 B1 15 5 B1 16 B1 17 5 SS B1 18 5 B1 20 B1 25 B1 26 10M SS B1 27 10M B1 28 B1 29 B1 31 B1 32 10M B1 33 B1 34 B1 34B B1 35 B1 36 5 B1 38 B1 38B B1 39 B1 40CP SS B1 40R SS B1 41N Parts Index Quantity 4 KA e e e e e e e N N e e e e e e e e We
10. h box end wrench 3 Push handle rest of the way down fast 4 Close bleeder screw snugly don t jam 5 Repeat if necessary You should now have a full handle stroke CAUSE Release plunger O rings and or pump piston O ring are worn and allow air to be pulled into system CORRECTION Replace release plunger O ring and or pump piston O ring PALLET MULE HYDRAULIC SYSTEM Schematic No 2 showing pump pressure stroke NORMAL ACTION On the downstroke of the main handle oil accumulated from the upstroke of the main handle is forced from the pump cylinder by the pump piston to the lift ram cylinder causing the lift ram to raise which in turn causes the frame and or load to raise Ball 2 is forced off its seat by the oil pressure Balls 1 and 3 are seated by spring pressure TROUBLE SHOOTNG EFFECT On the downstroke of the main handle the lift ram raises but drops back down when the main handle is raised If there isaload ori the forks you will not only see the lift ram drop back down but will feel back pressure on the handle CAUSE Ball 2 is not seating properly CORRECTION Remove B 1 33 spring and ball 2 wipe ball clean and probe ball seat with a magnetic pencil Reinstall spring and ball EFFECT On the downstroke or pump stroke of the main handle the lift ram does not raise CAUSE Ball 3 is not seating because of a particle under the ball or perhaps the release plunger i
11. justment of load lowering from extremely slow lowering to fast lowering depending on the handling requirements of the user EFFECT Load lowers too slowly CORRECTION Turn screw counter clockwise This action backs off screw and allows for faster release of oil from under lift ram EFFECT Load lowers too rapidly CORRECTION Turn screw clockwise This action further blocks passage and allows for slower release of oil from under lift ram EFFECT Main handle locks up cannot be pulled downward in pumping stroke CAUSE Restrictor has been screwed all the way into the outlet port under the ram blocking the flow of oil through the entire system CORRECTION Back off on restrictor screw PALLET MULE HYDRAULIC SYSTEM Schematic No 4 showing lift ram at top position with oil by pass NORMAL OPERATION When the load is fully raised the lift ram is at its top position which is controlled by the by pass which allows all additional oil pumped into the lift ram cylinder to flow back into the reservoir TROUBLE SHOOTING EFFECT Ram drifts down does not hold position CAUSE No 1 B 1 32 U cup that seals the lift cylinder has been cut by oil bypass No 2 B 1 6 O ring that seals the center cylinder into the tapered bore in the base of the pump housing has been nicked or chipped allowing oil from under the ram to by pass back into the reservoir CORRECTION No 1 Replace B 1 32 lift ram U cup No 2
12. ns years of trouble free hydraulic op eration SAFETY AND OPERATIONAL CONSIDERATIONS Read Manual before operating hand pallet jack Always make sure hand pallet truck is operated by trained personnel Keep hands feet and loose clothing clear of area beneath hand pallet truck Always make certain that your view is unobstructed in the direction that you are moving Do balance the load evenly on the forks Do Not exceed the maximum lifting capacity as shown on the id plate Do Not ride or carry personnel on hand pallet truck Do Not lift loads or objects with the fork tips Do Not use hand pallet truck on grades How to Operate To raise the load pump handle until load reaches desired height Hold the release lever up The truck will lower load Hold brake handle up to move Releasing brake handle will immediately apply brakes Take Hand Pallet Truck out of service immediately if Hydraulic pump is leaking Any fasteners are loose or missing Any part of the hand pallet truck is bent or damaged Brake does not automatically hold hand pallet truck in a locked position Drawing 1 ap 21 ml T 25 37 38 24 d la LLL Ke en Zz N P N SE 8 9 12 8 9 11 Uld OA 67 Ieg 10AId peoT I GZTA V POUM peoT T dSOdTXEV LV Tees Wey YT I WOL L714 c Dog Eau peoT 8 ASO LO TA EF Suny deus opuro L 9719 cc Teens SSOTUTEIS DKV POUM PLOT c oedssSTOH Z D O Jebunid oo C WTA 6L WJ O
13. s out of adjustment or hanging up so as to hold ball 3 off its seat allowing the oil to by pass and simply recirculate back through the reservoir and pump instead of applying pressure under the lift ram CORRECTION Remove B 1 35 spring and ball 3 Wipe ball clean and probe ball seat with a magnetic pencil Reinstall spring and ball PALLET MULE HYDRAULIC SYSTEM Schematic No 3 showing load release and lowering speed restrictor operation RELEASE OPERATION NORMAL ACTION Hand actuation ot the hand release lever located adjacent to the main handle activates the release plunger and rod which in turn pushes ball 3 off its seat allowing the oil that is holding the lift ram in a raised position to flow back into the reservoir with the resultant lowering of the lift ram and or load Ball 1 and 2 are seated by spring pressure TROUBLE SHOOTING EFFECT The load wil not release when the hand release lever is actuated CORRECTION The hand release adjustment nut needs to be adjusted downward on the short link P N B 1 44A EFFECT When a loaded truck is being pushed with the main handle in a vertical position the load lowers CORRECTION The hand release adjustment nut needs to be adjusted upward on the short link P N B 1 44A RESTRICTOR OPERATION The restrictor is a simple screw this screw is located at the rear lower portion of the hydraulic housing and is designed to enable the easy ad
14. then wipe with a clean rag 3 Next Spray the casting bore surface and outer perimeter of the pump seal again with Locquic Primer Cleaner grade T this time allowing to dry for approximately 5 minutes 4 Loctite Locquic Primer Cleaner grade T causes the Loctite retaining compound to harden faster and insures best results MIL Spec 22473 B Application of the Loctite Retaining Compound to the B1 15 5 pump seal and its respective over size casting bore MIL Spec R46082 1 Apply a coating of retaining compound to the inside perimeter of the casting bore Also apply a coating of retaining compound to the outside perimeter seal 2 Insert seal in casting bore allow 1 hour for proper hardening 3 Itis of great importance that the clearances between the mating parts be completely filled in or der to obtain a leak proof seal Make certain not to remove require material while wiping any excess specifically where the pump piston is involved Loctite is a material that hardens from a liquid state into a solid state when confined between mating parts without the presence of air The pump piston lift ram and release plunger cylinders are all burnished to a 10 finish In conjunction with this fine finish the Pallet Mule uses simplified packing consisting of polyurethane O rings and U cups This packing is made of the same tough resilient material that the wheels are coated with The combination of polyurethane working against this fine finish mea
15. with the steering handle 14 ne uNe DEADMAN BRAKE ASSEMBLY amp FRAME MAINTENANCE INSTRUCTIONS Inspect visually that all pins are in place Check tightness of all pivot screws Item 27 28 Drawing 3 Wipe down removing excess grease and foreign materials Oil any visible rust or corrosion spots One drop of moly disulfide bearing grease on each projecting clapper plate stop pins visi ble through holes in the Steer Wheel One drop of non detergent SAE 30 oil on the top end of Item 26 Drawing 5 on handle This will migrate down into Item 8 lubricating both Item 21 and Item 22 One drop of non detergent SAE 30 oil applied to the following locations Drawing Item Part Description 1 18 B1 13 SS Release Plunger Stainless Steel 1 25 B1 2610MSS Lift Ram 10M Stainless Steel 1 33 B1 38B Restrictor O ring 1 17 B1 15 5 Pump Piston Seal 1 16 B1 17 5 SS Pump Piston Stainless Steel 5 8 DM 8 Housing Clamp Adjustable 3 28 DM 28 Link Shoulder Screw 5 27 DM 27 Pivot Shoulder Screw 5 26 DM 26 Jam Nut 5 15 DM 15 Cable Tube Welded to Handle With pump handle turned 90 degrees reach inside of wheels and apply oil to Clapper Plate Pin Item 32 Drawing 3 one inside of each wheel Apply grease to 1 4 fitting with Corrosion Control Mystic Mfg P N J T6 HI T P type grease in the following locations Part Description of Fittings DM 09 Steer Wheel Assembly 2 B3 01 R7 Spec Right Bellcrank 2 B3 01L7 Spec L
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