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Flat Rate Guide

Version no

000

BT Prime-Mover, Inc.

LON Manual

1998-04-10

Flat Rate Guide

1. Purpose of the Guide

The flat rate guide purpose is to provide

BT Prime-Mover

dealers

with a tool to estimate the length of time required to

repair

BT Prime-Mover

products. The flat rate guide is

divided into separate model series sections. For example,
there is a section on HMX, RRX45, etc. Use the appropriate
section for the machine being repaired. The guide will also be
used to evaluate dealer warranty claims.

2. Using the Guide

Information for each repair operation is presented in four
columns:

Group

Operation Description

Labor Operation Number (LON)

Time

Group

Return

Summary of Contents for smx45

Page 1: ...te September 15 2005 Industrial Truck Flat Rate CMX60 80 CRX30 35 40 50 CSX10 20 30 40 OP15C OE35 OPX30 PMX QMX PMX45 SMX45 SN20 30 40 SR30 SC10 20 30 40 HMX RMX TMX WSX22 30 40 WRX30 RR30 34 45 RRX R...

Page 3: ...ation Number 4 Time 4 Review Of Labor Operation Times 4 CMX Model 5 CRX Model 9 CSX Model 23 OE15C Model 27 OE35 Model 29 OPX30 Model 33 PMX QMX Model 37 PMX45 Model 41 RDX30 Model 45 RMX HMX Model 49...

Page 4: ...BT Prime Mover Inc 2 Table of Contents SN SR Model 95 TMX Model 99 WRX Model 101 WSX22 30 40 Model 105 Labor Operation Time Review Request 109 Return...

Page 5: ...to repair BT Prime Mover products The flat rate guide is divided into separate model series sections For example there is a section on HMX RRX45 etc Use the appropriate section for the machine being...

Page 6: ...3 2 Labor Operation Number When an operation is performed the LON number is to be placed in the appropriate space on the warranty claim 3 3 Time The allowed time shown in this manual is the maximum ti...

Page 7: ...013 1 0 Electrical Replace Horn 2 001 0 3 Replace BDI 2 002 0 5 Replace Hourmeter 2 003 0 5 Replace Backrest Wiring Harness 2 004 1 0 Replace Key Switch 2 005 0 5 Replace Brake Interlock Switch 2 006...

Page 8: ...stat 2 080 0 3 Replace Cold Storage Heater 2 081 1 0 Replace Platform Switch 2 082 0 7 Replace Prime Trak Toggle Switch 2 083 0 3 Replace Prime Trak Limit Switch 2 084 0 3 Replace Prime Trak Solenoid...

Page 9: ...place Pull Rod 4 018 2 5 Replace Wheel Fork 4 019 1 0 Replace Lift Frame 4 020 4 0 Replace Lower Link Lift Frame 4 021 2 0 Replace Carrier Frame 4 022 4 0 Replace Stabilizer Caster 4 023 0 6 Replace C...

Page 10: ...8 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 11: ...3 Pad floor 2220 0 5 Pad elbow 2230 0 3 Pad seat 2240 0 5 Decal Any 2310 0 3 Case operators manual 2320 0 2 Battery gate 2400 0 1 Battery gate switch 2405 0 5 Battery roller 2410 0 25 Battery spacer p...

Page 12: ...druff 3250 0 7 Bearing wheel open 3260 2 6 Bearing wheel roller 3270 1 6 Bearing wheel cone 3280 2 6 Bearing wheel cup 3290 2 6 Seal steer assembly 3300 1 5 Pin spring steer 3310 0 3 Wheel hub assembl...

Page 13: ...unt 4330 0 7 Electrical System Broken wire repair 5000 0 25 Software PC Loader 5005 0 5 Vehicle manager 5010 0 5 Handle assembly 5020 0 3 Handle Left hand top 5030 0 4 Handle right hand bottom 5040 0...

Page 14: ...e contact switch ODI 5240 0 2 Panel assembly contactor 5300 0 6 Contactor Any 5305 0 4 Card assembly Fuse and Relay 5310 0 5 Plate contactor 5315 1 5 Fuse contactor assembly Any 5320 0 2 Insulator sta...

Page 15: ...mbly JC4 JL JTR and JL 5540 0 5 Cable assembly JF1 B TP4 5545 0 2 Cable assembly TPC 2 LA B 5550 0 3 Cable assembly LA B M1 A1 5555 0 3 Cable assembly LA M M1 A2 5560 0 3 Cable assembly RA B M2 A1 556...

Page 16: ...cable 5730 0 2 Lamp warning light assembly 5735 0 1 Light warning Amber or Red 5740 0 4 Lamp warning light assembly includes lens Amber or Red 5745 0 4 Lens warning light assembly Amber or Red 5750 0...

Page 17: ...es Element 6022 0 3 Filter element 6024 0 25 Manifold plug 313666 167 6026 0 25 Manifold elbow 90 degree Any 6028 0 3 Manifold adapter hydraulic Any 6030 0 3 Manifold fitting hose or elbow 6032 0 3 Ca...

Page 18: ...Mast 6420 0 5 Hose assembly Manifold A1 2 to HSA A1 A2 6430 0 5 Hose assembly Manifold A2 to AUX A2 6440 0 3 Hose assembly Manifold A2 to HSA A2 6450 0 5 Motor hydraulic steer 6500 0 5 Pump auxiliary...

Page 19: ...ift hose 7120 0 7 Mast main spacer pulley 2 Techs 7130 1 0 Mast main bearing chain roller 2 Techs 7140 1 1 Mast main bearing mast roller bottom top re shim 7150 0 5 Mast main pin pulley bracket center...

Page 20: ...inder sideshift assembly 7420 0 5 Cylinder sideshift carriage snap ring 7425 0 6 Cylinder sideshift carriage retainer ring or O Ring 7430 1 2 Cylinder sideshift carriage rod 7435 1 2 Cylinder sideshif...

Page 21: ...t quad mast 7675 0 1 Bracket outer upright quad mast 7680 0 4 Pad outer upright quad mast 7685 0 3 Bar outer upright quad mast 7690 0 3 Anchor chain outer inner telescopic quad mast 7695 0 7 Pin outer...

Page 22: ...right hand cylinder 7870 0 5 Spring right hand cylinder 7875 0 5 Guide right hand cylinder 7880 0 5 Fitting top right hand cylinder 7885 1 75 Service kit right hand or left hand cylinder 7890 1 75 Ser...

Page 23: ...0 2 Fitting reeving group Any 7968 0 3 Bracket reeving group 7970 0 5 Shreave shaft guard or plate reeving group 7972 0 2 Fitting mast installation 7985 0 3 Bar mast installation 7990 0 2 Hose mast i...

Page 24: ...22 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 25: ...Drive Tire 1 012 0 5 Replace Brake Shoe 1 013 1 0 Replace Handle Bumper 1 014 0 3 Electrical Replace Horn 2 001 0 3 Replace BDI 2 002 0 5 Replace Hourmeter 2 003 0 5 Replace Key Switch 2 005 0 5 Repl...

Page 26: ...2 081 1 0 Hydraulic Replace Reservoir 3 001 2 0 Replace Hydraulic Control Valve 3 002 2 5 Replace Two Stage Lift Cylinder 3 004 2 5 Reseal Two Stage Lift Cylinder 3 005 1 2 Replace Free Lift Cylinder...

Page 27: ...13 0 5 Replace Stabilizer Caster 4 023 0 6 Replace Caster Wheel 4 024 0 5 Replace Stabilizer Caster Spring 4 025 0 7 Replace Platform Cushion Bumper 4 026 0 5 Mast Carriage Shim Carriage 5 001 2 0 Shi...

Page 28: ...26 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 29: ...Replace Brake Interlock Switch 2 006 0 5 Replace Foot Pedal Switch 2 007 0 7 Replace Horn Switch 2 009 0 7 Replace Master Control Switch 2 010 1 0 Replace Potentiometer 2 014 1 0 Replace Drive Motor...

Page 30: ...Reseal Lift Cylinder 3 007 1 0 Replace any Hydraulic Hose 3 011 1 3 Replace Velocity Fuse 3 012 0 8 Replace Lift Pump 3 013 2 5 Replace Lowering Valve 3 014 0 7 Frame Replace Control Handle 4 003 1 0...

Page 31: ...ace Hourmeter 2 003 0 8 Replace Accessory Wiring Harness 2 004 2 0 Replace Key Switch 2 005 1 0 Replace Brake Foot Interlock Switch 2 006 0 5 Replace Start Switch 2 007 1 0 Replace Horn Switch 2 009 1...

Page 32: ...1 0 Replace Lift Pump Motor 2 039 1 5 Replace Lift Pump Valve Coil 2 043 0 5 Replace Brake Valve Coil 2 046 0 5 Replace Masts Cable 2 058 2 5 Replace 24 in Limit Switch 2 059 1 0 Replace 150 in Limit...

Page 33: ...Brake Valve 3 017 0 8 Replace Steer Pump 3 022 2 0 Frame Replace Control Handle 4 003 2 0 Replace Control Handle Support 4 004 1 5 Replace Transmission Eccentric Bearing One 4 007 1 0 Each Additional...

Page 34: ...e Column Roller 5 010 5 0 Wire Guidance Replace Indicator Light 7 001 1 0 Replace Auto Manual Switch 7 002 1 0 Replace Servo Motor 7 003 2 5 Replace Regulator 7 004 0 5 Replace Steer Servo FSA 7 005 0...

Page 35: ...0 3 Replace Brake Foot Interlock Switch 2 006 0 2 Replace Travel Alarm 2 007 0 3 Replace Horn Switch 2 009 0 9 Replace Control Handle 2 010 0 7 Replace Emergency Disconnect Button 2 011 0 5 Replace Em...

Page 36: ...in Limit Switch and adjust 2 060 0 2 Replace 226 in Limit Switch and adjust 2 061 0 5 Replace Turn Angle Limit Switch and adjust 2 062 0 5 Replace Chain Tensions Switch and adjust 2 063 0 5 Replace G...

Page 37: ...08 0 3 Replace Load Wheel 4 013 0 3 Mast Shim Carriage 5 001 3 5 Shim Inner Column 5 002 5 0 Shim Intermediate Column 5 003 5 5 Replace Carriage Roller 5 004 2 5 Replace Inner Column Roller 5 005 5 0...

Page 38: ...36 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 39: ...2 0 5 Replace Brake Shoe 1 013 1 0 Electrical Replace Horn 2 001 0 3 Replace BDI 2 002 0 5 Replace Hourmeter 2 003 0 5 Replace Handrail Wiring Harness 2 004 1 0 Replace Key Switch 2 005 0 5 Replace Br...

Page 40: ...place Drive Motor Brushes 2 073 1 0 Replace Pump Motor Brushes 2 074 1 5 Replace Battery 2 077 0 5 Replace Battery Charger 2 078 1 0 Replace Thermostat 2 080 0 5 Replace Heater 2 081 1 0 Hydraulic Rep...

Page 41: ...ft Frame 4 021 1 5 Replace Stabilizer Caster 4 023 0 8 Replace Caster Wheel 4 024 0 5 Replace Rider Platform Cushion Bumper QMX 4 026 0 8 Remove And Replace Rider Platform QMX 4 029 0 5 Replace Rider...

Page 42: ...40 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 43: ...eplace Drive Tire 1 012 0 3 Replace Brake Shoe 1 013 0 5 Electrical Replace Horn 2 001 0 3 Replace BDI 2 002 0 5 Replace Hourmeter 2 003 0 5 Replace Key Switch 2 005 0 5 Replace Brake Switch 2 006 0 5...

Page 44: ...Lift Limit Switch 2 069 0 3 Replace Drive Motor Brushes 2 073 0 5 Replace Pump Motor Brushes 2 074 1 5 Replace Battery 2 077 0 5 Replace Battery Charger 2 078 1 0 Replace Thermostat 2 080 0 5 Replace...

Page 45: ...r Inc 43 LON Manual 2005 08 15 Replace Wheel Fork 4 019 0 8 Replace Lift Frame 4 020 4 5 Replace Lower Link Lift Frame 4 021 1 5 Replace Stabilizer Caster 4 023 0 8 Replace Caster Wheel 4 024 0 5 Grou...

Page 46: ...44 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 47: ...1 016 2 0 Electrical Replace Horn 2 001 0 3 Replace Emergency Disconnect 2 002 0 8 Adjust Brake Switch 2 003 0 7 Replace Accessory Wiring Harness OHG 2 004 1 0 Replace Key Switch 2 005 1 0 Replace Br...

Page 48: ...t Electrical Cable 2 043 2 0 Replace Chassis Wiring Harness 2 044 3 5 Replace Hydraulic Solenoid Coil Each 2 045 0 5 Replace Reach Wiring Harness 2 046 1 0 Replace Steer Motor 2 047 0 7 Replace Steer...

Page 49: ...e Lowering Proportional Valve 3 015 1 0 Reseal Lowering Proportional Valve 3 016 1 5 Replace A B Valve 3 017 0 8 Reseal A B Valve 3 018 0 8 Replace Hydraulic Solenoid Valve Each 3 019 0 7 Replace Reac...

Page 50: ...e Height Indicator Cable 5 017 0 5 Reach Remove And Install Reach Assembly 5 009 1 5 Replace Front Frame 5 010 3 0 Replace Rear Frame 5 011 3 0 Replace Arm Roller 5 012 2 0 Install Sidshifter 5 014 3...

Page 51: ...place Brake Shoe 1 013 1 0 Replace Handle Bumper 1 014 0 3 Electrical Replace Horn 2 001 0 3 Replace BDI 2 002 0 5 Replace Hourmeter 2 003 0 5 Replace Handrail Wiring Harness HMX Only 2 004 1 0 Replac...

Page 52: ...Harness 2 059 1 0 Replace Handle Harness 2 063 1 5 Replace Lift Switch 2 064 0 5 Replace Lower Switch 2 065 0 5 Replace Reverser Switch 2 066 1 0 Replace Lift Switch Handrail HMX Only 2 067 0 5 Replac...

Page 53: ...d 4 018 2 5 Replace Wheel Fork 4 019 1 0 Replace Lift Frame 4 020 4 0 Replace Lower Link lift Frame 4 021 2 0 Replace Carrier Frame 4 022 4 0 Replace Stabilizer Caster 4 023 0 6 Replace Caster Wheel 4...

Page 54: ...52 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 55: ...able 1 017 1 5 Electrical Replace Horn 2 001 0 5 Replace BDI 2 002 0 5 Replace Hourmeter 2 003 0 5 Replace Accessory Wiring Harness 2 004 1 0 Replace Key Switch 2 005 0 5 Replace Brake Interlock Switc...

Page 56: ...Pump Motor Armature 2 040 1 8 Replace Lift Pump Motor Fields 2 041 1 8 Replace Speed Limit Switch 2 042 1 0 Replace Mast Electrical Cable 2 043 3 5 Replace Chassis Wiring Harness 2 044 3 5 Replace One...

Page 57: ...elocity Fuse 3 012 0 8 Replace Lift Pump 3 013 3 0 Reseal Lift Pump 3 014 3 5 Replace Auxiliary Pump 3 015 1 5 Reseal Auxiliary Pump 3 016 2 0 Replace Torque Generator 3 017 1 5 Reseal Torque Generato...

Page 58: ...e Carriage Roller 5 004 2 5 Replace Inner Column Roller 5 005 4 0 Replace Intermediate Column Roller 5 006 4 5 Install Mast 5 007 2 5 Reach Replace Center Pivot Bearing 5 008 3 0 Replace Front Frame 5...

Page 59: ...ose 1 010 1 2 Adjust Brakes 1 011 0 5 Replace Drive Tire 1 012 0 6 Replace Brake Shoes 1 013 1 2 Replace Support Yoke 1 014 3 0 Replace Brake Pedal 1 016 1 0 Electrical Replace BDI 2 002 0 5 Replace H...

Page 60: ...3 0 6 Replace Capacitor 2 034 1 1 Replace Reactor 2 035 1 1 Replace Battery Connector 2 036 0 6 Replace One Power Cable 2 037 1 0 Repair Open Wire 2 038 1 0 Replace Lift Pump Motor Each 2 039 1 5 Repl...

Page 61: ...3 005 2 0 Replace Free Lift Cylinder 3 006 3 0 Reseal Free Lift Cylinder 3 007 1 0 Replace Staging Cylinder 3 008 3 5 Reseal Staging Cylinder 3 009 1 2 Replace any Hydraulic Hose 3 011 1 3 Replace Ve...

Page 62: ...olumn 5 002 4 0 Shim Intermediate Column 5 003 4 5 Replace Carriage Roller 5 004 2 5 Replace Inner Column Roller 5 005 4 0 Replace Intermediate Column Roller 5 006 4 5 Install Mast 5 007 2 5 Reach Rep...

Page 63: ...st Brake Switch 2 003 0 7 Replace Accessory Wiring Harness OHG 2 004 1 0 Replace Key Switch 2 005 1 0 Replace Brake Switch 2 006 0 7 Replace Lift Potentiometer 2 007 1 0 Replace Reach Tilt Sideshifter...

Page 64: ...4 3 5 Replace Hydraulic Solenoid Coil Each 2 045 0 5 Replace Reach Wiring Harness 2 046 1 0 Replace Steer Motor 2 047 0 7 Replace Steer Sensor Each includes adjusting 2 048 1 0 Adjust Steer Sensor Eac...

Page 65: ...rtional Valve 3 016 0 5 Replace A B Valve 3 017 0 8 Reseal A B Valve 3 018 0 8 Replace Hydraulic Solenoid Valve Each 3 019 0 7 Replace Reach Cylinder 3 020 1 0 Reseal Reach Cylinder 3 021 1 5 Replace...

Page 66: ...able 5 017 0 5 Reach Replace Center Pivot Bearing 5 008 3 0 Remove and Install Reach Assembly 5 009 1 5 Replace Front Frame 5 010 3 0 Replace Rear Frame 5 011 3 0 Replace Arm Roller 5 012 2 0 Recondit...

Page 67: ...1 016 2 0 Electrical Replace Horn 2 001 0 3 Replace Emergency Disconnect 2 002 0 8 Adjust Brake Switch 2 003 0 7 Replace Accessory Wiring Harness OHG 2 004 1 0 Replace Key Switch 2 005 1 0 Replace Br...

Page 68: ...t Electrical Cable 2 043 2 0 Replace Chassis Wiring Harness 2 044 3 5 Replace Hydraulic Solenoid Coil Each 2 045 0 5 Replace Reach Wiring Harness 2 046 1 0 Replace Steer Motor 2 047 0 7 Replace Steer...

Page 69: ...Lowering Proportional Valve 3 015 1 0 Reseal Lowering Proportional Valve 3 016 0 5 Replace A B Valve 3 017 0 8 Reseal A B Valve 3 018 0 8 Replace Hydraulic Solenoid Valve Each 3 019 0 7 Replace Reach...

Page 70: ...Mast 5 007 1 0 Replace Height Indicator Cable 5 017 0 5 Reach Replace Center Pivot Bearing 5 008 3 0 Remove And Install Reach Assembly 5 009 1 5 Replace Front Frame 5 010 3 0 Replace Rear Frame 5 011...

Page 71: ...1 017 1 5 Electrical Replace Horn 2 001 0 5 Replace BDI 2 002 0 5 Replace Hourmeter 2 003 0 5 Replace Accessory Wiring Harness 2 004 1 0 Replace Key Switch 2 005 0 5 Replace Brake Interlock Switch 2 0...

Page 72: ...mp Motor 2 039 1 5 Replace Lift Pump Motor Armature 2 040 1 8 Replace Lift Pump Motor Fields 2 041 1 8 Replace Speed Limit Switch 2 042 1 0 Replace Mast Electrical Cable 2 043 3 5 Replace Chassis Wiri...

Page 73: ...3 Replace Velocity Fuse 3 012 0 8 Replace Lift Pump 3 013 3 0 Reseal Lift Pump 3 014 3 5 Replace Auxiliary Pump 3 015 1 5 Reseal Auxiliary Pump 3 016 2 0 Replace Torque Generator 3 017 1 5 Reseal Tor...

Page 74: ...5 Shim Inner Column 5 002 4 0 Shim Intermediate Column 5 003 4 5 Replace Carriage Roller 5 004 2 5 Replace Inner Column Roller 5 005 4 0 Replace Intermediate Column Roller 5 006 4 5 Install Sideshift...

Page 75: ...aulic Hose 1 010 1 2 Adjust Brakes 1 011 0 8 Replace Drive Tire 1 012 0 6 Replace Brake Shoes 1 013 1 2 Replace Support Yoke 1 014 3 0 Replace Brake Pedal 1 016 1 0 Electrical Replace Horn 2 001 0 5 R...

Page 76: ...2 033 0 6 Replace Capacitor 2 034 1 1 Replace Reactor 2 035 1 1 Replace Battery Connector 2 036 0 6 Replace One Power Cable 2 037 1 0 Repair Open Wire 2 038 1 0 Replace Lift Pump Motor 2 039 1 5 Repl...

Page 77: ...r 3 005 2 0 Replace Free Lift Cylinder 3 006 3 0 Reseal Free Lift Cylinder 3 007 1 0 Replace Staging Cylinder 3 008 3 5 Reseal Staging Cylinder 3 009 1 2 Replace any Hydraulic Hose 3 011 1 3 Replace V...

Page 78: ...7 5 Mast Shim Carriage 5 001 2 5 Shim Inner Column 5 002 4 0 Shim Intermediate Column 5 003 4 5 Replace Carriage Roller 5 004 2 5 Replace Inner Column Roller 5 005 4 0 Replace Intermediate Column Rol...

Page 79: ...st Brake Switch 2 003 0 7 Replace Accessory Wiring Harness OHG 2 004 1 0 Replace Key Switch 2 005 1 0 Replace Brake Switch 2 006 0 7 Replace Lift Potentiometer 2 007 1 0 Replace Reach Tilt Sideshifter...

Page 80: ...4 3 5 Replace Hydraulic Solenoid Coil Each 2 045 0 5 Replace Reach Wiring Harness 2 046 1 0 Replace Steer Motor 2 047 0 7 Replace Steer Sensor Each includes adjusting 2 048 1 0 Adjust Steer Sensor Eac...

Page 81: ...rtional Valve 3 016 1 5 Replace A B Valve 3 017 0 8 Reseal A B Valve 3 018 0 8 Replace Hydraulic Solenoid Valve Each 3 019 0 7 Replace Reach Cylinder 3 020 1 0 Reseal Reach Cylinder 3 021 1 5 Replace...

Page 82: ...001 Version no RSX40 Model 80 LON Manual 2005 08 15 Install Mast 5 007 1 0 Replace Height Indicator Cable 5 017 0 5 Group Operation Description Lon Time Return...

Page 83: ...1 016 2 0 Electrical Replace Horn 2 001 0 3 Replace Emergency Disconnect 2 002 0 8 Adjust Brake Switch 2 003 0 7 Replace Accessory Wiring Harness OHG 2 004 1 0 Replace Key Switch 2 005 1 0 Replace Br...

Page 84: ...Electrical Cable 2 043 2 0 Replace Chassis Wiring Harness 2 044 3 5 Replace Hydraulic Solenoid Coil Each 2 045 0 5 Replace Reach Wiring Harness 2 046 1 0 Replace Steer Motor 2 047 0 7 Replace Steer S...

Page 85: ...Lowering Proportional Valve 3 015 1 0 Reseal Lowering Proportional Valve 3 016 0 5 Replace A B Valve 3 017 0 8 Reseal A B Valve 3 018 0 8 Replace Hydraulic Solenoid Valve Each 3 019 0 7 Replace Reach...

Page 86: ...Model 84 LON Manual 2005 08 15 Replace Inner Column Roller 5 005 4 0 Replace Intermediate Column Roller 5 006 4 5 Install Mast 5 007 1 0 Replace Height Indicator Cable 5 017 0 5 Group Operation Descri...

Page 87: ...er Brake 1 017 1 0 Replace Brake Pedal 1 018 0 5 Electrical Replace Horn 2 001 0 3 Replace Emergency Disconnect 2 002 0 3 Adjust Brake Switch 2 003 0 7 Replace Key Switch 2 005 0 7 Replace Handle Asse...

Page 88: ...udes adjusting 2 048 0 5 Adjust Steer Sensor Each 2 049 0 5 Replace Y10 Y11 Valve Coil 2 050 0 3 Replace Pulse Sensor 2 051 0 8 Replace Drive Motor Speed Sensor 2 052 0 2 Replace Drive Motor Direction...

Page 89: ...place Hydraulic Solenoid Valve Each 3 019 0 2 Replace Reach Cylinder 3 020 1 0 Reseal Reach Cylinder 3 021 1 5 Replace Sideshifter Cylinder 3 022 0 5 Reseal Sideshifter Cylinder 3 023 1 0 Frame Replac...

Page 90: ...ce Center Pivot Bearing 5 008 2 0 Remove and Install Reach Assembly 5 009 1 0 Replace Front Frame 5 010 2 0 Replace Rear Frame 5 011 3 0 Replace Arm Roller 5 012 2 0 Recondition Single Reach 5 013 4 5...

Page 91: ...Key Switch 2 005 0 5 Replace Brake Interlock Switch 2 006 0 5 Replace Lift Valve Switch 2 007 1 0 Replace Control Handle Horn Switch 2 009 2 0 Replace Master Control Switch 2 010 1 0 Replace Potentio...

Page 92: ...or Coil 2 056 1 3 Replace Lowering Solenoid 2 057 0 5 Replace Reverser Relay 2 058 0 5 Replace Handle Head Harness 2 059 1 3 Replace Handle Harness 2 063 2 0 Replace Lift Switch 2 064 2 0 Replace Lowe...

Page 93: ...Reel 3 026 2 5 Reseal Hose Swivel 3 027 1 5 Frame Replace Control Handle Head 4 001 2 5 Replace Control Handle 4 002 3 0 Replace Hand Guard 4 003 1 0 Replace Trans Eccentric Bearing One 4 007 1 0 Each...

Page 94: ...92 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 95: ...lace Brake Shoe 1 013 0 5 Remove and Replace 1 001 1 0 Electrical Replace Horn 2 001 0 3 Replace Key Switch 2 005 0 3 Replace Brake Switch 2 006 0 5 Replace Emergency Disconnect Switch 2 007 0 5 Repla...

Page 96: ...voir 3 001 1 0 Replace any Hydraulic Hose 3 011 0 5 Replace Lift Pump 3 013 1 5 Replace Lift Pump Check Valve 3 017 0 5 Replace Lift Cylinder 3 018 0 5 Reseal Lift Cylinder 3 019 1 0 Replace Lift Pump...

Page 97: ...sory Wiring Harness 2 004 1 0 Replace Key Switch 2 005 0 5 Replace Brake Interlock Switch 2 006 0 5 Replace Lift Valve Switch 2 007 1 0 Replace Control Handle Horn Switch 2 009 2 0 Replace Master Cont...

Page 98: ...tor 2 055 1 3 Replace 3rd Speed Contactor Coil 2 056 1 3 Replace Lowering Solenoid 2 057 0 5 Replace Reverser Relay 2 058 0 5 Replace Handle Head Harness 2 059 1 3 Replace Handle Harness 2 063 2 0 Rep...

Page 99: ...eel 3 026 2 5 Reseal Hose Swivel 3 027 1 5 Frame Replace Control Handle Head 4 001 2 5 Replace Control Handle 4 002 3 0 Replace Hand Guard 4 003 1 0 Replace Trans Eccentric Bearing One 4 007 1 0 Each...

Page 100: ...98 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 101: ...ke Shoe 1 013 1 0 Electrical Replace Horn 2 001 0 3 Replace BDI 2 002 0 5 Replace Hourmeter 2 003 0 5 Replace Key Switch 2 005 0 5 Replace Brake Interlock Switch 2 006 0 3 Replace Emergency Disconnect...

Page 102: ...orm Switch 2 062 0 7 Replace Handle Harness 2 063 1 5 Replace Drive Motor Brushes 2 073 1 5 Replace Cold Storage Thermostat 2 080 0 3 Replace Cold Storage Heater 2 081 1 0 Frame Replace Transmission P...

Page 103: ...Drive Tire 1 012 0 5 Replace Brake Shoe 1 013 1 0 Replace Handle Bumper 1 014 0 3 Electrical Replace Horn 2 001 0 3 Replace BDI 2 002 0 5 Replace Hourmeter 2 003 0 5 Replace Key Switch 2 005 0 5 Repl...

Page 104: ...2 081 1 0 Hydraulic Replace Reservoir 3 001 2 0 Replace Hydraulic Control Valve 3 002 2 5 Replace Two Stage Lift Cylinder 3 004 2 5 Reseal Two Stage Lift Cylinder 3 005 1 2 Replace Free Lift Cylinder...

Page 105: ...Pivot Bearing 4 009 1 5 Replace Load Wheel 4 013 0 5 Replace Stabilizer Caster 4 023 0 6 Replace Caster Wheel 4 024 0 5 Replace Stabilizer Caster Spring 4 025 0 7 Mast Carriage Shim Carriage 5 001 2...

Page 106: ...104 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 107: ...Replace Drive Tire 1 012 0 5 Replace Brake Shoe 1 013 1 0 Replace Handle Bumper 1 014 0 3 Electrical Replace Horn 2 001 0 3 Replace BDI 2 002 0 5 Replace Hourmeter 2 003 0 5 Replace Key Switch 2 005...

Page 108: ...eater 2 081 1 0 Hydraulic Replace Reservoir 3 001 2 0 Replace Hydraulic Control Valve 3 002 2 5 Replace Two Stage Lift Cylinder 3 004 2 5 Reseal Two Stage Lift Cylinder 3 005 1 2 Replace Free Lift Cyl...

Page 109: ...4 013 0 5 Replace Stabilizer Caster 4 023 0 6 Replace Caster Wheel 4 024 0 5 Replace Stabilizer Caster Spring 4 025 0 7 Replace Platform Cushion Bumper 4 026 0 5 Mast carriage Shim Carriage 5 001 2 0...

Page 110: ...108 LON Manual 2005 08 15 THIS PAGE INTENTIONALLY LEFT BLANK Return...

Page 111: ..._______________________________ _______________________________________________________________ Action Requested ________________________________________________ ______________________________________...

Page 112: ...Return...

Page 113: ...Return...

Page 114: ...BT Prime Mover Inc 3305 N Highway 38 Muscatine Iowa 52761 8800 U S A Tel 563 262 7700 Fax 563 262 7600 www primemover biz Back Cover Return...

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