BT PRIME-MOVER PRODUCT IMPROVEMENT NOTICE

BT Prime-Mover Inc.
3305 North Highway 38
Muscatine, Iowa 52761-8800

PIN No. 000301

May 08, 2000

Models
RRX35, WRX30

SUBJECT:

Reach mechanism.

DESCRIPTION:

Premature failure of components on the lower capacity, single reach assembly has
been brought to our attention. Our investigation of the issue identifies the cause, in
most cases, as proper adjustment and inspection of the reach assembly to correct
existing problems prior to adjustment.

REMEDY:

It is critical that proper inspection, adjustment and maintenance be performed at the

scheduled Planned Maintenance intervals. The reach should be inspected, adjusted
and/or maintenanced every 300 hours to ensure maximum performance and reliability
and eliminate costly premature failures.

PROCEDURES:

Before beginning this PIN check to ensure that the reach is not damaged. It is
recommended to check the rear frame for cracks and to ensure that the upper, rear pin
holes have not wallowed out. Also check to make sure that the correct cylinders are
installed on the truck, as well as making sure that there is no existing damage to the
cylinders, such as cracks in the cylinder tube or bent cylinder rods.

Table of Contents
Section 1
Reach Mechanism Adjustment Procedures 2
Section 2
Reach Cylinder Removal and/or Replacement Instructions . 6
Section 3
Rear Frame Inspection and Maintenance Instructions .. 11

PARTS AVAILABILITY:

Order parts as needed.

FILING INSTRUCTIONS:

When inspection is complete place this PIN in the RRX35s service manual.

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Section 1
Reach Mechanism Adjustment Procedures
To properly set up the reach assembly verify that all three reach retract bumpers
(49563-00) are in good condition. There should be no splitting, cracking or deformities
on the bumpers. The reach retract bumpers are critical to proper operation of the
reach assembly and must be inspected at every Planned Maintenance visit.
Bumpers that show signs of wear, cracking, splitting or deformities must be
replaced!

Install 1 shim
(21837-00) behind
each reach retract
bumper

Figure 1

Ensure one 0.125 inch [3.18 mm] Shim (21837-00) is installed behind each reach
retract bumper. Use this as a starting point. See figure 1.

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Figure 2

Place spanner
wrench here to
adjust the reach

Reach rod jam

Fully extend the reach assembly. Loosen the reach rod jam nuts and adjust the
reach cylinder rods so the reach assembly extends evenly and in time. Caution:
The cylinder rod should never be adjusted to the point that the rod end
touches the inner arm assembly through the clevis. See figure 2.

Fully retract the reach assembly. The reach assembly must retract evenly to all
three reach retract bumpers. If the reach assembly does not retract to all bumpers
evenly, add a 0.0625 inch [1.59 mm] shim (21837-01) or 0.125 inch [3.18 mm] shim
(21837-00) accordingly, to the bumper, to achieve proper retraction to reach
bumpers. See figure 3.

Measure from the face of

the inner column rail to
the backside of the fork
hanger carriage.

Figure 3

Fully retract the reach assembly, and take a measurement from the face of the
inner column rail to the backside of the fork hanger carriage. Note this
measurement. See figure 3.

Fully extend the reach assembly and take a measurement from the face of the
inner column to the backside of the fork hanger carriage. Note this measurement.
See figure 4.

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Subtract the retracted measurement from the extended measurement. This is your
overall reach stroke. Example: Extended measurement 25.75 inch [654.05 mm]
- Retracted measurement 2.75 inch [69.85 mm] = 23 inch [584.2 mm] Overall
Reach Stroke

BT Prime-Mover specifications call for a minimum overall reach stroke of 22.75

inch [577.85 mm] and a maximum overall reach stroke of 23 inch [584.2 mm].

Figure 4

Measure from the face of the inner

column rail to the backside of the
fork hanger carriage.

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Figure 5

When rods are adjusted

correctly there should
be approximately three,
full threads exposed
above the jam nut.

When proper adjustment is

achieved clean, dry, and apply

Loctite 242 Threadlock to the

piston threads then lock down
the jam nuts.

Adjust the reach cylinder rods so that the overall reach stroke is between 22.75 inch
[577.85 mm] and 23 inch [584.2 mm]. If the measurement is correct there should
be approximately three full threads showing above the jam nuts at the clevis end of
both reach cylinders.
Maintenance reminder: The cylinder rod should never be adjusted where the
rod end touches the inner arm assembly. The pins and bushings for the inner
arms should be inspected if the amount of threads above the jam nut are
excessively less or greater than three threads. See figure 5.

When proper adjustment is achieved, clean using approved cleaner, dry and apply

Loctite 242 Threadlock to the piston threads. Lock down the jam nuts.
Maintenance Reminder: The piston threads must be cleaned, dried and have

Loctite applied whenever the reach assembly is readjusted. The jam nuts
must be inspected for tightness at every Planned Maintenance visit to insure
proper operation of reach assembly. See figure 5.

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Section 2
Reach Cylinder Removal and/or Replacement Instructions

Fully extend the reach assembly and disconnect the battery.

With the reach fully extended, block both sides of the reach channels to prevent the
reach assembly from accidentally retracting. See figures 6 and 7.

Figure 6

Extend reach fully and block

both sides of the reach here to
prevent accidental retraction.

Figure 7

Close up of blocking
procedure. Note:
remember to block
both sides.

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Remove the reach cylinder mounting roll pins at the clevis end of the reach
cylinders. See figure 8. Note: the roll pins must be replaced once removed. The
roll pins must NEVER be reused. The correct part number for this metric roll pin is
20174.

Figure 8

Remove the reach cylinder mounting roll pins

at the clevis end of the reach cylinders. Note:
the roll pins must be replaced once removed.

Remove the reach cylinder mounting pins and inspect the bushings at the inner
arm. Bushings must be replaced if they are worn, cracked, or chipped. Failure to
replace faulty bushings could result in premature reach mechanism failures. See
figure 9.

Figure 9

Reach cylinder
mounting pin.

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Connect the battery and turn the truck on.

Raise the reach above free lift to expose the rear of the reach assembly, and the
reach cylinder rear mounting pins. Secure the reach to prevent accidental lowering.

Turn the truck off and disconnect the battery, then disconnect both hydraulic hoses
from both reach cylinders. See figure 10.

Disconnect both
hydraulic hoses from
both reach cylinders.

Figure 10

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Remove the reach cylinder rear mounting pin roll pins, reach cylinder mounting
pins and reach cylinders.
Maintenance Reminder: The roll pins must be replaced once removed. The
roll pins must NEVER be re used. The correct part number for this metric
roll pin is 20174.

Figure 11

Remove the mounting pin roll pins,

mounting pins and reach cylinders.

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Inspect the mounting holes for the reach cylinder rear pins. The holes must
not be out of round. Using a set of calipers the measurement should read
0.7519 inch, +0.0019 inch and 0.0 inch [19.10 mm, +0.05 mm and 0.0 mm].
Maintenance reminder: If the roll pins are reused or the incorrect roll pin is used, the
roll pin could back out or break allowing the cylinder mounting pin to back out and
cause damage to the rear frame mounting plate. The correct part no. for these
metric roll pins is 20174.

Inspect the mounting holes of the

reach cylinder rear pins. The holes
must not be out of round. Using a
set of calipers, the measurement
should read 0.7519 inch, +0.0019
inch and -0.0 inch [19.10 mm, +0.05
mm and -0.0].
Figure 12

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Section 3
Rear Frame Inspection and Maintenance Instructions

Machines with a serial number RRX3528163001 and above will use a rear pin that
has a tear drop shaped retaining tab welded to the pin with a bolt used to secure
the rear pin to the rear frame (part number 308042-000). This pin secures the inner
arm assemblies to the rear frame. During Planned Maintenance visits the retaining
bolt should be inspected and tightened if necessary. Torque to 3033 ft-lb [40.67

44.74 Nm]. With Loctite 242 Threadlock. See figure 13.

Rear mounting pin

Rear mounting pin

retaining bolt.

Figure 13

Serial number RRX3528163001

and above will have rear frame
308042-000.

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Machines with a serial number RRX3528163000 and below will use a rear pin with a
retaining nut to secure the inner arm assembly to the rear frame (part number
307295-000). See figures 14 and 15.
Maintenance reminder: The rear frame mounting plate is milled so the rear
pin will not be allowed to rotate. The head of the rear pin must be aligned so
that it will fit flush to the mounting plate and will not be allowed to rotate. If
the rear pin is able to rotate in the rear pin mounting plate the rear frame
must be replaced!

During planned maintenance visits the rear pin and retaining nut must be
inspected. If the retaining nut is loose, the rear pin must be realigned into the
mounting plate, the rear pin and retaining nut threads must be cleaned, dried and

Loctite 242 Threadlock applied to ensure proper operation of the reach

mechanism.
Maintenance reminder: If the rear pin is able to rotate in the rear pin mounting
plate the rear frame must be replaced!

Milled head of rear

pin with roll pin.

Figure 14

Rear pin
retaining nut.

Figure 15

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