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prime mover CMX60 Manual

Industrial truck flat rate
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Industrial Truck Flat Rate
CMX60/80
OP15C
SN20/30/40
HMX/RMX
OE35
SR30
SC10/20/30/40
PMX/QMX
OPX30
TMX
PMX45
RR30/34/45
WSX22/30/40
SMX45
RRX/RSX
WRX30
CSX10/20/30/40
CRX30/35/40/50
RTX/RTX30DR
Part no: 301553-001
Date: September 15, 2005
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  • Page 1 Industrial Truck Flat Rate CMX60/80 OP15C SN20/30/40 HMX/RMX OE35 SR30 SC10/20/30/40 PMX/QMX OPX30 PMX45 RR30/34/45 WSX22/30/40 SMX45 RRX/RSX WRX30 CSX10/20/30/40 CRX30/35/40/50 RTX/RTX30DR Part no: 301553-001 Date: September 15, 2005 Return...
  • Page 2 Prime-Mover is a trademark of BT Prime-Mover Inc., © 2005 BT Prime-Mover Inc., Muscatine, Iowa. All Rights Reserved. Return...

  • Page 3: Table Of Contents

    Table of Contents Flat Rate Guide ....................3 Purpose of the Guide ................. 3 Using the Guide ..................3 This section identifies the major area of the machine........ 4 Operation Description ................ 4 Labor Operation Number ..............4 Time ....................4 Review Of Labor Operation Times ............
  • Page 4 Table of Contents SN/SR Model ....................95 TMX Model ....................99 WRX Model ....................101 WSX22/30/40 Model ..................105 Labor Operation Time Review Request ............ 109 BT Prime-Mover, Inc. Return...

  • Page 5: Flat Rate Guide

    Flat Rate Guide Version no 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.

  • Page 6: This Section Identifies The Major Area Of The Machine

    Flat Rate Guide Version no 3. This section identifies the major area of the machine. 3.1. Operation Description The operation description identifies specific repairs and combinations that are to be performed. The description is the final result of the operation and any sub-operations which are required to complete the major operation are included in the operation description and time allowance.

  • Page 7: Cmx Model

    CMX Model Version no CMX Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Control Handle Head 1-006 Replace Control Handle Stem 1-007 Replace Hand Guard 1-008 Replace Brake Spring 1-010...
  • Page 8 CMX Model Version no Group Operation Description Time Reseal Lift Pump Motor 2-042 Replace Time Delay 2-045 Replace Circuit Breaker 2-050 Replace High Speed Relay 2-058 Replace Handle Head Harness 2-059 Replace Handle Harness 2-063 Replace Lift Switch 2-064 Replace Lower Switch 2-065 Replace Lift Switch Handrail 2-067...
  • Page 9 CMX Model Version no Group Operation Description Time Frame Replace Transmission Pivot Bearing 4-009 Replace Load Wheel 4-013 Replace Pull Rod 4-018 Replace Wheel Fork 4-019 Replace Lift Frame 4-020 Replace Lower Link/Lift Frame 4-021 Replace Carrier Frame 4-022 Replace Stabilizer Caster 4-023 Replace Caster Wheel 4-024...
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  • Page 11: Crx Model

    CRX Model Version no CRX Model Group Operation Description Time Finish and Accessories Overhead guard 2110 Cover assembly, (Any cover) 2120 Cover, bracket (right hand, left hand, and center) 2130 Cover, top support 2140 Covers, seat 2150 Covers, manual pocket 2160 0.25 Pad, foam (right hand or left hand)
  • Page 12 CRX Model Version no Group Operation Description Time Plate, steering 3104 Chain, steer 3105 0.25 Chain, anchor, (313665-112) 3106 Plate, sensor, steer includes spacer 3108 Sprocket, steer includes key 3110 Adapter, mechanical or hydraulic 3112 Bracket, mounting 3114 Elbow, steer motor 3120 Switch, proximity multi head 3130...
  • Page 13 CRX Model Version no Group Operation Description Time Key, woodruff, dive motor armature lower 4170 Plug, mechanical, drive 4180 Drive unit plate 4190 Wheel, hub assembly 4200 Wheel, drive tire bolt 4205 Wheel, hub, machined, includes pressing 4210 Tire, drive, rubber or polyurethane 4220 Brake assembly, electric 4300...
  • Page 14 CRX Model Version no Group Operation Description Time Handle, positioner SFC 5115 Cable assemble, handle 5120 Horn assembly 5150 Insulator, shoulder washer-horn 5155 Horn with bracket 5160 Bracket tab, fan 5170 Fan, electric blower 5175 Operator display, indicator 5200 Spacer, hex, ODI 5205 Bracket assembly, ODI 5210...
  • Page 15 CRX Model Version no Group Operation Description Time Amplifier, power traction or power lift 5465 Plate, electrical 5470 Bar, bus, electrical 5475 Bar, pivot weldment 5480 Strap, (tie wrap) 5485 Pin, roll, control handle 5490 Cable JH1-SOL2 or JA2-SOL12&10 5500 Cable assembly, JF3-S1, EPO 5505 Cable assembly, JC5-JD1...
  • Page 16 CRX Model Version no Group Operation Description Time Light, electric, travel 5665 Connector, pin housing, light, bin 5670 Pin, light, bin 5675 Light, bin assembly, includes bulb 5680 Light, bulb (Any) 5681 Bulb, bin assembly 5685 Cable assembly, Right or Left mast light 5690 Guard, cable/hose 5695...
  • Page 17 CRX Model Version no Group Operation Description Time Motor brush replacement 5902 Thermistor sensor 5903 Motor, lift 4K or 5K STD 5905 Motor, steer 5910 Hourmeter 5940 Hydraulic Components Manifold assembly with out HSA 6002 Manifold 6004 Valve, solenoid, (Any) 6008 Valve, relief 6010...
  • Page 18 CRX Model Version no Group Operation Description Time Hose assembly (Manifold T1 to Union tee) 6310 Hose assembly (Manifold T2 to Swivel tee) 6320 Hose assembly (Swivel tee to Tilt ram rear, Left) 6330 Hose assembly 6340 (Union tee to Tilt ram front, Left hand or Light hand) Hose assembly (Manifold cylinder to Lift ram at Mast) 6350 Hose (Manifold to Reservoir return)
  • Page 19 CRX Model Version no Group Operation Description Time Cylinder valve, hydraulic, flow control 7012 Cylinder, main piston (2 Techs) 7014 Cylinder, main housing (2 Techs) 7016 Cylinder, main bleeder screw, back-up ring, screw 7018 Cylinder, main piston cap (2 Techs) 7020 Cylinder, repack, square seal (2 Techs) (313665-971) 7022...
  • Page 20 CRX Model Version no Group Operation Description Time Mast tilt assembly 7330 Tube assembly, tilt ram 7340 Piston, tilt ram 7345 Rod, tilt ram 7350 Gland, tilt ram 7355 Bearing, tilt ram 7360 Seal kit, tilt ram 7365 Anchor, tilt ram 7370 Pin, clevis, tilt ram 7375...
  • Page 21 CRX Model Version no Group Operation Description Time Ring, retaining, quad mast 7600 1.75 Washer, quad mast 7605 1.75 Ring,wear, quad mast 7610 O Ring, quad mast 7615 1.75 Valve check, quad mast 7620 1.75 Service kit, quad mast 7625 1.75 Service kit, check valve, quad mast 7630...
  • Page 22 CRX Model Version no Group Operation Description Time Hose, inner telescopic, quad mast, lift over pulley 7775 Clamp tube, inner telescopic, quad mast, lift hose 7780 Line assembly, inner telescopic, quad mast, tube, bottom 7785 center ram Fitting, inner telescopic, quad mast, bottom center ram 7790 Band, inner telescopic quad mast 7792...
  • Page 23 CRX Model Version no Group Operation Description Time Guide (313665-325) 7964 Fitting, reeving group, (Any) 7968 Bracket, reeving group, 7970 Shreave, shaft, guard or plate, reeving group 7972 Fitting, mast installation 7985 Bar, mast installation 7990 Hose, mast install, main cylinder to flow control 7995 BT Prime-Mover, Inc.
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  • Page 25: Csx Model

    CSX Model Version no CSX Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Control Handle Head 1-006 Replace Control Handle Stem 1-007 Replace Hand Guard 1-008 Replace Handle Spring 1-009...
  • Page 26 CSX Model Version no Group Operation Description Time Replace Lift Pump Motor 2-039 Replace Hydraulic Control Handle Switch 2-044 Replace Hydraulic Solenoid Coil (Each) 2-045 Replace Circuit Breaker 2-050 Replace Lowering Solenoid Coil 2-057 Replace Handle Head Harness 2-059 Replace Handle Harness 2-063 Replace Lift Switch 2-064...
  • Page 27 CSX Model Version no Group Operation Description Time Reseal Tilt Cylinder 3-025 Replace Sideshifter Cylinder 3-026 Reseal Sideshifter Cylinder 3-027 Frame Replace Transmission Pivot Bearing 4-009 Replace Load Wheel 4-013 Replace Stabilizer Caster 4-023 Replace Caster Wheel 4-024 Replace Stabilizer Caster Spring 4-025 Replace Platform Cushion Bumper 4-026...
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  • Page 29: Oe15C Model

    OE15C Model Version no OE15C Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Brake Separators / Disc 1-005 Adjust Brake 1-011 Replace Drive Tire 1-012 Electrical Replace Horn 2-001...
  • Page 30 OE15C Model Version no Group Operation Description Time Replace Circuit Breaker 2-050 Replace Lowering Valve Coil 2-057 Replace Mast Electrical Cable 2-058 Replace Chain Tension Switch 2-063 Replace Lift Switch 2-064 Replace Lower Switch 2-065 Replace Drive Motor Brushes 2-073 Replace Pump Motor Brushes 2-074 Hydraulic...

  • Page 31: Oe35 Model

    OE35 Model Version no OE35 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Brake Separators / Disconnect 1-005 Replace Slave Cylinder 1-008 Rebuild Slave Cylinder 1-009 Replace Brake Hydraulic Hose 1-010...
  • Page 32 OE35 Model Version no Group Operation Description Time Replace 1A Contactor Coil 2-025 Replace Lift Pump Contactor Coil 2-026 Replace Steer Pump Contactor Coil 2-027 Replace EV100 LX Card 2-028 Replace Number 1 SCR 2-029 Replace Number 2 SCR 2-030 Replace Number 5 SCR 2-031 Replace Number 3 SCR...
  • Page 33 OE35 Model Version no Group Operation Description Time Hydraulic Replace Reservoir 3-001 Replace Lift Pump Solenoid Valve 3-002 Replace Free Lift Cylinder 3-006 Reseal Free Lift Cylinder 3-007 Replace Staging Cylinder 3-008 Reseal Staging Cylinder 3-009 Replace any Hydraulic Hose 3-011 Replace Velocity Fuse 3-012...
  • Page 34 OE35 Model Version no Group Operation Description Time Replace Inner Column Roller 5-005 Replace Intermediate Column Roller 5-006 Install Mast And Platform 5-007 Replace Carriage Roller 5-008 Replace Inner Column Roller 5-009 Replace Intermediate Column Roller 5-010 Wire Guidance Replace Indicator Light 7-001 Replace Auto / Manual Switch 7-002...

  • Page 35: Opx30 Model

    OPX30 Model Version no OPX30 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Drive Tire 1-012 Electrical Replace Horn 2-001 Replace Dash Display 2-002 Replace Hourmeter 2-003 Replace Accessory Wiring Harness 2-004...
  • Page 36 OPX30 Model Version no Group Operation Description Time Replace Carriage Manager Card 2-029 Replace Electromagnetic Brake Assembly 2-031 Replace Electromagnetic Brake Coil 2-032 Replace Electomagnetic Brake Armature 2-033 0.75 Adjust Electromagnetic Brake 2-034 Replace Battery Connector 2-036 0.25 Replace One Power Cable 2-037 Repair Open Wire 2-038...
  • Page 37 OPX30 Model Version no Group Operation Description Time Replace Staging Cylinder 3-008 Reseal Staging Cylinder 3-009 Replace any Hydraulic Hose 3-011 Replace Velocity Fuse 3-012 Replace Lift Pump 3-013 Replace Lowering Valve 3-014 Replace Lift Valve 3-016 Frame Replace Control Handle 4-003 Each Additional Bearing 4-008...
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  • Page 39: Pmx/Qmx Model

    PMX/QMX Model Version no PMX/QMX Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal (QMX Only add 0.5) 1-002 Rebuild/Recondition 1-004 Replace Control Handle Head 1-005 Replace Control Handle Stem 1-006 Replace Hand Guard 1-007 Replace Handle Spring 1-008 Replace Brake Spring 1-009...
  • Page 40 PMX/QMX Model Version no Group Operation Description Time Replace Lift Pump Motor 2-039 Reseal Lift Pump Motor 2-042 Replace Time Delay 2-045 Replace Circuit Breaker 2-050 Replace Lowering Solenoid Coil 2-057 Replace Handle Head Harness 2-059 Replace Handle Harness 2-063 Replace Lift Switch 2-064 Replace Lower Switch...
  • Page 41 PMX/QMX Model Version no Group Operation Description Time Replace Lift Frame 4-020 Replace Lower Link / Lift Frame 4-021 Replace Stabilizer Caster 4-023 Replace Caster Wheel 4-024 Replace Rider Platform Cushion Bumper (QMX) 4-026 Remove And Replace Rider Platform (QMX) 4-029 Replace Rider Platform Caster (QMX)
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  • Page 43: Pmx45 Model

    PMX45 Model Version no PMX45 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Rebuild/Recondition 1-004 Replace Control Handle Head 1-005 Replace Control Handle Stem 1-006 Replace Hand Guard 1-007 Replace Handle Spring 1-008 Replace Brake Spring 1-009 Adjust Brake 1-011...
  • Page 44 PMX45 Model Version no Group Operation Description Time Repair Open Wire 2-038 Replace Lift Pump Motor 2-039 Reseal Lift Pump Motor 2-042 Replace Circuit Breaker 2-050 Replace Lowering Solenoid Coil 2-057 Replace Handle Head Harness 2-059 Replace Handle Harness 2-063 Replace Lift Switch 2-064 Replace Lower Switch...
  • Page 45 PMX45 Model Version no Group Operation Description Time Replace Wheel Fork 4-019 Replace Lift Frame 4-020 Replace Lower Link / Lift Frame 4-021 Replace Stabilizer Caster 4-023 Replace Caster Wheel 4-024 BT Prime-Mover, Inc. LON Manual 2005-08-15 Return...
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  • Page 47: Rdx30 Model

    RDX30 Model Version no RDX30 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Steer Bearing 1-005 Replace Drive Motor Brake Disc (includes adjusting) 1-010 Adjust Brakes 1-011 Replace Drive Tire 1-012...
  • Page 48 RDX30 Model Version no Group Operation Description Time Replace Electronic Fan 2-027 Replace A5 Main Logic Card (includes programing) 2-028 Replace A1 Drive Transistor Regulator 2-029 Replace A2 Lift Transistor Regulator 2-030 Replace A6 Dash Display 2-031 Replace A7 Preset Height Card 2-032 Replace A8 Height Indicator Card 2-033...
  • Page 49 RDX30 Model Version no Group Operation Description Time Hydraulic Replace Reservoir 3-001 Replace Lift Valve 3-002 Reseal Lift Valve 3-003 Replace Tilt Cylinder 3-004 Reseal Tilt Cylinder 3-005 Replace Free Lift Cylinder 3-006 Reseal Free Lift Cylinder 3-007 Replace Staging Cylinder 3-008 Reseal Staging Cylinder 3-009...
  • Page 50 RDX30 Model Version no Group Operation Description Time Replace Inner Column Roller 5-005 Replace Intermediate Column Roller 5-006 Install Mast 5-007 Replace Height Indicator Cable 5-017 Reach Remove And Install Reach Assembly 5-009 Replace Front Frame 5-010 Replace Rear Frame 5-011 Replace Arm Roller 5-012...

  • Page 51: Rmx/Hmx Model

    RMX/HMX Model Version no RMX/HMX Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Control Handle Head 1-006 Replace Control Handle Stem 1-007 Replace Hand Guard 1-008 Replace Handle Spring 1-009...
  • Page 52 RMX/HMX Model Version no Group Operation Description Time Replace Battery Connector 2-036 Replace One Power Cable 2-037 Repair Open Wire 2-038 Replace Lift Pump Motor 2-039 Reseal Lift Pump Motor 2-042 Replace Handrail High Speed Switch (HMX Only) 2-043 Replace Handrail Horn Switch (HMX Only) 2-044 Replace Time Delay...
  • Page 53 RMX/HMX Model Version no Group Operation Description Time Frame Replace Pivot Bearing 4-009 Replace Load Wheel 4-013 Replace Pull Rod 4-018 Replace Wheel Fork 4-019 Replace Lift Frame 4-020 Replace Lower Link/lift Frame 4-021 Replace Carrier Frame 4-022 Replace Stabilizer Caster 4-023 Replace Caster Wheel 4-024...
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  • Page 55: Rr30C/Rr34B Model

    RR30C/RR34B Model Version no RR30C/RR34B Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 10.0 Replace Support Yoke Bearing 1-005 Adjust Brake 1-011 Replace Drive Tire 1-012 Replace Brake Shoes 1-013 Replace Support Yoke...
  • Page 56 RR30C/RR34B Model Version no Group Operation Description Time Replace Forward Contactor Coil 2-023 Replace Reverse Contactor Coil 2-024 Replace 1A Contactor Coil 2-025 Replace Steer Pump Contactor Coil 2-027 Replace EV100 LX Card 2-028 Replace Number 1 SCR 2-029 Replace Number 2 SCR 2-030 Replace Number 5 SCR 2-031...
  • Page 57 RR30C/RR34B Model Version no Group Operation Description Time Replace Pump Motor Brushes 2-075 Replace Auxiliary Motor Brushes 2-076 Hydraulic Replace Reservoir 3-001 Replace Lift Valve 3-002 Reseal Lift Valve 3-003 Replace Tilt Cylinder 3-004 Reseal Tilt Cylinder 3-005 Replace Free Lift Cylinder 3-006 Reseal Free Lift Cylinder 3-007...
  • Page 58 RR30C/RR34B Model Version no Group Operation Description Time Replace Lower Steering Chain 4-028 Mast Shim Carriage 5-001 Shim Inner Column 5-002 Shim Intermediate Column 5-003 Replace Carriage Roller 5-004 Replace Inner Column Roller 5-005 Replace Intermediate Column Roller 5-006 Install Mast 5-007 Reach Replace Center Pivot Bearing...

  • Page 59: Rr45 Model

    RR45 Model Version no RR45 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 10.0 Replace Support Yoke Bearing 1-005 Replace Master Cylinder 1-006 Rebuild Master Cylinder 1-007 Replace Slave Cylinder (Each)
  • Page 60 RR45 Model Version no Group Operation Description Time Replace Forward / Reverse Contactor 2-018 Replace 1A Contactor 2-020 Replace Lift Pump Contactor (Each) 2-021 Replace Auxiliary Pump Contactor 2-022 Replace Forward Contactor Coil 2-023 Replace Reverse Contactor Coil 2-024 Replace 1A Contactor Coil 2-025 Replace Lift Pump Contactor Coil (Each)
  • Page 61 RR45 Model Version no Group Operation Description Time Replace Forward / Reverse Contactor Tips 2-070 Replace 1A Contactor Tips 2-071 Replace Pump Motor Contactor Tips 2-072 Replace Auxiliary Pump Motor Contactor Tips 2-073 Replace Drive Motor Brushes 2-074 Replace Pump Motor Brushes 2-075 Replace Auxiliary Pump Motor Brushes 2-076...
  • Page 62 RR45 Model Version no Group Operation Description Time Adjust Articulating Stops 4-002 Replace Control Handle 4-003 Replace Idler Wheel 4-004 Replace Load Wheel 4-013 Recondition Steer Axle 4-014 Mast Shim Carriage 5-001 Shim Inner Column 5-002 Shim Intermediate Column 5-003 Replace Carriage Roller 5-004 Replace Inner Column Roller...

  • Page 63: Rrx35 Model

    RRX35 Model Version no RRX35 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Steer Bearing 1-005 Replace Drive Motor Brake Disc (includes adjusting) 1-010 Adjust Brakes 1-011 Replace Drive Tire 1-012...
  • Page 64 RRX35 Model Version no Group Operation Description Time Replace A1 Drive Transistor Regulator 2-029 Replace A2 Lift Transistor Regulator 2-030 Replace A6 Dash Display 2-031 Replace A7 Preset Height Card 2-032 Replace A8 Height Indicator Card 2-033 Replace A22 Preset Height Key Pad 2-034 Replace Mast Upper Position Switch 2-035...
  • Page 65 RRX35 Model Version no Group Operation Description Time Replace Lift Valve 3-002 Reseal Lift Valve 3-003 Replace Tilt Cylinder 3-004 Reseal Tilt Cylinder 3-005 Replace Free Lift Cylinder 3-006 Reseal Free Lift Cylinder 3-007 Replace Staging Cylinder 3-008 Reseal Staging Cylinder 3-009 Replace any Hydraulic Hose 3-011...
  • Page 66 RRX35 Model Version no Group Operation Description Time Install Mast 5-007 Replace Height Indicator Cable 5-017 Reach Replace Center Pivot Bearing 5-008 Remove and Install Reach Assembly 5-009 Replace Front Frame 5-010 Replace Rear Frame 5-011 Replace Arm Roller 5-012 Recondition Single Reach 5-013 Install Sideshifter...

  • Page 67: Rrx45 Model

    RRX45 Model Version no RRX45 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Steer Bearing 1-005 Replace Drive Motor Brake Disc (includes adjusting) 1-010 Adjust Brakes 1-011 Replace Drive Tire 1-012...
  • Page 68 RRX45 Model Version no Group Operation Description Time Replace Electronic Fan 2-027 Replace A5 Main Logic Card (includes programing) 2-028 Replace A1 Drive Transistor Regulator 2-029 Replace A2 Lift Transistor Regulator 2-030 Replace A6 Dash Display 2-031 Replace A7 Preset Height Card 2-032 Replace A8 Height Indicator Card 2-033...
  • Page 69 RRX45 Model Version no Group Operation Description Time Hydraulic Replace Reservoir 3-001 Replace Lift Valve 3-002 Reseal Lift Valve 3-003 Replace Tilt Cylinder 3-004 Reseal Tilt Cylinder 3-005 Replace Free Lift Cylinder 3-006 Reseal Free Lift Cylinder 3-007 Replace Staging Cylinder 3-008 Reseal Staging Cylinder 3-009...
  • Page 70 RRX45 Model Version no Group Operation Description Time Replace Inner Column Roller 5-005 Replace Intermediate Column Roller 5-006 Install Mast 5-007 Replace Height Indicator Cable 5-017 Reach Replace Center Pivot Bearing 5-008 Remove And Install Reach Assembly 5-009 Replace Front Frame 5-010 Replace Rear Frame 5-011...

  • Page 71: Rrs40C Model

    RRS40C Model Version no RRS40C Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 10.0 Replace Support Yoke Bearing 1-005 Adjust Brakes 1-011 Replace Drive Tire 1-012 Replace Brake Shoes 1-013 Replace Support Yoke...
  • Page 72 RRS40C Model Version no Group Operation Description Time Replace FWD Contactor Coil 2-023 Replace REV Contactor Coil 2-024 Replace 1A Contactor Coil 2-025 Replace Lift Pump Contactor Coil 2-026 Replace Steer Pump Contactor Coil 2-027 Replace EV100 LX Card 2-028 Replace Number 1 SCR 2-029 Replace Number 2 SCR...
  • Page 73 RRS40C Model Version no Group Operation Description Time Replace Pump Motor Brushes 2-075 Replace Auxiliary Pump Motor Brushes 2-076 Hydraulic Replace Reservoir 3-001 Replace Lift Valve 3-002 Reseal Lift Valve 3-003 Replace Tilt Cylinder 3-004 Reseal Tilt Cylinder 3-005 Replace Free Lift Cylinder 3-006 Reseal Free Lift Cylinder 3-007...
  • Page 74 RRS40C Model Version no Group Operation Description Time Mast Shim Carriage 5-001 Shim Inner Column 5-002 Shim Intermediate Column 5-003 Replace Carriage Roller 5-004 Replace Inner Column Roller 5-005 Replace Intermediate Column Roller 5-006 Install Sideshifter 5-007 Install Mast 5-008 LON Manual 2005-08-15 Return...

  • Page 75: Rrs50B Model

    RRS50B Model Version no RRS50B Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 10.0 Replace Support Yoke Bearing 1-005 Replace Master Cylinder 1-006 Rebuild Master Cylinder 1-007 Replace Slave Cylinder (Each)
  • Page 76 RRS50B Model Version no Group Operation Description Time Replace Forward / Reverse Contactor 2-018 Replace 1A Contactor 2-020 Replace Lift Pump Contactor 2-021 Replace Auxiliary Pump Contactor 2-022 Replace Forward Contactor Coil 2-023 Replace Reverse Contactor Coil 2-024 Replace 1A Contactor Coil 2-025 Replace Lift Pump Contactor Coil 2-026...
  • Page 77 RRS50B Model Version no Group Operation Description Time Replace Forward / Reverse Contactor Tips 2-070 Replace 1A Contactor Tips 2-071 Replace Pump Motor Contactor Tips 2-072 Replace Auxiliary Pump Motor Contactor Tips 2-073 Replace Drive Motor Brushes 2-074 Replace Pump Motor Brushes 2-075 Replace Auxiliary Pump Motor Brushes 2-076...
  • Page 78 RRS50B Model Version no Group Operation Description Time Replace Load Wheel 4-013 Recondition Steer Axle 4-014 Mast Shim Carriage 5-001 Shim Inner Column 5-002 Shim Intermediate Column 5-003 Replace Carriage Roller 5-004 Replace Inner Column Roller 5-005 Replace Intermediate Column Roller 5-006 Install Mast 5-007...

  • Page 79: Rsx40 Model

    RSX40 Model Version no RSX40 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Steer Bearing 1-005 Replace Drive Motor Brake Disc (includes adjusting) 1-010 Adjust Brakes 1-011 Replace Drive Tire 1-012...
  • Page 80 RSX40 Model Version no Group Operation Description Time Replace A1 Drive Transistor Regulator 2-029 Replace A2 Lift Transistor Regulator 2-030 Replace A6 Dash Display 2-031 Replace A7 Preset Height Card 2-032 Replace A8 Height Indicator Card 2-033 Replace A22 Preset Height Key Pad 2-034 Replace Mast Upper Position Switch 2-035...
  • Page 81 RSX40 Model Version no Group Operation Description Time Replace Lift Valve 3-002 Reseal Lift Valve 3-003 Replace Tilt Cylinder 3-004 Reseal Tilt Cylinder 3-005 Replace Free Lift Cylinder 3-006 Reseal Free Lift Cylinder 3-007 Replace Staging Cylinder 3-008 Reseal Staging Cylinder 3-009 Replace any Hydraulic Hose 3-011...
  • Page 82 RSX40 Model Version no Group Operation Description Time Install Mast 5-007 Replace Height Indicator Cable 5-017 LON Manual 2005-08-15 Return...

  • Page 83: Rsx50 Model

    RSX50 Model Version no RSX50 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Steer Bearing 1-005 Replace Drive Motor Brake Disc (includes adjusting) 1-010 Adjust Brakes 1-011 Replace Drive Tire 1-012...
  • Page 84 RSX50 Model Version no Group Operation Description Time Replace Electronic Fan 2-027 Replace A5 Main Logic Card (includes programing) 2-028 Replace A1 Drive Transistor Regulator 2-029 Replace A2 Lift Transistor Regulator 2-030 Replace A6 Dash Display 2-031 Replace A7 Preset Height Card 2-032 Replace A8 Height Indicator Card 2-033...
  • Page 85 RSX50 Model Version no Group Operation Description Time Hydraulic Replace Reservoir 3-001 Replace Lift Valve 3-002 Reseal Lift Valve 3-003 Replace Tilt Cylinder 3-004 Reseal Tilt Cylinder 3-005 Replace Free Lift Cylinder 3-006 Reseal Free Lift Cylinder 3-007 Replace Staging Cylinder 3-008 Reseal Staging Cylinder 3-009...
  • Page 86 RSX50 Model Version no Group Operation Description Time Replace Inner Column Roller 5-005 Replace Intermediate Column Roller 5-006 Install Mast 5-007 Replace Height Indicator Cable 5-017 LON Manual 2005-08-15 Return...

  • Page 87: Rtx35/45, Rtx30Dr Model

    RTX35/45, RTX30DR Model Version no RTX35/45, RTX30DR Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Steer Bearing 1-005 Replace Drive Motor Brake Disc (includes adjusting) 1-010 Adjust Brakes 1-011...
  • Page 88 RTX35/45, RTX30DR Model Version no Group Operation Description Time Replace A6 Dash Display 2-031 Replace Mast Upper Position Switch 2-035 Replace Battery Connector 2-036 Replace One Power Cable 2-037 Repair Open Wire 2-038 Replace Lift Pump Motor 2-039 Replace Speed Limit Switch 2-042 Replace Mast Electrical Cable 2-043...
  • Page 89 RTX35/45, RTX30DR Model Version no Group Operation Description Time Reseal Tilt Cylinder 3-005 Replace Free Lift Cylinder 3-006 Reseal Free Lift Cylinder 3-007 Replace Staging Cylinder 3-008 Reseal Staging Cylinder 3-009 Replace any Hydraulic Hose 3-011 Replace Safety Down Valve 3-012 Replace Lift Pump 3-013...
  • Page 90 RTX35/45, RTX30DR Model Version no Group Operation Description Time Reach Replace Center Pivot Bearing 5-008 Remove and Install Reach Assembly 5-009 Replace Front Frame 5-010 Replace Rear Frame 5-011 Replace Arm Roller 5-012 Recondition Single Reach 5-013 Install Sideshifter 5-014 LON Manual 2005-08-15 Return...

  • Page 91: Sc Model

    SC Model Version no SC Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Brake Separators / Disc 1-005 Adjust Brakes 1-011 Replace Drive Tire 1-012 Electrical Replace Horn 2-001...
  • Page 92 SC Model Version no Group Operation Description Time Repair Open Wire 2-038 Replace Lift Pump Motor 2-039 Replace Lift Pump Motor Armature 2-040 Replace Lift Pump Motor Fields 2-041 Reseal Lift Pump Motor 2-042 Replace Speed Switch 2-043 Replace Handrail Horn Switch 2-044 Replace Time Delay 2-045...
  • Page 93 SC Model Version no Group Operation Description Time Reseal Free Lift Cylinder 3-007 Replace Staging Cylinder 3-008 Reseal Staging Cylinder 3-009 Replace Hydraulic Filter 3-010 Replace any Hydraulic Hose 3-011 Replace Velocity Fuse 3-012 Replace Lift Pump 3-013 Replace Lowering Valve 3-014 Replace Lift Pump/motor Assy 3-021...
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  • Page 95: Smx45 Model

    SMX45 Model Version no SMX45 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Rebuild/Recondition 1-004 Replace Control Handle Head 1-005 Replace Control Handle Stem 1-006 Replace Hand Guard 1-007 Replace Handle Spring 1-008 Adjust Brake 1-011 Replace Drive Tire 1-012...
  • Page 96 SMX45 Model Version no Group Operation Description Time Replace Handle Head Harness 2-059 Replace Handle Harness 2-063 Replace One Drive Motor Cable 2-068 Replace Lift Limit Switch 2-069 Replace Drive Motor Brushes 2-073 Replace Pump Motor Brushes 2-074 Replace Battery 2-077 Replace Battery Charger 2-078...

  • Page 97: Sn/Sr Model

    SN/SR Model Version no SN/SR Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Brake Separators / Disc 1-005 Adjust Brakes 1-011 Replace Drive Tire 1-012 Replace Brake Rod / Screw 1-014 Electrical...
  • Page 98 SN/SR Model Version no Group Operation Description Time Replace One Power Cable 2-037 Repair Open Wire 2-038 Replace Lift Pump Motor 2-039 Replace Lift Pump Motor Armature 2-040 Replace Lift Pump Motor Fields 2-041 Reseal Lift Pump Motor 2-042 Replace Speed Switch 2-043 Replace Handrail Horn Switch 2-044...
  • Page 99 SN/SR Model Version no Group Operation Description Time Replace Staging Cylinder 3-008 Reseal Staging Cylinder 3-009 Replace Hydraulic Filter 3-010 Replace any Hydraulic Hose 3-011 Replace Velocity Fuse 3-012 Replace Lift Pump 3-013 Replace Lowering Valve 3-014 Replace Lift Pump / Motor Assembly 3-021 Replace Reach Cylinder 3-022...
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  • Page 101: Tmx Model

    TMX Model Version no TMX Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Control Handle Head 1-006 Replace Control Handle Stem 1-007 Replace Hand Guard 1-008 Replace Brake Spring 1-010...
  • Page 102 TMX Model Version no Group Operation Description Time Replace High Speed Relay 2-058 Replace Handle Head Harness 2-059 Replace Platform Switch 2-062 Replace Handle Harness 2-063 Replace Drive Motor Brushes 2-073 Replace Cold Storage Thermostat 2-080 Replace Cold Storage Heater 2-081 Frame Replace Transmission Pivot Bearing...

  • Page 103: Wrx Model

    WRX Model Version no WRX Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Control Handle Head 1-006 Replace Control Handle Stem 1-007 Replace Hand Guard 1-008 Replace Handle Spring 1-009...
  • Page 104 WRX Model Version no Group Operation Description Time Replace Lift Pump Motor 2-039 Replace Hydraulic Control Handle Switch 2-044 Replace Hydraulic Solenoid Coil (Each) 2-045 Replace Circuit Breaker 2-050 Replace Lowering Solenoid Coil 2-057 Replace Handle Head Harness 2-059 Replace Handle Harness 2-063 Replace Lift Switch 2-064...
  • Page 105 WRX Model Version no Group Operation Description Time Reseal Reach Cylinder 3-023 Replace Tilt Cylinder 3-024 Reseal Tilt Cylinder 3-025 Replace Sideshifter Cylinder 3-026 Reseal Sideshifter Cylinder 3-027 Frame Replace Pivot Bearing 4-009 Replace Load Wheel 4-013 Replace Stabilizer Caster 4-023 Replace Caster Wheel 4-024...
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  • Page 107: Wsx22/30/40 Model

    WSX22/30/40 Model Version no WSX22/30/40 Model Group Operation Description Time Transmission Remove and Replace 1-001 Replace Axle Seal 1-002 Replace Drive Axle 1-003 Rebuild / Recondition 1-004 Replace Control Handle Head 1-006 Replace Control Handle Stem 1-007 Replace Hand Guard 1-008 Replace Handle Spring 1-009...
  • Page 108 WSX22/30/40 Model Version no Group Operation Description Time Replace Lift Pump Motor 2-039 Replace Hydraulic Control Handle Switch 2-044 Replace Hydraulic Solenoid Coil (Each) 2-045 Replace Circuit Breaker 2-050 Replace Lowering Solenoid Coil 2-057 Replace Handle Head Harness 2-059 Replace Handle Harness 2-063 Replace Lift Switch 2-064...
  • Page 109 WSX22/30/40 Model Version no Group Operation Description Time Reseal Tilt Cylinder 3-025 Replace Sideshifter Cylinder 3-026 Reseal Sideshifter Cylinder 3-027 Frame Replace Transmission Pivot Bearing 4-009 Replace Load Wheel 4-013 Replace Stabilizer Caster 4-023 Replace Caster Wheel 4-024 Replace Stabilizer Caster Spring 4-025 Replace Platform Cushion Bumper 4-026...
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  • Page 111: Labor Operation Time Review Request

    Labor Operation Time Review Request Version no Labor Operation Time Review Request Operation Description: _____________________________________________ LON: _________________Model: ____________________________________ Specific Comment: ________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ Action Requested: ________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ Reply To: _______________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ Signed: ____________________________________ Date: _______________ LON Manual 2004-12-15 ©...
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  • Page 114 Back Cover 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 Return...

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