Mec 4191RT Service And Parts Manual
Mec 4191RT is a versatile and powerful machine that is perfect for a variety of tasks requiring precision and maneuverability. With its high reach and capacity, the Mec 4191RT can easily handle even the most challenging jobs. Whether you need to lift heavy materials, access hard-to-reach areas, or perform delicate tasks, the Mec 4191RT is up to the task.
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SERVICE AND PARTS MANUAL
2591RT / 3391RT / 4191RT
Serial Number Range
2591RT - 9401000 - Present
3391RT - 9501000 - Present
4191RT - 9601000 - Present
Part # 91495 R1
Issued October 2008
Revision History:
October 2008
Pages
Reason for update
V
VI
Introduction
Update Specifications Table
Update Illustration
C-2
C-3
C-4
C-5
C-6
C-7
F-2
F-3
F-5
F-16
F-18
F-19
F-20
F-22
F-23
2-3
4-11
5-15
D-2
D-4
D-5
G-4
G-5
Section 2
Update illustration: Deutsch Connectors
Section 4
Update Step 3:Setting Counterbalance Valves
Section 5
Update illustration: Outrigger Electric Schematic
Section C
Update illustration: Scissor Assembly - 2591RT
Update parts list: Scissor Assembly - 2591RT
Update illustration: Scissor Assembly - 3391RT
Update parts list: Scissor Assembly - 3391RT
Update illustration: Scissor Assembly - 4191RT
Update parts list: Scissor Assembly - 4191RT
Section D
Update illustration: Rear Axle Assembly
Update illustration: Rear Axle Assembly
Update parts list: Rear Axle Assembly
Section F
Update illustration: Base Assembly
Update parts list: Base Assembly
Update parts list: Control Module
Update illustration: Dual Fuel Engine, Kubota DF752
Update illustration: Dual Fuel Engine, Kubota DF752
Update parts list: Dual Fuel Engine, Kubota DF752
Update illustration: Diesel Engine, Kubota D1105
Update illustration: Diesel Engine, Kubota D1105
Update parts list: Diesel Engine, Kubota D1105
Section G
Update illustration: Decals, Base Assembly
Update parts list: Decals, Base Assembly
Aerial Platform Sales Corp.
1775 Park Street, Suite 77 • Selma, CA 93662 USA
Ph: 1-800-387-4575 • 559-891-2488 • Fax: 559-891-2448
E-mail:[email protected] • Web:www.mecawp.com
Table of Contents
Service Manual
INTRODUCTION ............................................................................................... I
General Safety Tips ............................................................................................... III
Hydraulic System ............................................................................................... IV
Electrical System ................................................................................................ IV
Total System ....................................................................................................... IV
Machine Specifications .......................................................................................... V
Primary Machine Components ............................................................................ VII
LUBRICATION ...................................................................................................... VIII
SECTION 1:
HYDRAULIC SYSTEM ............................................................................. 1-1
Hydraulic System - General ................................................................................ 1-2
Hydraulic Fluid ..................................................................................................... 1-3
Hydraulic Fluid Reservoir ................................................................................... 1-6
Hydraulic Pump ................................................................................................... 1-7
Wheel Drive .......................................................................................................... 1-7
Parking Brake and Towing Circuit .................................................................... 1-14
Emergency Systems And Procedures ............................................................. 1-15
Steering Circuit .................................................................................................. 1-16
Platform Lift Circuit ........................................................................................... 1-18
Optional Outriggers ........................................................................................... 1-20
Cylinder Repair .................................................................................................. 1-21
Hydraulic Manifold............................................................................................. 1-24
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page i
Table of Contents
SECTION 2:
ELECTRICAL SYSTEM ........................................................................... 2-1
Electrical System - General ................................................................................ 2-2
Deutsch Connectors ............................................................................................ 2-3
Battery .................................................................................................................. 2-4
Battery Preventative Maintenance: ................................................................... 2-5
Battery Replacement ........................................................................................ 2-6
Alarms and Switches .......................................................................................... 2-7
Tilt Alarm .......................................................................................................... 2-8
Relays .............................................................................................................. 2-9
Limit Switch ....................................................................................................... 2-10
Optional Outriggers Switches .......................................................................... 2-10
Continuity Checks ............................................................................................. 2-11
SECTION 3:
MECHANICAL COMPONENTS ............................................................... 3-1
Torque Specifications ......................................................................................... 3-2
Mechanical Components .................................................................................... 3-3
Base/ Undercarriage ........................................................................................ 3-3
Raising the Machine ......................................................................................... 3-3
Tires ................................................................................................................. 3-4
Drive Motors ..................................................................................................... 3-5
Steer Cylinder .................................................................................................. 3-6
Hoses and Cables ............................................................................................ 3-7
Platform Removal ............................................................................................. 3-7
Lift Cylinder Removal and Installation .............................................................. 3-8
Scissor Beam Assembly ................................................................................... 3-8
Engine Maintenance ............................................................................................ 3-9
Diesel Engine ................................................................................................... 3-9
Gasoline and Dual Fuel Engine ...................................................................... 3-12
Outrigger Function ............................................................................................ 3-14
Outrigger Calibration ...................................................................................... 3-15
GP106 Outrigger Control Module Troubleshooting ......................................... 3-17
Outrigger Module GP106 LED Flash Codes .................................................. 3-18
October 2008
Page ii
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Table of Contents
SECTION 4:
TROUBLESHOOTING ............................................................................. 4-1
Troubleshooting ................................................................................................... 4-3
General Troubleshooting Tips ........................................................................... 4-3
Common Causes of Hydraulic System Malfunctions: ....................................... 4-3
Hydraulic Pressure Adjustment Procedures ..................................................... 4-9
Proportional Speed Adjustment ....................................................................... 4-12
Controls and Switches ...................................................................................... 4-14
SECTION 5:
SCHEMATICS .......................................................................................... 5-1
Hydraulic Schematic ........................................................................................... 5-2
Main Hydraulic Manifold ................................................................................... 5-4
Optional Outriggers Hydraulic Manifold ............................................................ 5-5
Electric Schematics ............................................................................................. 5-6
Circuit Board .................................................................................................... 5-8
Controls .......................................................................................................... 5-10
Engine ............................................................................................................ 5-13
Optional Outriggers ........................................................................................ 5-15
Optional Generator ......................................................................................... 5-16
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page iii
Table of Contents
Parts Manual
SECTION A: CONTROL BOXES
SECTION B: PLATFORM AND RAILS
SECTION C: SCISSORS
SECTION D: AXLES
SECTION E: HYDRAULICS
SECTION F: BASE
SECTION G: DECALS
October 2008
Page iv
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
INTRODUCTION
This manual consists of Service and Parts illustrations sections.
The Service Section of this manual is designed to provide you, the customer, with the instructions needed to properly maintain the MEC self-propelled scissors lift. When used in conjunction with the illustrated parts section and the Operators Manual (provided separately), this manual will assist you in making necessary adjustments, repairs, identifying, and ordering the correct replacement parts.
All parts represented here are manufactured and supplied in accordance with MEC’s quality standards.
We recommend that you use Genuine MEC parts to insure proper OPERATION and reliable
PERFORMANCE.
To obtain maximum benefits from your MEC scissors lift, always follow the proper operating and maintenance procedures. Only trained authorized personnel should be allowed to operate or service this machine. Service personnel should read and study the Operator’s, Service and Parts
Manuals in order to gain a thorough understanding of the unit prior to making any repairs.
To help you recognize important safety information, we have identified warnings and instructions that directly impact on safety with the following signals:
“DANGER” INDICATES AN IMMINENTLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS
INJURY. THIS SIGNAL WORD IS LIMITED TO THE MOST EXTREME
SITUATIONS.
“WARNING” INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS
INJURY.
“CAUTION” INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE
INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE
PRACTICES. “CAUTION” IS USED FOR PROPERTY-DAMAGE ONLY
ACCIDENTS.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page I
NOTE:
The best method to protect yourself and others from injury or death is to use common sense. If you are unsure of any operation, don’t start until you are satisfied that it is safe to proceed and have discussed the situation with your supervisor.
Service personnel and machine operators must understand and comply with all warnings and instructional decals on the body of the machine, at the ground controls, and platform control console.
MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN
AND SPECIFICATIONS WITHOUT WRITTEN PERMISSION FROM
MEC ARE STRICTLY FORBIDDEN. A MODIFICATION MAY
COMPROMISE THE SAFETY OF THE MACHINE, SUBJECTING
OPERATOR(S) TO SERIOUS INJURY OR DEATH.
MEC’s policies and procedures demonstrate our commitment to Quality and our relentless ongoing efforts towards Continuous Improvement, due to which product specifications are subject to change without notice.
Any procedures not found within this manual must be evaluated by the individual to assure oneself that they are “proper and safe.”
Your MEC Scissors Lift has been designed, built, and tested to provide many years of safe, dependable service. Only trained, authorized personnel should be allowed to operate or service the machine.
MEC, As Manufacturer, Has No Direct Control Over Machine Application And Operation. Proper
Safety Practices Are The Responsibility Of The User And All Operating Personnel.
If There Is A Question On Application And/Or Operation Contact:
Aerial Platform Sales Corp.
1775 Park Street, Suite 77 • Selma, CA 93662 USA
Ph: 1-800-387-4575 • 559-891-2488 • Fax: 559-891-2448 www.mecawp.com
October 2008
Page II
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
GENERAL SAFETY TIPS
Regular inspection and conscientious maintenance is the key to efficient economical operation of your scissors lift. It will help to assure that your equipment will perform satisfactorily with a minimum of service and repair.
The actual operating environment of the machine governs the inspection schedule. Correct lubrication is an essential part of the preventative maintenance to minimize wear on working parts and ensure against premature failure. By maintaining correct lubrication, the possibility of mechanical failure and resulting downtime is reduced to a minimum.
NEVER PERFORM SERVICE ON THE MACHINE (WITH THE
PLATFORM ELEVATED) WITHOUT FIRST BLOCKING THE BEAMS
(SCISSORS) ASSEMBLY IN PLACE USING THE MAINTENANCE
LOCK!
♦
Block scissors assembly using Maintenance
Lock if machine is in the elevated/extended position.
♦
Never leave hydraulic components or hoses open. They must be protected from contamination (including rain) at all times.
♦
Never open a hydraulic system when there are contaminants in the air.
♦
Always clean the surrounding area before opening hydraulic systems.
♦
Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as harmful as no lubrication.
♦
Watch for makeshift “fixes” which can jeopardize safety as well as lead to more costly repair.
ART_2022
Maintenance Lock In Position
REAR
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page III
Hydraulic System
HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND
BURN SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY,
BLINDNESS, AND EVEN DEATH.
CORRECT LEAKS IMMEDIATELY.
Hydraulic fluid leaks under pressure may not always be visible.
Check for pin hole leaks with a piece of cardboard, not your hand.
Electrical System
Prevent damage to battery and/or electrical system;
• Always disconnect the negative battery cable first.
• Always connect the positive battery cable first.
If contact is made between the positive side of the battery and a metal surface on the machine when the negative cable is installed a spark will occur. This can cause damage to the electrical system, battery explosion, and personal injury.
Total System
Engine coolant level must be checked only after engine has cooled.
If radiator cap is removed while the coolant is at normal operating temperature, pressure within the coolant system will force hot liquid out through the filler opening and possibly cause severe scalding.
Failure to perform preventive maintenance at recommended intervals may result in the unit being operated with a defect that could result in injury or death of the operator.
Immediately report to your supervisor any Defect or malfunction.
Any defect shall be repaired prior to continued use of the scissors lift.
Inspection and maintenance should be performed by qualified personnel familiar with the equipment.
October 2008
Page IV
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
MACHINE SPECIFICATIONS
Workin g Hei g ht*
Platform Hei g ht
S towed Hei g ht
Platform Entry Hei g ht
Rail s Up
Rail s Folded Down
Maximum Number of Occupant s
Lift Capacity (Evenly Di s tributed)
Roll-out Deck Capacity
31 FT
*
2591RT
9.62 m
*
25 FT
57 IN
100.5 IN
71 IN
5
2000 LB
500 LB
7.62 m
1.45 m
2.55 m
1.80 m
5
907 kg
227 kg
39 FT
*
33 FT
66 IN
109.5 IN
79 IN
4
1500 LB
500 LB
3391RT
12.06 m
*
10.06 m
1.67 m
2.78 m
2.01 m
4
680 kg
227 kg
47 FT
*
4191RT
14.50 m
*
41 FT
74 IN
119 IN
87.5 IN
4
1000 LB
500 LB
12.50 m
1.88 m
3.02 m
2.22 m
4
454 kg
227 kg
Platform Dimen s ion s
With Roll-Out Deck Extended
With Roll-Out Deck Retracted
Deck Width (in s ide)
Guardrail Hei g ht
Toeboard Hei g ht
Roll-out Deck Len g th
180 IN
132 IN
71 IN
44.5 IN
4.57 m
3.35 m
1.80 m
1.13 m
180 IN
132 IN
71 IN
44.5 IN
4.57 m
3.35 m
1.80 m
1.13 m
180 IN
132 IN
71 IN
44.5 IN
4.57 m
3.35 m
1.80 m
1,13 m
7.0 IN
48 IN
18 cm
1.22 m
7.0 IN
48 IN
18 cm
1.22 m
7.0 IN
48 IN
18 cm
1.22 m
Overall Len g th
With Outri gg er s
144 IN
180 IN
3.66 m
4.57 m
144 IN
180 IN
3.66 m
4.57 m
144 IN
180 IN
3.66 m
4.57 m
Overall Width
Wheel Ba s e
Wheel Track
Turnin g Radiu s In s ide
Out s ide
Ground Clearance
Machine Wei g ht** (Unloaded) (Approx.)
Drive
Brake
S s y s tem (Proportional)
Drive
Drive
Lift/Lower S
Gradeability
Ground Pre
Tire S izeS
S
S peed (Approx.) ss peed (Platform Elevated) peed (Platform Lowered) ure/Wheel (Maximum) tandard
Tire Pre ss ure, 12 Ply Pneumatic
12 Ply Foam-Filled
Wheel Load
Wheel Lu g Nut Torque
Hydraulic Pre ss ure
91 IN
102.5 IN
78.5 IN
76 IN
195 IN
12.0 IN
8,000 LB
Multi disc
115 PSI
80 PSI
3437 LB
**
0 – 0.8 MPH
0 – 3.8 MPH
25 sec / 30 sec
45% / 24.2°
Foam-Filled
150-165 FT/LB
2.31 m
2.60 m
1.99 m
1.93 m
4.95 m
30.48 cm
91 IN
102.5 IN
78.5 IN
76 IN
195 IN
12.0 IN
2.31 m
2.60 m
1.99 m
1.93 m
4.95 m
30.48 cm
91 IN
102.5 IN
78.5 IN
76 IN
195 IN
12.0 IN
3629 kg
** 8,700 LB **
3946 kg
** 9,700 LB **
0 –1.3 km/h
2 Wheel Drive Standard, 4 Wheel Drive Option
0 – 0.8 MPH
0 –1.3 km/h
0 – 0.8 MPH
0 – 6.1 km/hr
Multi disc
25 sec / 30 sec
45% / 24.2°
8.09 kg/cm²
12-16.5 NHS “Outrigger”
5.5 bar
Foam-Filled
1559 kg
204-225 Nm
0 – 3.8 MPH
Multi disc
33 sec / 35 sec
45% / 24.2°
117 PSI
0 – 6.1 km/hr
Multi disc
33 sec / 35 sec
45% / 24.2°
8.23 kg/cm²
12-16.5 NHS “Outrigger”
80 PSI
Foam-Filled
3497 LB
150-165 FT/LB
5.5 bar
Foam-Filled
1586 kg
204-225 Nm
0 – 3.8 MPH
Multi disc
40 sec / 50 sec
45% / 24.2°
122 PSI
2.31 m
2.60 m
1.99 m
1.93 m
4.95 m
30.48 cm
0 –1.3 km/h
0 – 6.1 km/hr
12-16.5 NHS “Outrigger”
80 PSI
Foam-Filled
3647 LB
150-165 FT/LB
Main S y s tem
Lift S y s tem
S teer
3000 PSI
2500 PSI
207 bar
172 bar
3000 PSI
2650 PSI
207 bar
183 bar
3000 PSI
2500 PSI
Hydraulic Fluid Capacity
Fuel Capacity
Power S y s tem – Volta g e
Alternator (Li g htin g Coil)
1500 PSI
23 GAL
15 GAL
12 Volts DC
40 Amp
57 liters
12 Volts DC
En g ine Availability S tandard
Option
Meet s re qu irement s of AN S I A92.6-2006 S ection 4.
*Working height a dd s 6 feet (2 m) to pl a tform height.
**Weight m a y incre as e with cert a in option s or co u ntry s t a nd a rd s .
103 bar
87 liters
1500 PSI
23 GAL
15 GAL
12 Volts DC
103 bar
87 liters
57 liters
12 Volts DC
1500 PSI
23 GAL
15 GAL
12 Volts DC
40 Amp
40 Amp
40 Amp
40 Amp
Kubota DF752E, 22 HP (16.4 kW), Dual Fuel, Liquid Cooled
Kubota D1105, 25 HP (8.7kW), Diesel, Liquid Cooled
4400 kg
Multi disc
5.5 bar
**
40 sec / 50 sec
45% / 24.2°
8.58 kg/cm²
Foam-Filled
1654 kg
204-225 Nm
207 bar
172 bar
103 bar
87 liters
57 liters
12 Volts DC
40 Amp
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page V
Roll-O u t
Exten s ion Deck
Control Box
Pl a tform
Rollo u t Exten s ion Deck
"H" H a ndle
M a in
Pl a tform Deck
Lift
Cylinder
B
P as
Control a e nel
Be a m s
M a inten a nce
Lock
ART_2023
October 2008
Page VI
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
B as e
L a dder
PRIMARY MACHINE COMPONENTS
Component
Platform Assembly
Uppe r Co n t r ol s
Deck a n d Rail s
Chai n Clo sur e
Optio n al Gate
Exte ns io n Deck
Co n t r ol Te r mi n al S t r ip
Ho rn (optio n al)
Beam
Mai n
Lift Cyli
Limit s te
S n n a n de ce Lock rs witch
Service Section
2 | 4 | 5
3
5
2 | 5
3 i n t r o
1 | 3 | 4 | 5
2 | 4
Base Assembly
F r o n t D r ive Moto rs i n t r o | 1 | 3 | 4 | 5
R D r ive Moto rs w/B r ake s i n t r o | 1 | 3 | 4 | 5
S tee r i n g Compo n e n t s
Wheel s & Ti r e s
1 | 3 | 4 | 5 i n t r o | 3
H u b s
B r ake s
Axle Lock
Eme r ge n cy Lowe r i n g i i n n t t r r i n t r o o | 1 | 3
1 | 3 o | 1 | 5
Ho s e s & Cable s
O u t r igge r (Optio n )
LPG (Optio n )
1 | 3 |
1 | 2 | 3 | 4 | 5
3 | 5
Power Module
E n gi n e
Hyd r a u lic P u mp
Hyd r a u lic r e s e r voi r
Hyd r a u lic Filte r i i
3 | 4 | 5
1 | 4 | 5 n n t t r r o | 1 o | 1
Parts Section
A
B
B
B
B
B
A | B
C
C
C | E
C
D
D
D
D
D
D
D | E
E | F
C | E | F
E | F
F
F
F
F
F
Component
Control Module
Lowe
Hyd
Pa
Eme
F
F
Powe
Tilt
O
P
O u u
To r u
Th u r r el Ta el r t m Powe eheat t ki r q ottle r r
S
Batte r a
S
Platfo u r n
S igge
AC Ge ge e r r
Relays
r
Co u h e n lic Ma g B n n u
to Platfo ns igge e k r r r cy Lowe toff o r n r t ake Relea y & Di r ato ol s
Ma peed r n s ifold co n r r
(Optio n r m nn ifold
) i n
(Optio s g ect n e
O u t r igge r Co n t r ol Mod u le
(O u t r igge r Optio n )
AC Ge n e r ato r (Optio n )
)
Service Section Parts Section
i
2 | 3 | 4 | 5
1 | 3 | 4 | 5 n t r i n t r o o | 1 | 5
5
5
5
2 | 3 | 4 | 5
2 | 4 | 5
1 | 3 | 4 | 5
3 | 5
1 | 5
2 | 4 | 5
2 | 4 | 5
2 | 4 | 5
2 | 4 | 5
2 | 3 | 4 | 5
1 | 5
A | F
E | F
F
F
F
B | F
F
F
E | F
F
E | F
A | F
F
F
F
F
F
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page VII
LUBRICATION
NO.
ITEM
1
SPECIFICATION
Hydraulic
Reservoir
Fill To The Middle Of The Sight Gauge
With Platform In The Stowed Position.
Mobile Fluid 424.
Do not substitute with lower grade oils as pump damage may result.
2
FREQUENCY OF
LUBRICATION
Check Daily.
Change Yearly or
Every 1,000 Hours, whichever occurs first.
3
Hydraulic
Filter
Hubs
Filter Element Change Every Six Months or
500 Hours, whichever occurs first for Normal Usage.
Change Every Three Months or 300 Hours, whichever occurs first for Severe Usage.
SAE 90 Multipurpose Hypoid Gear Oil.
API Service Classification GL5
Check Every Three Months or
250 Hours, whichever occurs first for Normal Usage
Change Yearly or every 1000
Hours, whichever occurs first for Severe Usage.
1
ART_2024
2
3
LEVEL
Fill to Here
October 2008
Page VIII
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Add Oil Here
EMERGENCY SYSTEMS AND PROCEDURES
IF THE CONTROL SYSTEM FAILS WHILE THE PLATFORM IS
ELEVATED, HAVE AN EXPERIENCED OPERATOR USE THE
EMERGENCY LOWERING PROCEDURE TO SAFELY LOWER THE
PLATFORM.
DO NOT ATTEMPT TO CLIMB DOWN BEAMS (SCISSORS)
ASSEMBLY.
BEFORE LOWERING PLATFORM, RETRACT THE DECK EXTENSION.
Emergency Lowering - 2591RT and
33
91RT
Emergency Down system is used to lower the platform in case of power or valve failure. To lower the platform, pull the red “T” handle located at the rear of the machine.
Lowering stops when you release the “T” handle.
ART_X91_E-Low_Man
Emergency Lowering - 4191RT
The Emergency Down System is used to lower the platform in case of power or valve failure. To lower the platform, perform the following steps:
1. Push down on the toggle switch and hold it to lower the platform to the desired height.
2. Once the platform is fully lowered, release the toggle switch to close the valve.
910 83
Emergency Lowering S witch
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_RT_E-Low_Elect
October 2008
Page IX
PARKING BRAKE AND TOWING CIRCUIT
Note:
Refer to Parts Section E for hose routing.
Machine can be winched or moved short distances in case of power failure at speeds not to exceed 5 MPH (8.05 kph).
Towing/ Winching The Machine
Your machine is equipped with a hub disengage mechanism.
PRIOR TO MANUALLY RELEASING BRAKES, INSURE WHEELS ARE
CHOCKED TO PREVENT MACHINE FROM MOVING.
Disengage Brakes Before Towing:
• Chock the wheels.
• Remove the Torque Engage Cap and reinstall with the bump facing inward on all four hubs
(see illustration).
• Machine is now ready for towing.
AFTER DISENGAGING HUBS THERE
IS NOTHING TO STOP THE MACHINE’S
TRAVEL. MACHINE WILL ROLL
FREELY ON SLOPES. BE ON GUARD
AGAINST RUNAWAY.
Engage Hubs Before Driving:
• Remove the Torque Engage Cap and reinstall with the bump facing outward on all four hubs
(see illustration).
• Machine is now ready for driving.
ENGAGED
DI S ENGAGED
October 2008
Page X
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_Hub-Engage
LIFT AND SUPPORT THE MACHINE
THE USE OF SUBSTANDARD LIFTING DEVICES AND/OR JACK
STANDS MAY CAUSE THE MACHINE TO FALL RESULTING IN DEATH
OR SERIOUS PERSONAL INJURY.
The following are needed to safely lift and support the machine;
• a jack with a lifting capacity of two (2) tons or more.
• jack stands with a rating of one (1) ton or more.
To raise the machine
1. Move machine to a firm level surface capable of supporting the weight of the machine.
2. Chock tires on one end of machine and raise the other end of machine.
3. If wheel is to be removed, loosen but
do not remove
lugs before raising the machine.
4. Position a jack at the end of the machine to be lifted, under a solid lifting point in the center of the frame.
5. Raise the machine and place two (2) suitable jack stands under solid support points at the outer ends of the frame.
6. Lower the machine to rest on the jack stands and inspect for stability.
To lower the machine
1. Tighten lugs to proper torque (refer to machine specifications).
2. Raise machine slightly and remove jack stands.
3. Lower the machine and remove the jack.
4. Remove chocks.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page XI
Notes:
October 2008
Page XII
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION 1:
HYDRAULIC
SYSTEM
SECTION 1:
HYDRAULIC SYSTEM .............................................................................. 1-1
Hydraulic Components Torque Table ............................................................................................................. 1-2
Hydraulic System - General ........................................................................................................................... 1-3
Hydraulic Fluid ............................................................................................................................................... 1-4
Hydraulic Fluid Reservoir ............................................................................................................................... 1-6
Hydraulic Pump ............................................................................................................................................. 1-7
Hydraulic Manifold ....................................................................................................................................... 1-10
Drive and Brake System .............................................................................................................................. 1-12
Floating Axle Lock Cylinder ......................................................................................................................... 1-15
Steering Circuit ............................................................................................................................................ 1-16
Platform Lift Circuit ....................................................................................................................................... 1-18
Optional Outriggers ...................................................................................................................................... 1-20
Optional Generator ...................................................................................................................................... 1-21
Cylinder Repair ............................................................................................................................................ 1-22
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications October 2008
Page 1-1
HYDRAULIC COMPONENTS TORQUE TABLE
Note:
Always lubricate threads with clean hydraulic fluid prior to installation.
Use the following values to torque hydraulic components when a specific value is not available.
Always check for torque values in the following places before relying on the Hydraulic Components Torque Table;
♦
Section E of the Parts portion of this manual.
♦ packaging and instruction sheets provided with new parts.
♦ instruction manuals provided by the manufacturer of the component being serviced.
TYPE: SAE PORT SERIES
#4
#6
#8
#10
#12
#16
CARTRIDGE POPPET
FT. LBS Nm
N/A
N/A
25 - 30
35 - 40
85 - 90
130 - 140
N/A
N/A
31 - 41
47 - 54
115 - 122
176 - 190
FT. LBS
N/A
10 - 20
25 - 30
35 - 40
85 - 90
130 - 140
FITTINGS
Nm
N/A
14 - 27
34 - 41
47 - 54
115 - 122
176 - 190
FT. LBS
135 - 145
215 - 245
430 - 470
680 - 750
950 - 1050
1300 - 1368
HOSES
Nm
15 - 16
24 - 28
49 - 53
77 - 85
107 - 119
147 - 155
October 2008
Page 1-2
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
HYDRAULIC SYSTEM - GENERAL
The hydraulic system is an open center, open–loop type. Generally in this type of system, hydraulic fluid is provided by a variable displacement, pressure compensated, piston type pump which is directly coupled to the engine. As the engine turns, the hydraulic pump drains fluid from the reservoir and pumps this fluid to the valve packages.
If no function is selected to perform, the pump remains on standby and no fluid is pumped through the manifold. Each function has a maximum pressure control limit set by pressure relief valve.
Hydraulic integrated circuit, generally known as the manifold system (valve type) is designed to control all or part of machine functions by integrating various hydraulic cartridge valves into a manifold to provide directional, pressure, flow, and load control.
Hydraulic Roadmap
Hydraulic Reservoir
Hydraulic fluid is held in the reservoir for delivery to the various components and then returned to the reservoir. Returning hydraulic fluid is routed through a filter before entering the reservoir.
Pump
When required, the variable displacement pump delivers hydraulic fluid under pressure to the main hydraulic manifold. Pump volume is controlled by a load sense system.
Hydraulic Manifold
The main manifold directs the hydraulic fluid to the hydraulically operated components and returns fluid to the reservoir through the use of electronically operated solenoid valves.
Drive and Brake System
2 Wheel Drive machines are equipped with two (2) hydraulically operated drive motors.
4 Wheel Drive machines are equipped with four (4) hydraulically operated drive motors.
Each motor is connected to a gear reduction hub. The hubs on the rear drive motors are equipped with spring applied - hydraulically released brakes.
Floating Axle Lock Cylinders
Two (2) hydraulic cylinders control the floating axle on the rear of the machine. When platform is elevated, the cylinders lock into place to increase machine stability.
Steering System
Two (2) hydraulic cylinders control steering.
Lift System
The 2591RT and 3391RT are equipped with one (1) hydraulic lift cylinder.
The 4191RT is equipped with two (2) hydraulic lift cylinders.
Optional Outrigger System
If equipped, the main hydraulic manifold delivers fluid to the outrigger hydraulic manifold. Hydraulic fluid is then directed to four (4) hydraulic cylinders, one at each corner of the machine.
Optional Generator System
If equipped, the generator is driven by a hydraulic motor which receives hydraulic fluid directly from the pressure port of the pump.
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications October 2008
Page 1-3
HYDRAULIC FLUID
Handling Precautions
PERSONS IN REGULAR CONTACT WITH MINERAL-BASED
HYDRAULIC FLUID NEED TO BE AWARE OF THE IMPORTANCE OF
THOROUGH HYGIENE, AND THE PROPER METHODS FOR
HANDLING MINERAL OILS IN ORDER TO AVOID POTENTIAL
HAZARDS TO HEALTH.
If mineral- based hydraulic fluid is SPLASHED INTO THE EYES, it must be WASHED OUT
THOROUGHLY using abundant quantities of water. If irritation persists, medical advice should be sought.
HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND
BURN SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY
OR BLINDNESS.
FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE.
Fluid Recommendations
MEC recommends the use of
Mobil Fluid 424
hydraulic fluid. Do not substitute with lower grade fluids as pump damage may result.
October 2008
Page 1-4
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
Hydraulic Fluid Analysis
Use the following as a guide to determine when analysis of the hydraulic fluid is necessary:
• Anytime the hydraulic pump is replaced.
• If fluid discoloration is noticed in the hydraulic reservoir sight gauge tube.
• If after the first 50 hours of operation, the hydraulic filter element is plugged.
• Anytime the hydraulic filter element shows signs of metal contamination.
• Once every six (6) months, under normal operating conditions.
• Every three (3) months, in extremely dusty or dirty operating conditions.
The hydraulic fluid analysis must be done by a qualified laboratory. Always provide the following information with the test sample.
• Type of hydraulic fluid (see lubrication chart for recommended hydraulic fluid and/or your records).
• Model and Serial number of machine from which sample was taken.
• Purpose of analysis: pump failure, discoloration, etc.
• Type of analysis: complete to show additive breakdown, acid buildup, viscosity, type and percent of contaminants; also, comparison to new fluid and recommendations.
Following the above guidelines will prevent premature failure of pumps, cylinder seals, drive motors, and unnecessary downtime.
If system flushing and replacement of fluid is recommended, refer to the flushing procedure.
System Flushing Procedure
1. With platform fully down, drain hydraulic fluid from hydraulic reservoir into a clean, empty container. Use an fluid filter cart so the fluid may be reused if analysis is good.
2. When the hydraulic reservoir is empty, remove suction strainer and hoses.
3. Remove the bypass filter and hose.
4. Flush the hoses with clean hydraulic fluid.
5. Discard old bypass filter element and replace.
6. Flush out the reservoir with hoses removed from the hydraulic reservoir.
7. Reinstall all hoses removed in the previous steps.
8. Fill hydraulic reservoir with filtered, fresh hydraulic fluid (refer to Lubrication Chart).
9. Loosen output hose fittings at pump to flood with hydraulic fluid. Tighten fittings.
10. Start up the machine. Briefly operate all functions. Two or three lift cycles may be necessary to purge all air from lift cylinder(s).
11. When the above procedures have been completed, fill hydraulic reservoir to full mark on sight gauge.
12. Check all leaks and correct as necessary. Machine is now ready to be placed back in operation.
NOTE:
AVOID MIXING PETROLEUM AND SYNTHETIC BASE FLUIDS. IT IS NOT
ADVISABLE TO MIX FLUIDS OF DIFFERENT BRANDS OR TYPES, EXCEPT
AS RECOMMENDED.
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications October 2008
Page 1-5
HYDRAULIC FLUID RESERVOIR
This consists of the reservoir, a filler cap with breather, a drain plug, a sight gauge, and a bypass filter with a 10 micron filter element.
• Check reservoir for signs of leakage, every week.
Hydraulic Reservoir Assembly
All machines are produced with a spin-on, bypassing filter. When the filter is clogged, hydraulic flow bypasses the filter element. The filter element must be changed every six (6) months or
500 hours. Extremely dirty conditions may require that the filter be replaced more often.
BEWARE OF HOT FLUID. CONTACT WITH HOT FLUID MAY CAUSE SEVERE BURNS.
S ight
G au ge
Filler C a p
Filter
Element
Dr a in
Pl u g
ART_2025
October 2008
Page 1-6
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
HYDRAULIC PUMP
Note:
Refer to Section 4 – Hydraulic Pressure Adjustment Procedures.
Refer to Parts Section F.
An internal combustion engine drives a variable displacement axial piston pump. Flow is proportional to drive speed and displacement.
Remove
1. Turn the Battery Disconnect Switch (inside Control Module) to the OFF position.
2. Tag and disconnect hydraulic hoses, and IMMEDIATELY cap or cover the openings to prevent contamination.
3. Remove the two (2) bolts that hold the pump to the housing.
4. Remove the pump.
Install
1. Install drive hub onto pump shaft. Torque bolt to 45 Ft. Lbs. (61 Nm).
2. Position the pump to the housing. Turn the pump until the splines on the hub align allowing the pump to become flush with the housing.
3. Turn the pump until the bolt holes align with the mounting holes on the housing and install the bolts. Torque to 25-28 Ft. Lbs. (35-38 Nm).
4. Install the hydraulic hoses.
5. Turn the Battery Disconnect Switch to the ON position.
6. Check for leaks and check all hydraulic pressures (refe r to Section 4 ).
Engine
Flywheel
KTR
P u mp Drive
P u mp Ho s e Connection s
Lo a d S en s e
C as e Dr a in
Die s el Engine S hown.
D ua l F u el Applic a tion differ s only in engine s t a rt-motor loc a tion.
KTR Ho us ing
ART_2026
H ub
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
Su ction
Pre ssu re
S t a nd b y
Pre ssu re
Relief
M a in
Pre ssu re
Relief
October 2008
Page 1-7
Hydraulic Pump Seals
Drive Shaft Seal Replacement
Caution:
Be careful not to damage the drive shaft when removing the old seal.
1. Remove the shaft key.
2. Remove the snap ring.
3. Remove the shaft seal.
• Check the surface of the shaft and the housing for imperfections.
4. Install new shaft seal.
• Cover the drive shaft with tape to prevent damage to the seal during installation.
• Coat the shaft seal with grease.
• Seat the shaft seal with a seal setting tool.
5. Install the snap ring.
6. Install the shaft key.
Hydraulic Pump Rebuild
Pump rebuild should only be performed by a qualified mechanic. Contact MEC Technical Support before attempting to rebuild the pump.
October 2008
Page 1-8
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
S n a p Ring
Groove
S n a p Ring
S h a ft S e a l
Drive s h a ft s pline s
Covered with t a pe
To protect s e a l d u ring
In s t a ll a tion
Roller
Be a ring
S h a ft S e a l In s t a ll a tion
Be a ring
Be a ring
S hell
Drive
S h a ft
C as e Dr a in
Port
S w as h
Pl a te
Control
Pi s ton
ART_2027
Su ction Port
Minim u m Flow
Adj us tment
Pre ssu re Port
M a in Pre ssu re
Adj us tment
S t a nd b y Pre ssu re
Adj us tment
Rot a ry
Gro u p
Ret a iner B a ll
S e a l Pin s
S pring
Control
Pi s ton
G u ide
O-ring
Line S en s e
Port
Allen
He a d
S crew s
Control
V a lve
Min Flow
S topper
S top N u t
C a p N u t
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
S n a p
Ring
S h a ft
S e a l
Ho us ing
Ret a iner
Pl a te
Pi s ton
Pi s ton s
(9 tot a l)
Pi s ton
S pring
Pi s ton
Cylinder
Pi s ton G u ide
S him
S him
S n a p Ring
Be a ring
Port
Body
Allen
He a d
S crew s
October 2008
Page 1-9
HYDRAULIC MANIFOLD
Note:
Refer to
Parts Section E.
Tag all components as they are removed to aid in reassembly.
Hydraulic Manifold Removal
1. Disconnect the negative battery terminal.
2. Tag and disconnect the solenoid valve leads.
3. Tag and disconnect hydraulic hoses, and IMMEDIATELY cap the openings to prevent contamination.
4. Remove the bolts that hold the manifold to the mounting bracket.
5. Remove the manifold block.
Disassembly
1. Remove coils from solenoid valves.
2. Remove valves.
3. Remove fittings, plugs, springs, balls, and orifices.
Cleaning and Inspection
1. Wash the manifold in cleaning solvent to remove built-up contaminants, then blow out all passages with clean compressed air.
2. Inspect the manifold for cracks, thread damage and scoring where O-rings seal against internal and external surfaces.
3. Wash and dry each component and check for thread damage, torn or cracked O-rings, and proper operation.
4. Replace defective parts and O-rings.
Assembly
Note:
Lubricate all O-rings before installation to prevent damage to the O-ring. Seat balls in manifold block by lightly tapping on the ball with a brass drift punch.
1. Install fittings, plugs, springs, balls, and orifices. Use one drop of Loctite #424 or equivalent thread locker on each screw-in orifice.
2. Install valves.
Installation
1. Attach manifold assembly to mounting plate with mounting bolts.
2. Connect solenoid leads (as previously tagged).
3. Connect hydraulic hoses (as previously tagged). Be certain to tighten hoses.
4. Connect the battery.
5. Operate each hydraulic function and check for proper operation and leaks.
6. Adjust valve pressures.
October 2008
Page 1-10
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
BACK
TO TANK
DRIVE FORWARD
111 - GRY/RED
LIFT
204 - RED/BLU
GAUGE PORT
COUNTERBALANCE
FRONT
HIGH TORQUE
3 1 3 - YEL/BLK
DRIVE REVER S E
110 - GRY/BLK
S TEER RIGHT
107 - ORG/WHT
S TEER LEFT
10 8 - GRN/RED
PROPORTIONAL
333 - PPL/WHT
ART_2028
RIGHT
LEFT REAR A
RIGHT REAR B
LEFT REAR B
RIGHT REAR A
RIGHT FRONT B
LEFT FRONT A
RIGHT FRONT A
LEFT FRONT B
OA
2 S PEED
BRAKE
LIFT PORT
LOAD S EN S E
- TO PUMP -
ORL S
S TEER RIGHT
S TEER LEFT
PRE SS
ORR
OR S
URE PORT
- FROM PUMP -
LEFT
HIGH S PEED
21 3 - YEL/WHT
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications October 2008
Page 1-11
DRIVE AND BRAKE SYSTEM
Wheel Drive
Note:
Refer to Section 3 for Remove and Install instructions.
Refer to
Parts Section D.
Drive motors are axial piston hydraulically operated. Each motor is connected to a gear reduction hub. Braking is a function of the gear reduction hub.
2 Wheel Drive machines are equipped with two (2) drive motors.
4 Wheel Drive machines are equipped with four (4) drive motors.
Drive Shaft Seal Replacement
Caution:
Be careful not to damage the drive shaft when removing the old seal.
1. Remove the snap ring.
2. Remove the shaft seal.
♦
Check the surface of the shaft and the housing for imperfections.
3. Install new shaft seal.
♦
Cover the drive shaft splines with tape to prevent damage to the seal during installation.
♦
Coat the shaft seal with grease.
♦
Seat the shaft seal with a seal setting tool.
4. Install the snap ring.
S n a p Ring
Groove
S n a p Ring
S h a ft S e a l
Drive s h a ft s pline s
Covered with t a pe
To protect s e a l d u ring
In s t a ll a tion
Roller
Be a ring
ART_2029
October 2008
Page 1-12
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
Hydraulic Motor Rebuild
Motor rebuild should only be performed by a qualified mechanic. Contact MEC Technical Support before attempting to rebuild the pump.
Min Flow
S topper
S top
N u t
C a p
N u t
Be a ring
S n a p
Ring
S h a ft
S e a l
Ho us ing
Be a ring
S hell
Drive
S h a ft
Pi s ton
Rod
Control
Pi s ton
Pl u g
S w as h
Pl a te
Ret a iner
Pl a te
Pi s ton s
(9 tot a l)
Ret a iner
B a ll
S e a l
Pin s
Pi s ton
Cylinder
S pring
S n a p Ring
O-ring
Rot a ry
Gro u p
ART_2030
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
S him
Be a ring
Port
Body
Allen
He a d
S crew s
October 2008
Page 1-13
Gear Reduction Hubs with Brakes
Note:
Refer to
Section 3 for Remove, Replace, and Service instructions.
Refer to Parts Section E.
All machines are equipped with two (2) gear reduction hubs with spring applied - hydraulically released brakes.
4 Wheel Drive machines are equipped with four (4) gear reduction hubs. Only the rear hubs are equipped with spring applied - hydraulically released brakes.
Service and Repair
Refe r to Section 3 for brake repair and all other service for the Gear Reduction Hubs.
ART_2031
October 2008
Page 1-14
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
FLOATING AXLE LOCK CYLINDER
Note:
Refer to Cylinder Repair.
Refer to Section 3 for Remove and Replace instructions.
Refer to the
Parts Manual, Section E for parts list.
There are two (2) cylinders utilized in the floating axle system. These cylinders allow fluid to transfer from one side to the other while the platform is in the stowed position. When the platform is elevated, the electrically operated valve closes, preventing fluid flow and thereby locking the cylinders.
Be a ring
Bleed V a lve
Gree s e Zerk
Be a ring
El b ow Fitting
Poppet V a lve
ART_2032
91RT
FLOATING AXLE LOCK CYLINDER
WITH BEARING S
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications October 2008
Page 1-15
STEERING CIRCUIT
Note:
Refer to
Hydraulic Manifold and Relief Pressure Adjustment Procedure.
Refer to Section 3 for Remove and Replace instructions.
Refer to Parts Section E for hose routing.
The steering system consists of the following components:
• The wheel motor housings have pivots on the top and bottom, and are mechanically linked together via a tie-rod.
• Steering is accomplished hydraulically by using two (2) double-acting cylinders, and a
4-way 3-position solenoid-operated, hydraulic directional control cartridge valve.
• Maximum steering pressure is limited by the steering relief valve (refer to
Relief Pressure
Adjustment Procedure).
Co u nter ba l a nce
V a lve s
Art_2033
S teer Relief V a lve
4 W a y3 Po s ition S olenoid
Oper a ted Hydr au lic
Direction a l Control
C a rtridge V a lve
S teer Right
ORG/WHT
S teer Right
Port
S teer Left
Port
S teer Left
GRN/RED
October 2008
Page 1-16
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
Steer Cylinder
Note:
Refer to
Cylinder Repair.
Refer to Section 3 for Remove and Replace instructions.
Refer to the
Parts Manual, Section E for parts list.
There are two (2) cylinders utilized in the steering system. These cylinders are a double acting type which requires fluid flow to operate the cylinder rod in both directions. Directing fluid forces the piston to travel towards the rod end of the barrel, extending the cylinder rod. By directing fluid to the rod side of the cylinder the piston will be forced in the opposite direction and the cylinder rod will retract.
ART_2034
Front Vie w fro m A b ove
Re a r View from Below
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications October 2008
Page 1-17
PLATFORM LIFT CIRCUIT
Note:
Refer to
Hydraulic Manifold and Relief
Pressure Adjustment Procedure.
Refer to Section 3 for Remove and
Replace instructions.
• The lift system uses the hydraulic pump to obtain proportional lifting function controlled by the lift valve and proportional valve.
• Lowering is single speed. When lowering, the holding valves on the lift cylinder(s) open allowing gravity to lower the platform. Lowering speed is regulated by a fixed orifice located on the lift cylinder(s) as fluid is returned to the reservoir.
• Platform capacity is limited by a hydraulic relief valve in the lift circuit. (Refer to Machine
Specifications or the Hydraulic Schematic for proper setting).
Lift Cylinder
Note:
Refer to
Cylinder Repair.
2591RT AND 3391RT
One (1) single acting type hydraulic cylinder.
The cylinder has an integrated 2-position, 2-way solenoid operated platform lower valve for holding the platform in position. The valve is also externally actuated via a cable for manually lowering the platform.
4191RT
Two (2) single acting type hydraulic cylinders.
Each cylinder has an integrated 2-position, 2-way solenoid operated platform lower valve for holding the platform in position. The valves are also electrically actuated via a toggle switch for manually lowering the platform.
The normally closed holding valve prevents retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve.
Lift
RED/BLU
Co u nter ba l a nce
V a lve s
3 W a y S olenoid
Oper a ted Hydr au lic
S pool V a lve
Lift Relief V a lve
Lift Port
Orifice Under Fitting
ART_2035
October 2008
Page 1-18
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
4191RT
UPPER LIFT CYLINDER
WITH BEARING S
Be a ring
El b ow Fitting
Relief V a lve
Orifice
Pre ssu re Ho s e
Electric a lly
Oper a ted
Down V a lve
B a r b ed El b ow Fitting
Ho s e Cl a mp
Ret u rn Ho s e
Be a ring
4191RT
LOWER LIFT CYLINDER
WITH BEARING
B a r b ed El b ow Fitting
Ho s e Cl a mp
Ret u rn Ho s e
S
Pre ssu
El b ow Fitting re Ho s e
Orifice
Relief V a lve
Ret u rn Ho s e
Tee Fitting
Electric a lly
Oper a ted
Down V a lve
2 B a r b ed S tr a ight
Fitting s a nd
Ho s e Cl a mp s
Be a ring
B a r b ed Fitting
Ho s e Cl a mp
Ret u rn Ho s e
2591RT - 33 91RT
LIFT CYLINDER
WITH BEARING S
ART_2036
El b ow
Fitting
Down V a lve
Orifice
Pre ssu re Ho s e
Cylinder V a lve M a nifold
Emergency Down C ab le
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications October 2008
Page 1-19
OPTIONAL OUTRIGGERS
Note:
Refer to Section 3 for detailed description and troubleshooting.
Refer to Cylinder Repair.
Outrigger Hydraulic Manifold
The Optional outrigger manifold is located in the Control Module behind the Lower Control Box.
Cylinders
Four (4) double acting type hydraulic cylinders.
Retr a ct Coil
Extend Coil
OUTRIGGER
MANIFOLD
O u
V trigger
Retr a a ct lve
O u trigger
Extend
V a lve
OUTRIGGER EXTEND
OUTRIGGER RETRACT
O u trigger
S towed
S witch
(UP)
O u trigger
Pre ssu re
S witch
(DOWN)
FRONT
ORR
OR S
LEFT
ART_2037
October 2008
Page 1-20
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
RIGHT
ORL S
OPTIONAL GENERATOR
Note:
Refer to Section 5, .
Refer to Parts Sections E and F
TO:
BASE
CONTROL BOX
12
11
10
9
8
7
3
4
1
2
5
6
7
8
5
6
3
4
1
2
9
10
11
12
00
00
16
15
220
15
124
PLUGGED
225
116
23
22
RED
RED
FUSE
BATTERY
RED
ORG/GRN
BLK
RED/WHT 71
85 86 87a 30
85 87a
87
1 2
YEL/RED
BLK
ORG/WHT
ORG
GRN/WHT
BLK/WHT
BLU/WHT
ORG/GRN
RED/GRN
BLK
RED/WHT
EXISTING UPPER CONTROL CABLE
220
15
124
PLUGGED
225
116
23
22
PLUGGED
PLUGGED
16
15
7
8
5
6
3
4
1
2
9
10
11
12
3
4
1
2
5
6
TO:
ENGINE
HARNESS
12
11
10
9
8
7
BLK 15
ORG/GRN 171
1 2
Engine
Throttle Control
S olenoid
Gener a tor
Idle Control
S olenoid
Gener a tor
S witch
Control
Mod u le
Gener a tor
Rel a y
Upper
Control s
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications October 2008
Page 1-21
CYLINDER REPAIR
CYLINDERS ARE HEAVY. SUPPORT CYLINDERS BEFORE
REMOVING HARDWARE THAT SECURES THE CYLINDER TO THE
MACHINE.
Rod
S e a l s
S e a l s
Pi s ton
Ret u rn to T a nk
Vent to T a nk
Rod
He a d
Pi s ton S ec u ring N u t
Typic a l S ingle Acting Cylinder
S e a l s
B a rrel
Pre ssu re
S e a l s
Pi s ton
Pi s ton S ec u ring N u t
Pre ssu re a nd
Ret u rn
He a d
S e a l s
Typic a l D ua l Acting Cylinder
B a rrel
ART_2040
Removal
Note:
Refer to
Section 3 for Remove and Replace instructions, and the Parts Manual for a list of hardware specific to the cylinder being repaired.
1. Tag hoses for proper reassembly.
2. Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination.
3. Remove cylinder from the machine as described in Section 3.
October 2008
Page 1-22
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
Preparation
Take care not to damage rod surface and guard against dirt or other foreign objects entering system.
1. Drain all fluid from cylinder.
2. Clean all dirt and grit from outside of cylinder.
3. Insert cylinder into vise.
Cylinder Disassembly
1. Remove the head from the cylinder body.
2. Remove the shaft assembly from the barrel, pulling in a straight line, so as not to scar the internal parts.
3. Insert shaft into a
soft jawed
vise so that the head and piston can be removed. Be sure the shaft and vise are both clean before using.
4. Remove nut at the end of the shaft and pull head and piston off of the rod.
5. Remove all seals from the head and piston using a non-sharp seal tool. These tools are available from various seal suppliers.
9. Clean all fluid and debris off of the head, piston, shaft, collar and barrel using solvent, rags, and an air hose.
10. Inspect parts for scratches, pits or polishing. Check seal groves and sealing surfaces.
a. Scratches or pits deep enough to catch the fingernail are unacceptable; replace the cylinder.
b. Polishing is a sign of uneven loading. Check for roundness. If a polished surface is not round within .007 in. (0.18 mm) replace the cylinder.
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications October 2008
Page 1-23
Cylinder Assembly
CAUTION:
• To insure a quality repair, cylinder parts must be thoroughly cleaned, dry, and free of solvents, and assembly must be performed in a clean area free of dust and contamination.
• To avoid cutting the seals, do not use sharp edged tools during seal replacement. After installing seals allow at least one hour for the seals to restore to their original shape before assembling the cylinder.
• Torque all hardware according to the Hydraulic Components Torque Table unless otherwise specified.
1. Lubricate all components with clean hydraulic fluid.
2. Install new seal kit components. Install all seals on the head and piston using the nonsharp seal tool.
3. Place a small amount of fluid on the inside seals of the head and reinstall it on the shaft, by slipping head over the piston end of the shaft being very careful not to damage the inside seals.
4. Place a small amount of fluid on the inside seals of the piston and reinstall it on the shaft by slowly twisting the piston on over the threads of the shaft being very careful not to damage the inside seals.
5. Reinstall the shaft nut; torque 1 ½” nut to 160 ft. lbs. (216 Nm).
6. Grease the outside seals of the head and piston.
7. Reinstall the shaft into the barrel of the cylinder and push in until groove of the head lines up with the slot in the barrel.
17. Reinstall the cylinder retainer. Installation is reverse of removal.
18. Cycle the cylinder using air to check for proper operation.
NOTE:
It is very important to keep all parts clean when working with hydraulic cylinders, even one small piece of dirt or grit can damage the cylinder.
October 2008
Page 1-24
"2591RT / 3391RT / 4194RT" Service & Parts Manual - ANSI Specifications
SECTION 2:
ELECTRICAL
SYSTEM
SECTION 2:
ELECTRICAL SYSTEM ............................................................................ 2-1
Electrical System - General ............................................................................................................................... 2-2
Deutsch Connectors .......................................................................................................................................... 2-3
Battery ................................................................................................................................................................. 2-4
Battery Preventative Maintenance: ................................................................................................................ 2-5
Battery Replacement ..................................................................................................................................... 2-6
Alarms and Switches ......................................................................................................................................... 2-7
Tilt Alarm ........................................................................................................................................................ 2-8
Relays ............................................................................................................................................................ 2-9
Limit Switch ...................................................................................................................................................... 2-10
Optional Outriggers Switches ......................................................................................................................... 2-10
Continuity Checks ............................................................................................................................................ 2-11
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 2-1
ELECTRICAL SYSTEM - GENERAL
The electrical control system consists of a base control station and a platform control station.
Base Control Station
The base control station, when enabled via the Base/Platform Selector Switch, disables the platform station and provides control for a fixed speed Lift UP/DOWN functionality.
Platform Control Station
The platform control station will operate all functions including drive/steer and lift/lower. Momentary bidirectional rocker switch on the drive controller handle (joystick) provides the steering function. The control system for operation of drive/steer and lift/lower are electric-over-hydraulic type. The drive and lift system is a proportional system controlled by position and direction of the upper control box controller handle (joystick).
October 2008
Page 2-2
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
DEUTSCH CONNECTORS
Deutsch connectors used on MEC equipment is designed so that individual parts may be replaced without replacing the entire component. Special tools and detailed instructions are provided in Deutsch
Connector field kits, MEC part no. 84091.
Male Plug Connector
• Use the flat end of the Removal Tool or a flat blade screwdriver to pry the locking wedge from the connector, taking care not to damage the
Sealing Gasket.
• Inspect and replace damaged parts.
• Replace or re-crimp wires and contacts.
Female receptacle Connector
• Use the notched end of the removal tool or a wire hook to pull the locking wedge from the connector
• Replace worn or damaged parts
• Replace or re-crimp wires and contacts.
Locking Fingers
• Remove the locking wedge as outlined above.
• Using the removal tool or a flat blade screwdriver, push the Locking Fingers aside to release the contact.
• Pull the wire and contact out of the connector.
Heavy Duty Plug
• Slide the removal tool along the wire to be replaced and push into the connector to release the contact.
• Pull the wire and contact out of the plug.
Crimping
ART_2041
Deutsch Connector Field Kit
MEC part # 84091
• Strip 1/4 in. (6 mm) insulation from the wire.
• Insert the contact into the crimping tool and insert the stripped wire into the contact making sure no wires are outside the contact barrel.
• Close the handles of the crimping tool, then release the handles to remove the crimped contact.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 2-3
BATTERY
CHARGING BATTERIES CREATE EXPLOSIVE HYDROGEN GAS.
KEEP SPARKS, FLAMES AND SMOKING MATERIALS AWAY FROM
BATTERIES.
ALWAYS WEAR SAFETY GLASSES WHEN WORKING WITH
BATTERIES.
BATTERY FLUID IS CORROSIVE. THOROUGHLY RINSE SPILLED
FLUID WITH CLEAN WATER.
REPLACE WITH MANUFACTURER APPROVED BATTERIES.
BEFORE DISCONNECTING THE BATTERY NEGATIVE (–) LEAD,
MAKE SURE THAT ALL SWITCHES ARE OFF. IF ON, A SPARK WILL
OCCUR AT THE GROUND TERMINAL THAT COULD IGNITE
HYDROGEN GAS OR FUEL VAPORS.
A 12 volt battery supplies the electrical power required to start the engine and operate the electrical circuits.
Battery Maintenance (in storage)
Follow these procedures for maintenance of battery on a machine not in use:
• Keep battery clean. Electrolyte of batteries should be checked regularly and kept at proper level.
• Never stack one battery directly on top of another because post or container damage can result. If batteries are stored individually, place supporting boards between layers. Rotate stock so that the oldest batteries are used first.
• Batteries should be kept fully charged. A battery, while in storage, should be recharged to full charge at recommended intervals.
A battery fully (100%) charged at 80°F (26.6°C)
- drops to 65% at 32°F (0°C)
- drops to 40% at 0°F (-32°C)
Recommended Intervals
If Stored At:
Below 40°F (4°C)
Above 60°F (15°C)
40°-60°F (4°-15°C)
Recharge:
None required
Every month
Every 2 months
October 2008
Page 2-4
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Battery Maintenance (in use)
Check battery and surrounding area for signs of damage or corrosion.
Check battery terminals for:
• Corrosion: Regularly clean connections and apply a nonmetallic grease or protective spray to retard corrosion.
• Loose connections: Be sure all cable connections are tightly secured, and that good contact is made with terminals.
• Broken or frayed cables: Be sure all connections are good and that no loose or broken wires are exposed. Replace as necessary.
Check battery electrolyte level. Replenish the electrolyte, if necessary. Remove vent caps before filling, and USE ONLY DISTILLED WATER. DO NOT OVERFILL. Fill to level indicator (or ½ inch over the top of separators, if there is no level indicator). Fill after charging to prevent overflow of acid due to expansion. Do not use a hose to add water to batteries.
Allowing the electrolyte level to drop below the top of the separators will lead to shortened battery life.
Excessive water usage can indicate that a battery has been overcharged, has been subjected to excessively high temperatures, or is nearing the end of its service life.
Battery Preventative Maintenance:
Every 15 hours (after battery has been charged), spot-check the specific gravity of two or more cells. A fully charged battery should indicate 1.28 specific gravity. If low readings are noted, check the following:
• Check terminals for corrosion, loose connections and broken or frayed cables.
• Check all cells with a hydrometer for variance in specific gravity. A variation of 0.03 points or more between cells is a cause for concern. Mark the low cells.
Recheck specific gravity of all cells after recharging. Wash the top of the battery, making sure all vents are in place. Do not allow cleaning water or other foreign matter to enter the cells. Use a solution of bicarbonate soda (5 tsp. of baking soda per quart of warm water) and water to wash the battery if there is an accumulation of acid.
Battery Specific Gravity and Voltage Table
SPECIFIC GRAVITY
EACH CELL
Fully Charged
Fully Discharged
1.280
1.130
VOLTS DC
PER CELL 12V BATTERY
2.10
1.75
12.60
10.50
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 2-5
Battery Replacement
To remove battery, follow these procedures.
BEFORE REMOVING THE BATTERY FROM THE MACHINE, TURN
OFF THE BATTERY DISCONNECT SWITCH. THERE SHOULD BE NO
POWER.
Battery is located in the Control Module of the machine.
Always disconnect the negative battery cable first.
Remove bolts holding battery. Lift the battery from the compartment. Put the battery to the side and dispose of properly.
Prevent damage to battery and/or electrical system;
• Always disconnect the negative battery cable first.
• Always connect the positive battery cable first.
To install battery, reverse the process by positioning the battery in the compartment securely with hold down bolts. Connect battery cables. Always connect the positive cable first.
October 2008
Page 2-6
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ALARMS AND SWITCHES
Emergency Stop Button
There are two red emergency stop buttons: one located on the platform control console and the other on the base control panel. This stop button, when in the “OUT” (ON) position, provides power to the desired control station. Also, the stop button, in the event of an emergency can be used to turn off the power by pushing “IN” (OFF). All functions stop immediately when depressed.
Engine
S t a rt / S top
Turn the button clockwise to reset.
NOTE:
As a safety feature, selecting and operating the base controls will override the platform controls, except the platform emergency stop button.
The base control emergency stop button will stop all machine operations, even if the selector switch is switched to platform controls.
R a i s e
(Green)
Lower
(Green)
Throttle
(Green)
Selector Switch
Engine S top
(Red)
Machine can be operated from the base/ ground or platform controls. Activation of one or the other is achieved with this switch.
With the platform controls selected, from the base control panel, if the platform up/ lower function is operated there should be
NO movement. Similarly with the base controls selected, from the platform control console if any machine function is operated, there should be NO movement.
Pl a tform /
Ch ass i s
Diagnostic LED’s
There are Diagnostic LED’s located on the Printed Circuit Board inside the Base
Control box. Each LED represents a function. When the LED is ON the function is ENERGIZED. Refer to the DIAG-
NOSTIC LED’S label to identify the LED function.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Lift / Drive
S peed / Tor qu e
Emergency S top
Choke / Glow Pl u g
Gener a tor (Option a l)
Horn (Option a l)
Drive En ab led Indic a tor
(Option a l)
O u trigger Extend/Retr a ct
(Option a l)
Emergency S top
Ho u r Meter
Circ u it Bre a ker
G as oline/Prop a ne (D ua l F u el)
Engine S t a rt
(Green)
Choke/Prehe a t
(Bl a ck)
ART_2042
ART_2043
October 2008
Page 2-7
Tilt Alarm
The tilt sensor is located in the Control Module.
Level B ubb le
Tilt Alarm Audible
An audible warning is activated once machine is in the raised position and reaches an unsafe angle; all functions are disabled in this condition except Platform
Lower.
Fl a nge N u t
Tilt Alarm Test
Fl a nge n u t
This can be tested by manually tipping the sensor. This
“Push-To-Test” feature enables tilt alarm to be tested without losing its adjustment. Individually push down on each of the three fastened corners of the tilt alarm.
ART_2044
Tilt B as e
Mo u nting Pl a te
There should be enough travel to cause the alarm to sound as each corner is pressed. (There is approximately a three second delay). If the alarm does not sound, the flange nuts have been tightened too far. Loosen the nut on the 90° corners and repeat this test procedure.
Tilt Alarm Sensor Adjustment
• Before attempting to adjust the alarm, park the machine on a firm, flat, level surface. Use of an inclinometer is recommended to ensure front and rear of base is level.
• Adjust the three flange nuts until the bubble on top of the sensor is centered.
• Check that the electrical connections are correct and secured tight.
Master Disconnect Switch
Battery disconnect is provided in the Control Module to facilitate servicing and also to prevent unauthorized use of vehicle by using a padlock (to provide security).
Movement Alarm - Light (optional)
This light is activated as soon as the platform control console joystick (controller) lever is moved off the center “Neutral” position.
THE MOVEMENT ALARM IS PROVIDED FOR YOUR PROTECTION,
AND PROTECTION OF PERSONS WORKING IN THE IMMEDIATE
AREA. DISABLING THIS IMPORTANT SAFETY DEVICE MAY RESULT
IN SERIOUS INJURY OR DEATH.
October 2008
Page 2-8
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Relays
There are relays located inside the control module and inside the Upper
Controls. (Refer to the Section 5 for relay functions and interconnect).
Upper Control Power Relay
Purpose: Cuts power to Upper Controls when Lower Controls are selected.
Power Rel a y
Torque/Speed Relay
Purpose: Disperses power to Torque
Solenoid Valve when high speed or low speed is selected.
M as ter
Di s connect
S witch
Upper
Control s
O u trigger Mod u le (option)
Tor qu e/ S peed Rel a y
O u trigger
Rel a y (option)
Outrigger Relay (option)
Purpose: Cuts power to Lift circuits until
Outriggers are fully deployed and in firm contact with the ground.
Throttle Relay
Purpose: The electric throttle solenoid receives its power through the Throttle
Relay.
Tilt
S en s or
Control
Mod u le
Glow Plug Relay
Purpose: The diesel engine glow plug receives its power through the Glow Plug
Relay.
Power
Mod u le
Throttle S olenoid
Throttle Rel a y
Glow Pl u g Rel a y (Die s el only)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_2045
October 2008
Page 2-9
LIMIT SWITCH
The Limit Switch indicates Platform Height above approximately 10 feet (3 m). The switch operates in conjunction with the circuit board located in the lower control box and the proportional circuit board located in the upper control box.
Lower Controls Circuit Board
When the platform is elevated above 10 feet (3 m).
The limit switch is depressed and opened, causing the circuit board to;
• enable tilt sensor cutout operation.
• lock-out high torque and high speed.
• lockout outrigger operation.
• prevent drive when axle is not centered.
Upper Controls Proportional Circuit Board
When the platform is elevated above 10 feet (3 m).
The limit switch is depressed and opened, causing the proportional circuit board to;
ART_2047
• limit proportional output to approximately 25% in drive
(elevated drive speed).
O u trigger S towed
S witch
OPTIONAL OUTRIGGERS SWITCHES
O u trigger
Pre ssu re
S witch
If the machine is equipped with outriggers, each of the four (4) outriggers has a Stowed Switch and a Pressure Switch.
Outrigger Stowed Switch
• Indicates full retraction of the outrigger cylinder.
•
Drive Function:
The machine will drive when the
Outrigger Stowed Switch on all four (4) outriggers is engaged. If one (1) or more Outrigger Stowed Switch is open (not engaged) the machine will not drive.
•
Lift Function:
If one (1) or more Outrigger Stowed
Switch is open (not engaged) the machine will not lift unless all four (4) outriggers are fully deployed.
Outrigger Pressure Switch
• Indicates full deployment of the outrigger.
•
Lift Function:
When deployment begins the Outrigger
Stowed Switches open and lift function is disabled. When all four (4) outriggers reach full deployment the Outrigger
Pressure Switches close (engage) and lift function is restored.
ART_2046
October 2008
Page 2-10
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
CONTINUITY CHECKS
Check Toggle Switch:
• Disconnect wires and connect one probe of ohm meter to the connection on toggle switch and other probe on other connection.
• When toggle is open, there should be no reading, and when closed there should be a low reading.
Check Selector Switch
• Disconnect wires and connect one probe to common of switch and the other to normally open terminal.
• With the switch flipped, there should be a low resistance.
Check Emergency Stop Button
• Disconnect wires and connect one probe of ohm meter to connection on button and other probe on other connection.
• There should be no reading with the button pressed and a low resistance with it reset.
Check Relay Operation (refer to illustration)
• With the #85 terminal grounded, apply voltage to
#86 terminal connection.
• Confirm normally closed (#87A) contacts are opening. Continuity with #30 will be broken.
• Confirm normally open (#87) contacts are closing.
Continuity with #30 will be made.
Check Limit Switch Operation (refer to illustration)
• Loosen cover screw and lift cover from switch.
• Mark and disconnect wires.
B−
8 5
RELAY DETAIL
(relay energized)
3 0
8 7A
8 7
8 6
B+
ART_2330
• With one probe of ohm meter to “A” and other probe to “B”, release the plunger.
- Low resistance should be seen. Same result should be seen between “C” and “D”.
• With one probe of ohm meter to “A” and other probe to “B”, depress the plunger.
- High resistance should be seen. Same result should be seen between “C” and “D”.
• “E” and “F” should show opposite results as seen on previous tests though there may not be any circuits on these terminals.
SWITCH RELEASED
A - B CLOSED
C - D CLOSED
E - F OPEN
E
F
C
D
A
B
Cover
S crew
Cover
E C A
SWITCH DEPRESSED
A - B OPEN
C - D OPEN
E - F CLOSED
Pl u nger
F D B
ART_2331
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 2-11
Notes:
October 2008
Page 2-12
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION 3:
MECHANICAL
COMPONENTS
SECTION 3:
MECHANICAL COMPONENTS ................................................................ 3-1
Torque Specifications ........................................................................................................................................ 3-2
Mechanical Components ................................................................................................................................... 3-3
Base/ Undercarriage ...................................................................................................................................... 3-3
Tires ............................................................................................................................................................... 3-3
Drive Motors .................................................................................................................................................. 3-4
Gear Reduction Torque Hubs ........................................................................................................................ 3-5
Steer Cylinder .............................................................................................................................................. 3-14
Floating Axle Lock Cylinder ......................................................................................................................... 3-15
Hoses and Cables ....................................................................................................................................... 3-16
Platform Removal ........................................................................................................................................ 3-16
Lift Cylinder Removal and Installation .......................................................................................................... 3-17
Scissor Beam Assembly .............................................................................................................................. 3-18
Cable Routing .............................................................................................................................................. 3-19
Engine Maintenance ......................................................................................................................................... 3-20
Diesel Engine ............................................................................................................................................... 3-20
Gasoline and Dual Fuel Engine ................................................................................................................... 3-23
Outrigger Function ........................................................................................................................................... 3-25
Outrigger Calibration .................................................................................................................................... 3-26
GP106 Outrigger Control Module Troubleshooting ...................................................................................... 3-28
Outrigger Module GP106 LED Flash Codes ................................................................................................ 3-29
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-1
TORQUE SPECIFICATIONS
Fasteners
Use the following values to apply torque unless a specific torque value is called out for the part being used.
SAE GRADE
AMERICAN STANDARD CAP SCREWS
5 8
1/4 - 20
1/4 - 28
5/16 - 18
5/16 - 24
3/8 - 16
3/8 - 24
7/16 - 14
7/16 - 20
1/2 - 13
1/2 - 20
9/16 - 12
9/16 - 18
5/8 - 11
5/8 - 18
3/4 - 10
3/4 - 16
7/8 - 9
7/8 - 14
1 - 8
1 - 14
CAP SCREW
SIZE
- inches FT. LBS
MIN
TORQUE
MAX
Nm
MIN MAX
31
41
51
65
76
95
6.25
8
14
17.5
26
350
407
537
670
111
126
152
238
274
34
45
55
72
84
105
7.25
9
15
19
28
386
448
592
740
123
139
168
262
302
42
55.5
69
88
103
129
8.5
11
19
23
35
474
551
728
908
150
171
206
322
371
46
61
74.5
97.5
114
142
10
12
20
26
38
167
188
228
255
409
523
607
802
1003
TORQUE
FT. LBS
MIN MAX MIN
Nm
MAX
127
148
168
203
318
365
466
543
716
894
41
55
68
86
102
8.25
10.5
18.5
23
35
140
164
185
224
350
402
515
597
790
987
45
60
75
96
112
9.5
12
20
25
37
61
81
102
130
152
190
13
16
27
34
50
222
251
304
474
544
698
809
1070
1137
172
200
228
275
431
495
631
736
970
1211
55.5
74.5
92
116
138
11
14
25
31
47.5
METRIC GRADE
METRIC CAP SCREWS
8.8
10.9
M6 X 1.00
M8 X 1.25
M10 X 1.50
M12 X 1.75
M14 X 2.00
M16 X 2.50
M18 X 2.50
M20 X 2.50
M22 X 2.50
M24 X 3.00
M27 X 3.00
M3 X 3.00
CAP SCREW
SIZE
- millimeters-
8.8
10.9
FT. LBS
TORQUE TORQUE
Nm FT. LBS Nm
MIN MAX MIN MAX MIN MAX MIN MAX
130
172
247
332
423
637
6
16
29
52
85
872
8
20
35
62
103
158
210
301
404
517
779
1066
8
21.5
39
70
115
176
233
335
450
573
863
1181
214
284
408
547
700
11
27
47
84
139
1055
1444
176
240
343
472
599
9
23
42
75
120
898
1224
216
294
426
576
732
11
27
52
91
146
1098
1496
12
31
57
102
163
238
325
465
639
812
1217
1658
293
398
577
780
992
1488
15
36.5
70
123
198
2027
Torque value s apply to fa s teneer s a s received from the s upplier, dry or when lubricated with normal en g ine oil.
If s pecial g raphite g rea s e, molydi s ulphide g rea s e, or other extreme pre ss ure lubricant s are u s ed, the s e torque value s
do not apply
.
Hydraulic Components
Use the following values to apply torque to hydraulic components. Always lubricate threads with clean hydraulic fluid prior to installation.
TYPE: SAE PORT SERIES
#4
#6
#8
#10
#12
#16
October 2008
Page 3-2
CARTRIDGE POPPET
FT. LBS Nm
N/A
N/A
25 - 30
35 - 40
85 - 90
130 - 140
N/A
N/A
31 - 41
47 - 54
115 - 122
176 - 190
FT. LBS
N/A
10 - 20
25 - 30
35 - 40
85 - 90
130 - 140
FITTINGS
Nm
N/A
14 - 27
34 - 41
47 - 54
115 - 122
176 - 190
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
FT. LBS
135 - 145
215 - 245
430 - 470
680 - 750
950 - 1050
1300 - 1368
HOSES
Nm
15 - 16
24 - 28
49 - 53
77 - 85
107 - 119
147 - 155
MECHANICAL COMPONENTS
Following is a description of the major mechanical components of the scissor lift.
Base/ Undercarriage
When steam cleaning the base/ undercarriage, cover electrical components to prevent water penetration.
Steam clean the base as necessary, and inspect all welds and brackets . Check for cylinder pins that turn in their mounting , which will indicate sheared retaining pins.
Tires
Inspect for cuts, chunking, side-wall damage, or abnormal wear. Any tire faults MUST BE COR-
RECTED before further machine operation. Refer to Parts Manual Section for replacement tires.
FAILURE TO USE APPROVED PARTS MAY CAUSE DEATH OR
SERIOUS PERSONAL INJURY.
NOTE:
Replace tires with the correct tires to maintain the rating of this equipment.
Changing Tires
FOAM FILLED TIRES ARE EXTREMELY HEAVY. CARE MUST BE
TAKEN TO AVOID PERSONAL INJURY.
Always block the wheels before raising the machine.
When a tire change is necessary, follow these tips:
1. Chock tires on one end of machine and raise the other end of machine (see Intro Section
- Raising the Machine).
2. Remove lug nuts and pull wheel off.
3. Install the replacement wheel.
4. Fasten lug nuts and tighten to proper torque. (Refer to machine specifications).
5. Lower the machine and remove the chocks.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-3
Drive Motors
Refer to Section 1 for repair information.
There are two (2) hydraulic drive motors on the front axle and two (2) hydraulic drive motors on the rear drive axle. These can be damaged or leaks may occur; repair or replace as necessary.
CAUTION:
• Clean all fittings before disconnecting hoses.
• Tag hoses for proper reassembly.
• Plug all openings to prevent contamination.
Front Drive Motors
Be a ring
S teering B a r
S teer Cylinder
Re a r View from Below
Motor Ho us ing
Fl a t W as her s
ART_2048
Remove
1. Raise and support the front end of machine (see
Intro Section - Raising the Machine).
2. Disconnect the cylinder end and tie-rod from the motor housing.
3. Turn the motor housing to gain access to the motor and hose assemblies.
4. Disconnect hose assemblies from drive motor.
5. Remove the cap screws and remove the drive motor.
6. Be careful not to damage or misplace O-ring.
Replace
Installation is reverse of removal.
Rear Drive Motor
Remove
1. Raise and support the rear end of machine (see Intro Section - Raising the Machine).
2. Remove the wheel and remove cover on top of axle.
Wheel Motor
Mo u nting Bolt
(2 e a ch)
Lock W as her
Cover
Tor qu e H ub
Mo u nting Bolt
(6 e a ch)
3. Disconnect hose assemblies from drive motor.
4. Remove the mounting bolts.
5. Rotate the motor until parts face up.
Remove the motor.
6. Be careful not to damage or misplace
O-ring.
Fl a t W as her
Replace
Installation is reverse of removal.
Use Loctite
®
on mounting bolts.
MOTOR
O-Ring
TORQUE
HUB
ART_2049
October 2008
Page 3-4
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Gear Reduction Torque Hubs
There are two (2) gear reduction hubs on the front axle and two (2) gear reduction hubs with brakes on the rear axle.
Cover
TORQUE
HUB
Bleed Brake On Machine
1. Relocate the upper control box from the platform to a ground access point.
2. Loosen the brake hose approximately one (1) turn.
3. Start the machine and operate drive very slowly until all air is purged from the hose.
4. Tighten the hose fitting and check for leaks.
5. Repeat on opposite side.
Tor qu e H ub
Mo u nting Bolt
(6 e a ch)
ART_2050
Br a ke Ho s e Connection
Torque Hub Repair
Remove torque hubs from machine and move to a clean work surface.
Remove
1. Remove the drive motor (see
Drive Motors earlier in this section).
2. Support the torque hub and remove the six (6) mounting bolts.
Replace
Installation is reverse of removal. Use Loctite ® on mounting bolts. Torque in steps.
1. Hand tighten mounting bolts in sequence (see illustration).
2. Apply torque in sequence: 20 Ft. Lbs. (81 Nm).
3. Apply torque in sequence: 60 Ft. Lbs. (81 Nm).
4. Apply final torque in sequence: 95 Ft. Lbs. (130 Nm).
Torque S equence
Torque in steps
Final torque:
95 Ft. Lbs. (130 Nm)
ART_2051
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-5
Bench Test Torque Hubs
Torque Hubs should be roll and leak tested before and after repair to ensure that the gears, bearings and seals are working properly.
NOTE:
Release brake before performing the roll test.
Br a ke
Port
Release Brake
Brake can be released with hydraulic pressure or by compression.
Option a l
Br a ke
Port
Hydraulic Release
Refer to
Brake Test later in this section.
Compression Release
1. Install two (2) ¼–20 × 5/8” flat head cap screws through the pressure plate and into the piston.
2. Tighten one screw, then the other, a little at a time. Alternate screws until the springs compress and there is no pressure on the retaining ring.
Pre ssu re
Pl a te
Ret a ining
Ring
NOTE:
Remove bolts before performing brake release test.
Pre ssu re
Pl a te
S crew
Hole s
ART_2052
Roll Test
1. Release brake as previously described.
2. Apply constant force to roll the gears and check for smooth operation.
NOTE:
It may be difficult to roll the motor. This is acceptable as long as operation is smooth and consistent.
3. If inconsistency or drag is detected, the gears are not rolling freely and should be examined.
Leak Test
The unit must be air tight. Leaks usually occur at pipe plugs, the main seal, or around O-rings.
1. Attach an air pressure gauge at the brake port.
2. Pressurize the unit to 10 psi (.69 bar) and allow it to equalize. Let it stand for 20 minutes.
If the pressure drops a leak is present.
3. With the unit pressurized, brush a soap and water solution around fittings, O-rings and seals and watch for bubbles.
4. Replace faulty components.
October 2008
Page 3-6
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Brake Test
1. Connect hydraulic line from a hand pump to the brake port.
2. Ensure that the brake is set by trying to rotate the input shaft It should not rotate.
♦
To rotate the input shaft, insert a splined shaft or other tool that will engage the splines of the input coupling.
3. Bleed Brake.
♦
Gradually increase hydraulic pressure while trying to rotate the input shaft (tire/housing) until the brake just starts to release. The pressure should be from 200 to 260 psi (13.8
to 17.9 bar).
♦
Full release should occur at 280 psi
(19.3 bar).
4. Check for leaks
♦
Increase and maintain pressure to 1,000 psi
(69 bar) for 30 seconds.
♦
Leaks must be repaired.
5. Center the input coupling in the spindle, then release pressure.
♦
This will make it possible to install the motor without releasing the brake.
6. Ensure that brake engages when pressure is released.
Br a ke Port
S pindle
Inp u t Co u pling
Centered
Ho us ing
Inp u t Co u pling
Off-Center
ART_2053
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-7
Brake Repair
Only the rear hubs have brakes. Remove torque hub and move to a clean work surface.
CAUTION: Wear eye protection.
Disassembly
1. Compress the brake piston compression springs;
♦
Install two (2) ¼–20 × 5/8” flat head cap screws (provided in brake kit) through the pressure plate and into the piston.
♦
Tighten one screw, then the other, a little at a time. Alternate screws until the springs compress and there is no pressure on the retaining ring.
2. Use retaining ring pliers to remove the retaining ring.
3. Remove pressure plate;
♦
Loosen one screw, then the other, a little at a time.
♦
Alternate screws until the springs are loose.
♦
Remove the cap screws and pressure plate.
♦
Remove the compression springs.
4. Use air pressure to remove the brake piston;
♦
Using an air hose, slowly and carefully pressurize the brake port until the piston is partially out of the piston bore.
♦
Pull the piston the rest of the way out by hand.
5. Remove the backup rings and O-rings from the grooves in the piston.
6. Remove the reaction discs (rotors) and the friction discs (stators) from the brake cavity.
Option a l
Br a ke
Port
Br a ke
Port
Pre ssu re
Pl a te
Ret a ining
Ring
Pre ssu re
Pl a te
S crew
Hole s
ART_2052
October 2008
Page 3-8
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Assembly
1. Install brake kit;
♦
Place a stator (friction disc) then a rotor (reaction disc) into the brake cavity, until there are nine (9) stators and eight (8) rotors (refer to illustration).
2. Install the brake piston seals;
♦
Place the piston on a clean surface with the small opening facing upward.
♦
Apply grease to the O-rings and backup rings.
♦
Install the large diameter backup ring into the large diameter grove on the piston.
♦
Install the large diameter O-ring on top of the backup ring.
♦
Install and fully seat the small diameter O-ring into the small diameter groove on the piston.
♦
Install the small diameter backup ring on top of the O-ring.
3. Insert the piston into the piston bore until it contacts the stator (friction disc).
4. Place the ten (10) springs into the piston.
5. Place the pressure plate on top of the springs and compress the springs (see Step 1 of
Disassembly).
6. Install the retaining ring, making sure it is fully seated.
7. Remove the two (2) cap screws or the brake will not function.
ART_2054
Brake Kit
- S t a tor -
Friction Di s c
(9 e a ch)
- Rotor -
Re a ction Di s c
( 8 e a ch)
O-Ring B a ck u p
S eal Kit
Ret a ining Ring
O-Ring C a p S crew
(2 e a ch)
Br a ke Pi s ton
Br a ke Pi s ton
Compre ss ion
S pring
(10 e a ch)
Pre ssu re Pl a te
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-9
End Cover
Disassembly
Remove torque hub and move to a clean work surface.
CAUTION: Wear eye protection.
1. Drain fluid from torque hub. Note the condition and volume of the fluid.
2. Remove the retaining ring.
♦
Pry the open end of the retaining ring out of the groove with a screwdriver.
♦
Use pliers to pull the retaining ring completely out of the groove.
3. Remove the cover subassembly.
♦
The unit can be carefully pressurized with air to pop the cover out of the unit.
4. Remove the large diameter O-ring from the groove in the cover.
5. Remove the two (2) bolts from the disengage cap and remove the disengage cap.
6. Pull the disengage rod out from the cover.
7. Use appropriate tool to remove the disengage O-ring from the internal grove in the cover.
8. Remove the O-ring plugs from the cover.
Assembly
1. Grease the disengage O-ring and insert into the internal groove in the cover.
2. Install the disengage cap and torque bolts to 70–80 in. lbsl (8–9 Nm).
3. Insert the disengage rod, either end first, into the hole in the cover until it touches the disengage cover.
4. Grease the face of the thrust washer and place in the cover making sure the tangs on the washer seat into the pockets on the cover.
5. Install the O-ring plugs into the cover. Hand tighten only.
6. Grease the cover O-ring and insert it into the grove in the cover.
7. Install the cover and the retaining ring, making sure that the retaining ring is fully seated.
Cover
O-Ring
O-Ring
Pl u g
Di s eng a ge
O-Ring
Di s eng a ge
Rod
Ret
Di s eng a ge
C a p a ining
Ring
October 2008
Page 3-10
Thr us t W as her
ART_2055
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Replace Bearings
Disassembly
Remove torque hub and move to a clean work surface.
CAUTION: Wear eye protection.
1. Remove the Ring Gear Subassembly;
♦
Remove the three (3) flathead bolts that secure the ring gear subassembly to the housing.
♦
Lift the ring gear subassembly off of the housing.
♦
Remove the O-ring from between the housing and ring gear subassembly.
2. Remove the planet gears;
♦
Use a 1/8” diameter punch to drive the roll pin into the planet shaft until it bottoms against the spindle.
♦
Using needle nosed pliers of a hooked tool, reach into the end of the planet shaft to grasp the roll pin and pull the planet shaft out of the spindle.
♦
Drive the roll pin out of the planet shaft.
NOTE:
Use new roll pins when reassembling the unit.
♦
Slide the planet gear subassembly out of the spindle being careful not to drop the needle bearings.
♦
Repeat for the two (2) remaining planet gears.
Ho us ing
S pindle
Ret a ining
Ring
O-ring
Ring Ge a r
Subass em b ly
Bolt
Pl a net S h a ft
Pl a net Ge a r
Subass em b ly
Roll Pin
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_2056
October 2008
Page 3-11
3. Remove the bearing nut;
♦
Place the housing and spindle assembly on a clean surface with the spindle end down.
♦
Remove the two (2) set screws and the bearing nut.
NOTE:
The set screw holes in the bearing nut were staked to prevent the set screws from backing out. It will be necessary to clean up the holes prior to removing the set screws.
4. Remove the bearing cones;
♦
Remove the outer bearing cone.
♦
Turn the unit on its side and press the spindle out of the housing.
♦
Remove the inner bearing cone.
5. Remove the seal boot.
6. Remove the lip seal from the housing.
NOTE:
Use a new seal when reassembling.
7. Remove the bearing cones;
♦
Use a soft steel rod to knock both bearing cones out of the housing.
S pindle
S e a l Boot
Lip
Inner
Be a ringCone
S e a l
Be a ring C u p
Ho us ing
Be a
O u ter
Be a ring Cone ring C u p
S ocket
He a d
S crew
ART_2057
T a pered Be a ring
A ss em b ly
T a pered Be a ring
A ss em b ly
Be a ring N u t
October 2008
Page 3-12
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Assembly
NOTE:
Spray a light film of oil on all component parts during assembly. Spray a generous amount of oil on bearings during installation.
1. Use a pressing tool to press both bearing cups into the housing.
2. Place the inner bearing cone into the inner bearing cup.
3. Grease the seal lip and use an appropriate tool to press the seal into the housing until it is flush with the end of the housing.
4. Place the spindle on the work surface, flange side down, and install the seal boot.
5. Lower the housing onto the spindle.
6. Place the outer bearing cone into the outer bearing cup.
7. Install the bearing nut;
♦
Apply Loctite 243 on bearing nut thread and install the bearing nut.
♦
Leave .003–.005 inches (.076–.127mm) end play to check the initial rolling torque with the unit tied down.
♦
Torque the bearing nut until the rolling torque is 40–50 In. Lbs. (4–5 Nm) greater than initial rolling torque.
NOTE:
Final torque is initial rolling torque plus 40–50 in. lbs. (4–5 Nm). E.g., if the initial rolling torque is 30 in. lbs. (3.5 Nm), the final rolling torque is 70–80 in.
lbs. (8–9 Nm). Be sure the torque wrench is tangent to the housing OD.
8. Install the set screws into the bearing nut threaded holes.
♦
Make sure set screw is driven into the spindle thread.
♦
Tighten the set screws to damage the thread.
♦
Stake the edge of the nut around the set screws so the nut will not loosen.
9. Place thrust washer into the counter-bore of the spindle.
10. Install planet gear subassemblies;
♦
Place a planet gear subassembly into the spindle and align the planet gear bore with a planet shaft hole.
♦
Insert a planet shaft (roll pin hole up) into the planet shaft hole and through the planet gear subassembly with.
♦
Use a punch or similar tool to align the roll pin holes on the shaft and spindle.
♦
Being careful not to strike the planet gears, drive the roll pin into the roll pin holes until the pin is flush with the OD of the spindle.
♦
Repeat for the remaining planet gear subassemblies.
11. Grease the O-ring and place it into the groove on the housing.
12. Place the ring gear subassembly onto the housing and spindle assembly.
♦
Align the three (3) cap screw holes.
Install the cap screws and torque to 15–20 ft. lbs. (20–27 Nm).
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-13
Steer Cylinder
There are two (2) double acting type steer cylinders on this machine. During operation, cylinder(s) should not leak, but a slight damping at the rod seal is acceptable. The pins should be checked for wear.
To replace steer cylinder:
CAUTION:
♦
Clean all fittings before disconnecting hoses.
♦
Tag hoses for proper reassembly.
♦
Plug all openings to prevent contamination.
1. Raise and support the front end of machine (see Intro Section - Raising the Machine).
1. Disconnect hydraulic hoses and cap them.
2. Remove the nut and bolt holding the steer cylinder to the motor mounting bracket.
3. Remove the pin and cotter pin holding the steer cylinder to the front axle.
4. Carefully lift off the steer cylinder.
5. Position the new steer cylinder and install pin and cotter pin to hold cylinder to the front axle.
6. Install nut and bolt to hold cylinder to motor mounting bracket.
7. Connect hydraulic hoses.
8. To purge air from cylinder;
♦ place a suitable container beneath the hose connections to catch spilled fluid,
♦ loosen hose fittings slightly,
♦ actuate steer function,
♦ when all air is purged, tighten hose connections.
Steer Cylinder Seal Replacement
Refer to Section 1 for seal replacement instructions.
ART_2034
October 2008
Page 3-14
Front Vie w fro m A b ove
Re a r View from Below
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Floating Axle Lock Cylinder
There are two Floating Axle Lock Cylinders located at the rear of the machine.
Remove
1. Raise and support the front end of machine (see Intro Section - Raising the Machine).
2. Remove the bolt that secures the long clevis pin to the frame and remove the clevis pin.
3. Remove the bolt that secures the short clevis pin to the floating axle and remove the clevis pin.
Replace
Installation is reverse of removal. Apply one (1) drop of Loctite® to the bolts that secure clevis pins.
Bleed Procedure
1. Relocate the upper control box from the platform to a ground access point.
2. Loosen the bleed valve located on the top of the cylinder.
3. Operate drive very slowly while watching air escape from valve.
♦
Once a steady stream of fluid runs from the valve, release drive and tighten the valve.
4. Repeat on opposite side.
Test Locking and Center Position
1. Place a block approximately 4 inches (10 cm) high behind one of the rear tires.
2. Elevate the platform to 10 feet (3 m).
Clevi s Pin (5/ 8” x 5 1/4 ” )
3. Slowly drive the tire onto the block.
♦
The axle lock cylinders should be locked (no movement).
♦
The opposite tire should be off the ground.
4. Lower the platform.
♦
The axle lock cylinders should release.
♦
The suspended tire should lower to the ground.
Centering
S witch
Nylon
W as her s
Axle Lock
Cylinder
Nylon
Axle G u ide
Be a ring
Clevi s Pin
(5/ 8 ” x 2 1/ 8” )
Be a ring
Pivot Pin
Motor a nd Tor qu e H ub
ART_2058
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-15
Hoses and Cables
Note:
Refer to
Parts Section E for detailed hydraulic hose diagrams.
Inspect all hoses and electrical cables for security and damage. Hoses and cables should be examined for rubbing and chafing.
Check for leaks at fittings. Replace any damaged hose or cable.
1. Tag hoses for proper reassembly.
2. Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination.
3. Torque hose fittings according to the Hydraulic Torque Specification Table.
Platform Removal
1. Raise platform and set the maintenance lock.
2. Connect overhead crane by appropriate lifting device to platform.
3. Disconnect all platform wires.
4. Remove the bolts from both platform scissor mounts at the rear of the machine, and remove the scissor mounts.
5. Slide platform and roll out deck off the machine.
Installation is reverse of removal. Apply one (1) drop of Loctite® to all bolts.
S crew &
Lock
W as her
S ci ss or
Mo u nt
Termin a l
S trip
Termin a l S trip
Cover
S lide
Block
M a inten a nce
Lock
October 2008
Page 3-16
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_2059
Lift Cylinder Removal and Installation
Note:
Refer to
Section 1 for seal replacement instructions.
Refer to Parts Section C for detailed parts list and illustration.
CAUTION:
• Clean all fittings before disconnecting hoses.
• Tag hoses for proper reassembly.
• Plug all openings to prevent contamination.
•
Cylinders are heavy.
Provide proper support
before
removing pins.
•
Attach the lifting device to the cylinder body.
Lifting by either end will cause the cylinder to extend.
1. Raise the scissor arm assembly and support using the maintenance lock.
2. Disconnect hoses and wires and cables to the lift cylinder(s).
3. Use a suitable device to support the lift cylinder.
4. Remove lock plates and cylinder pins.
5. Guide the cylinder through the end of the scissor assembly and lift by the body using a suitable lifting device.
Installation is reverse of removal. Apply one (1) drop of Loctite® to all bolts.
Lock Pl a te S crew s
Lock Pl a te
Cylinder Pin
ART_2060
Lock Pl a te
Lock Pl a te S crew s
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-17
Scissor Beam Assembly
Note:
Refer to Parts Section C for detailed parts list and illustration.
Clean the beams once a year or as necessary and inspect along the beam’s surface, especially welds and brackets.
Scissor Beam Removal
1. Remove the platform and lift cylinder(s).
2. Attach a suitable lifting device to the scissor assembly.
3. Remove the Limit Switch cover and Limit Switch.
4. Remove the bolts from both fixed blocks at the rear of the machine.
5. Slide and lift the scissor assembly
Installation is reverse of removal. Apply one (1) drop of Loctite® to all bolts.
S lide Block
Fixed Block
Axle Center S witch
Limit S witch
Cover
Limit S witch
October 2008
Page 3-18
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_2061
Cable Routing
Cables are routed through scissor beams as illustrated.
2591RT
33 91RT
ART_2062
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
4191RT
October 2008
Page 3-19
ENGINE MAINTENANCE
Diesel Engine
Always wear protective eye-wear when working with fuel and oil.
Engine should be OFF when replacing filter elements.
For complete service information consult the engine manual that came with the machine.
Oil and Oil Filter- Diesel
Dispose of used oil and filters properly.
1. Use a suitable container to catch drained oil. Remove the drain plug.
After oil has drained, replace the drain plug.
2. Remove the old filter and wipe the filter seal contact surface with a clean towel. Coat the seal on the new filter with clean oil, then install and tighten by hand.
3. Fill engine with 10w-30 motor oil until the dipstick indicates FULL.
Capacity is 5.4 US quarts (5,1 l).
4. Recheck dipstick after running engine. Fill as necessary.
Air Filter Element- Diesel
1. Remove the hoses from the canister.
2. Loosen the bracket and remove the canister.
3. Remove the wing-bolt, remove old filter and replace with a new filter.
Replace and tighten the wing-bolt.
Do not run the engine with the air filter element removed.
4. Replace the canister and attach the hoses. Tighten the canister bracket and hose clamps.
F u el Filter
R a di a tor Dr a in
Cool a nt
Recovery T a nk
Air Filter
C a ni s ter
Oil Dr a in Acce ss
Under C ab inet
Oil Dip s tick
R a di a tor
Fill C a p
Oil Fill
C a p
Oil Filter
October 2008
Page 3-20
Air Filter
Element
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_2063
Fuel Filter- Diesel
1. Turn OFF valve on bottom of fuel tank.
2. Place a suitable container beneath the fuel filter assembly to catch spilled fuel. Clean the filter area.
3. Turn filter cartridge ¼ counterclockwise remove. Wipe the filter seal contact surface with a clean towel and install a new filter.
4. Open valve at fuel tank and check for leaks.
5. Purge the air from the fuel system as follows;
• Fill fuel tank to the fullest extent. Open valve on bottom of fuel tank.
F u el Filter
Ho us ing
F u el Filter
C a rtridge
F u el Filter Bleed S crew
W a ter
S eper a tor
¼ T u rn to Remove
F u el Injector
Bleed S crew
• Loosen bleed screw on top of fuel filter housing a few turns.
• Close the bleed screw when there are no more bubbles.
• Open the bleed screw on the fuel injector pump. Use the lift pump hand lever to pump fuel to the injectors. Close the bleed screw when there are no more bubbles.
Do not attempt to start the engine until
Step 5 has been performed.
F u el Injector
P u mp
Throttle
S olenoid
Idle S top
S crew
.020
High S peed
S top S crew
Lift
P u mp
H a nd Lever
Throttle Lever
6. If fuel becomes contaminated with water, use the Water Separator Valve at the bottom of the fuel cartridge to drain water.
Throttle Link
Throttle
S olenoid
Clevi
Pi s ton Throttle
S olenoid
Adj us tment s
ART_2064
Idle Speed Adjustment - Diesel
1. Bring engine to operating temperature.
2. Slow engine to complete idle.
3. Adjust the Idle Stop Screw until the RPM is 950. Adjust slightly up or down to avoid vibrations.
4. Hold the Idle Stop Screw while tightening the jam nut to prevent change in adjustment.
High Speed Adjustment - Diesel
IMPORTANT: In order to prevent electrical system damage, check the Throttle Solenoid
Adjustment after this procedure.
1. Bring engine to operating temperature.
2. Disconnect the Throttle Solenoid linkage at the clevis.
3. Manually pull the Throttle Lever until it contacts the High Speed Stop Screw.
4. Adjust the High Speed Stop Screw until the RPM is 3200 with the Throttle Lever against the High Speed Stop Screw.
5. Turn off the engine and reconnect the Throttle Solenoid linkage at the clevis.
6. Hold the High Speed Stop Screw while tightening the jam nut to prevent change in adjustment.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-21
Throttle Solenoid Adjustment - Diesel
IMPORTANT: This final adjustment must be made after all other throttle speed adjustments. The solenoid must be free to retract fully in order to turn OFF the High Amperage
Pull Circuit. Improper adjustment will result in solenoid failure and may damage the electrical system.
1. With the engine OFF, manually retract the solenoid by grasping the piston, just ahead of the boot, and pull to the fully retracted position.
2. With the solenoid piston fully retracted measure the distance between the High Speed
Stop Screw and the Throttle linkage using a .020 feeler gauge.
3. Adjust clearance at the Throttle Solenoid linkage only.
Do not adjust the High Speed
Stop Screw.
• Disconnect the linkage at the clevis and turn the clevis to lengthen or shorten as necessary.
• Reconnect the clevis and measure again. Repeat until the measurement is correct.
High S peed
S top S crew
.020
Throttle
S olenoid
Idle S top
S crew
Throttle
Lever
Throttle
S olenoid
Pi s ton
(Thre a ded Rod)
Clevi
Throttle
S olenoid
Adj us tment s
Throttle Link
ART_2065
October 2008
Page 3-22
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Gasoline and Dual Fuel Engine
Always wear protective eye-wear when working with fuel and oil.
Engine should be OFF when replacing filter elements.
For complete service information consult the engine manual that came with the machine.
Oil and Oil Filter - Gasoline and Dual Fuel
Dispose of used oil and filters properly.
1. Use a suitable container to catch drained oil. Remove the drain plug. After oil has drained, replace the drain plug.
2. Remove the old filter. Coat the seal on the new filter with clean oil, then install and tighten by hand.
Throttle
S olenoid
3. Fill engine with 10w-30 motor oil until the dipstick indicates FULL.
Capacity is 3.4 US quarts (3,25 l).
4. Recheck dipstick after running engine. Fill as necessary.
Oil Dip s tick
Fuel Filter - Gasoline
1. Turn OFF valve at fuel tank.
2. Loosen the hose clamps on the fuel lines and slide them away from the in-line fuel filter.
3. Remove the in-line fuel filter from the fuel lines.
4. Install a new in-line fuel filter.
• There is an arrow, indicating direction of flow, on the body of the in-line fuel filter. Make sure that the arrow points
from
the fuel tank and
to
the engine.
5. Reposition and tighten the hose clamps.
6. Open valve at fuel tank and check for leaks.
Air Filter
C a ni s ter
F u el Filter
Cool a nt
Recovery T a nk
Oil Fill
C a p
Oil Filter
Oil Dr a in Acce ss
Under C ab inet
ART_2066
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-23
Air Filter Element - Gasoline and Dual Fuel
1. Unlock the catches holding the filter canister cover.
2. Remove the wing-nut from the filter assembly and remove the filter element.
3. Inspect the canister for debris and clean as necessary.
4. Install a new filter element and tighten the wing-nut.
5. Replace the canister cover and lock the catches.
Engine Adjustment - Gasoline and Dual Fuel
The following adjustment points are sealed by the factory and cannot be adjusted.
• Carburetor Pilot Screw
• LPG Main Pressure Adjustment
Screw
• LPG Idle Pressure Adjustment Screw
• Distributor Ignition Timing Adjustment
Screw
Idle Adj us tment S crew
Choke Adj us tment S crew
Choke Adjustment - Gasoline and Dual Fuel
1. Loosen the Choke Adjustment Screw until the linkage rod can move freely.
Choke
S olenoid
2. Manually retract the Choke Solenoid
Piston until it stops.
3. While holding the solenoid fully retracted, close the choke plate until it stops in the fully closed position.
Throttle
S olenoid
Adj us tment
Throttle
Link a ge
4. Allow the choke plate to open slightly and tighten the Choke Adjustment Screw.
Throttle S olenoid
ART_2067
5. Check Choke Solenoid operation to ensure that the choke plate travel does not prevent the Choke Solenoid from retracting fully.
Idle Speed Adjustment - Gasoline and Dual Fuel
1. Bring the engine to operating temperature.
2. With the engine at idle, adjust the Throttle Stop Screw until the engine RPM is 1350±50.
High Speed Adjustment - Gasoline and Dual Fuel
1. Bring the engine to operating temperature.
2. Loosen the adjusting nuts on the Throttle Solenoid.
3. Have an assistant press the Throttle Button on the Lower Controls panel.
4. Adjust the nuts on the Throttle Solenoid Piston until the engine RPM is 3850±50.
5. Tighten the nuts to secure the adjustment.
October 2008
Page 3-24
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
OUTRIGGER FUNCTION
The outriggers on the RT series MEC Scissor Lifts are a One-Touch Activation system. To deploy the outriggers, simply push the outrigger toggle switch down until the outriggers level the unit and the engine returns to idle. You are now ready to lift the platform. The outrigger control module is a
“smart” unit, which will level the unit in all but extreme terrain so you don’t have to attempt to level it yourself.
Operational Characteristics
· To deploy the outriggers, push the Outrigger Switch down and hold until the engine returns to idle. The unit will self-level.
· The outrigger legs can not be operated individually.
· The outriggers system will not operate when the platform is elevated above approximately
10 feet (3 m).
· Travel is locked out when the outriggers are deployed. A Drive Indicator Light, above the outrigger switch, will illuminate when the outriggers are fully retracted.
· The engine will not return to idle when the outriggers are fully retracted. The drive indicator light is your signal that the outriggers are fully retracted.
· If the slope of the terrain is in excess of the outrigger’s leveling capabilities, the outrigger control system will continue to attempt to level and the engine will not return to idle. In this case, if the platform remains outside of the pre-described tilt sensor parameters, the unit will not elevate above 6 feet 2 m) and the alarm will sound, indicating the out-of-level situation.
· The outrigger system uses a Top-out limit switch and a Pressure switch on each leg to monitor their respective positions.
· Each outrigger leg uses a Retract valve and an Extend valve to control cylinder stroke.
These are located under the protective cover atop the outrigger leg.
· A 4-way, 3-position valve, on the outrigger hydraulic manifold controls the direction of oil flow to the outrigger legs.
· The GP106 Outrigger Control Module controls all outrigger valve and interlock duties as well as sensing unit level.
· Diagnosis of the GP106 Outrigger Control Module is possible by counting the number of flashes from the red LED and referring to Outrigger Module GP106 LED Flash Codes at the end of this section. Diagnosis and calibration of the outrigger module can also be done through the use of the EZ-Cal scan tool MEC part # 90888. (See GP106 troubleshooting in this section)
· If the GP106 Outrigger Control Module is ever replaced or removed or if you suspect that it requires calibration, you must use the EZ-Cal scan tool and the following directions to calibrate the outrigger module.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-25
Outrigger Calibration
Before attempting the calibration procedure, move the machine to an area that is level as measured by a spirit level or other leveling device. An EZ-Cal hand-held device (MEC part # 90888) is required to carry out all calibration procedures on the GP106 Outrigger Control Module.
S YMBOL KEY FUNCTION S
E S C/ENTER BUTTON S
To move ba ck a nd forth b etween men u a nd sub -men u
LEFT/RIGHT BUTTON S
S elect men us a nd s etting to b e a dj us ted
UP/DOWN BUTTON S
Adj us t s etting v a l u e s
GP106 Outri gg er Control Module
Connect s to P1
Calibrator
MEC P/N 90888
O u trigger s Rel a y
ART_2068
October 2008
Page 3-26
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Outrigger Tilt Sensor Calibration
The integral tilt sensor of the GP106 Outrigger Control Module must be calibrated to compensate for variations due to installation and vehicle construction. This procedure must be done if the control module is ever repositioned or replaced.
a. Drive machine to level ground.
b. Plug EZ-Cal into connector P1 on the control module.
Display reads HELP: PRESS ENTER.
c. Press right arrow to ACCESS LEVEL 3, Press Enter.
Display reads CODE 0000.
d. Press up and right arrows to enter code 1775, Press Enter.
Display reads ACCESS LEVEL 2.
e. Right arrow to MACHINE SETUP, Press Enter.
Display reads CHANGE DEFAULTS.
f. Right arrow to CALIBRATE LEVEL, Press Enter.
Display reads CALIBRATE LEVEL: YES:ENTER,NO:ESC.
g. Press Enter. Display reads TILT 0.0’,0.0’ h. Press ESC, ESC i. Disconnect EZ-Cal from the outrigger control module.
Outrigger calibration is now complete.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-27
GP106 Outrigger Control Module Troubleshooting
When the
EZ-Cal
hand-held device is connected to the
GP106
control module, the first menu available is “HELP” – just press the
ENTER
button to see a message describing the current status of the
GP106
; this can be very helpful in diagnosing problems with the system.
When an
EZ-Cal
is unavailable, an LED on the
GP106
flashes to provide limited diagnostics
The following messages might be displayed:
EVERYTHING OK
The
GP106
detects no problems.
If problems are being experienced with the system, use the DIAGNOSTICS menus to check for wiring problems.
B+ SUPPLY TOO LOW
The
GP106
is designed for use on 12V and 24V battery powered vehicles; it cannot operate with a supply below about 9V.
The “BATTERY” voltage can be checked in the “SYSTEM” menu (available in the
“DIAGNOSTICS” menu).
CANNOT LEVEL: BAD TILT SENSOR
Ensure that the
GP106
is correctly installed – if it is wrongly oriented, its integral tilt sensor will be unable to measure vehicle tilt correctly.
CHECK OUTRIGGERS SUPPLY (P4-9)
An auto-level or auto-retract signal has been detected by the
GP106
(on P2-5 or P2-6) but there is no supply on P4-9 to power the outrigger legs.
OUTRIGGERS MANUALLY CONTROLLED
The outrigger system cannot be manually controlled, but this message may appear. It indicates a wiring problem to terminal P2-2.
OUTRIGGERS CANNOT BE MOVED
The outrigger system will be unable to operate if the machine is on a steep slope greater than ten (10) degrees.
RELEASE OUTRIGGER DEMAND!
The
GP106
is waiting for an active signal on P2-5 or P2-6 to be released (due to activating a switch when power is applied, or in conjunction with manual use of the outriggers, or activating both switches together).
VEHICLE TILTED
Either the “X” or “Y” tilt (measured by the
GP106
integral tilt sensor) exceeds three degrees.
This does not affect operation of outriggers.
OUTRIGGER WIRING FAULT
The system has detected voltage on P2-2 but voltage is not present on P2-5 or P2-6. Check wiring to P2-5/6.
October 2008
Page 3-28
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Outrigger Module GP106 LED Flash Codes
The
GP106
has a built-in LED to provide simple diagnostics when no
EZ-Cal
is available. Please note that the use of an EZ-Cal provides significantly better diagnostics through the HELP messages listed previously.
LED on steady
This indicates power to, and no fault with, the
GP106
LED off always
This indicates no power to the
GP106
LED flash code 1
Wiring Fault. Check connection to P2-2.
LED flash code 2
This indicates a fault with the switch inputs to the
GP106
. Check wiring to connector P2.
LED flash code 3
This indicates a fault with the “stable” output of the
GP106
– a short to the supply has been detected. Check wiring from pin P2-8
LED flash code 4
This indicates that the outriggers cannot be operated because the machine is on a slope greater than ten (10) degrees. Move machine to a different location.
LED flash code 5
This indicates a fault with the “stable” output of the
GP106
– a short to 0V (ground) has been detected. Check wiring from pin P2-8
LED flash code 6
This indicates a fault with the “auto” inputs of the
GP106
– check the wiring to pins P2-5 &
P2-6
LED flash code 7
This indicates a fault with the supply to the
GP106
– check battery supply at least 8V on pins
P2-12 & P4-9
LED flash code 8
This indicates that the machine is not level. It is not a fault and will not affect operation of outriggers.
LED flash code 9
This indicates that the
GP106
is performing start-up tests.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 3-29
Notes:
October 2008
Page 3-30
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION 4:
TROUBLESHOOTING
SECTION 4:
TROUBLESHOOTING ............................................................................. 4-1
Troubleshooting ................................................................................................................... 4-3
General Troubleshooting Tips ............................................................................................ 4-3
Common Causes of Hydraulic System Malfunctions: ....................................................... 4-3
Hydraulic Pressure Adjustment Procedures ..................................................................... 4-9
Proportional Speed Adjustment .........................................................................................4-12
Controls and Switches ........................................................................................................4-14
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 4-1
HYDRAULIC MANIFOLD
PROPORTIONAL
333 - PPL/WHT
OA
BRAKE
BACK
RIGHT
DIAGNO S TIC LED s
TO TANK
DRIVE FORWARD
111 - GRY/RED
LIFT
204 - RED/BLU
GAUGE PORT
COUNTERBALANCE
FRONT
LEFT REAR A
RIGHT FRONT B
RIGHT REAR B
LEFT FRONT A
LEFT REAR B
RIGHT FRONT A
RIGHT REAR A
S
ORL S
LEFT FRONT B
TEER RIGHT
S TEER LEFT
LOAD S EN S E
- TO PUMP -
ORR
OR S
PRE SS URE PORT
- FROM PUMP -
LEFT
HIGH TORQUE
3 1 3 - YEL/BLK
DRIVE REVER S E
110 - GRY/BLK
S TEER RIGHT
107 - ORG/WHT
S TEER LEFT
108 - GRN/RED
2 S PEED
HIGH S PEED
21 3 - YEL/WHT
LIFT RELIEF
RV1
LIFT PORT
S TEER RELIEF
RV2
ART_2070
October 2008
Page 4-2
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
TROUBLESHOOTING
The 2591RT, 3391RT and 4191RT are designed for ease of diagnostics. There is a terminal strip located under the work platform for checking signals to and from Upper Controls. There are also
LED’s located in the Lower Controls box to indicate outputs from the circuit board.
Diagnostic Example: if the lift LED does not illuminate when attempting to lift, either the main power is not on, or board is not receiving a signal for lift. If LED is illuminated but machine does not lift, there would be an electrical problem between the Circuit board and the valve, or a hydraulic problem. The main valve block is equipped with a quick disconnect gauge port to help diagnose the hydraulic system.
General Troubleshooting Tips
Before investigating a malfunction, check the following items:
• Check that battery switch is turned on.
• Check that battery connections are secure and battery if fully charged.
• Check that the emergency stop button is released (UP/OUT position).
• Check that the hydraulic fluid is at the correct level.
• Check that the circuit breaker is in the “ON” position (not tripped).
Common Causes of Hydraulic System Malfunctions:
• Incompatible hydraulic fluids mixed, destroying the additives and causing varnish build up, resulting in the valves sticking.
• Water in the hydraulic fluid due to a damp climate.
• Improper hydraulic fluid used. Viscosity too high in cold climates. Viscosity too low in warm climates.
• Hydraulic fluid contaminated with debris - filter change interval neglected.
NOTE:
Mobil Fluid 424 Hydraulic Fluid, is a multiple viscosity fluid that is light enough for cold climates and resists thinning in warm climates. Only Mobil Fluid 424 or equivalent must be used. Substituting with a lower grade fluid will result in pump failure.
Following is a step by step basic troubleshooting guide.
NOTE:
Contamination always causes failure in any hydraulic system. It is very important to be careful not to introduce any contamination into hydraulic system during the assembly procedures. Please make sure all ports and cavities of the manifold and cylinders are properly covered/plugged during maintenance activities.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 4-3
PROBLEM
General Power Issue
No operation from upper or
Upper Control station
PROBABLE CAUSE
Main battery switch turned off
Emergency switch pushed in or Ignition switch turned off
Dead Battery
Blown fuse
Circuit breaker tripped
Damaged Upper Controls box harness
Failed 25 AMP diode
Failed Power Relay on Circuit board
Faulty relay, located in Upper Controls box Functions from Upper
Controls but not from Upper
Controls
Interlock switch (Joystick)
Lift/Lower
Platform will not Raise
REMEDY/SOLUTION
Located left of Lower Controls box
Upper or lower Emergency Stop switch will cut all power as will the Ignition switch in the Platform Controls box
Charge battery
Sealed unit just below Lower Controls box
Reset - Located in Lower Controls box panel
Inspect from harness plug to terminal strip under platform
Test/replace. Located inside Lower Controls box
Replace circuit board in Lower Controls box
Check power on wire 101 from Key switch
Check power on wire 101A from relay to Joystick plug
Check power to RED wire (power to switch) and power to
PURPLE wire (power out of switch) at Joystick plug
Platform will not Raise
(with outriggers option)
Excessive weight on Platform
Lift Relief valve out of adjustment
Lift Valve SV-1 not energized
Lowering valve SV-5 stuck open
(located at base of lift cylinder CYL-1)
Level Sensor out of level
(platform elevated above 6 feet)
Main system pressure inadequate
Proportional control out of adjustment
(High Range Adjustment)
All outrigger feet deployed but not firmly on ground.
Outrigger pressure switch inoperative
Reduce weight to within platform capacity
Adjust relief valve to rated capacity
Check lift circuit from Upper Controls box to SV-1 valve
Check and remove contamination, E-Down cable damaged or replace valve
Reposition machine to firm level surface,
Check Level Sensor function
Check pump output pressure (see Hydraulic Pump Adjustment in this section)
See Proportional Speed Adjustment in this section
Platform will not lower or lowers slowly
Redeploy outriggers by pushing the outrigger switch down.
Inspect all four outrigger pressure switches located on top of the outrigger legs.
Return Maintenance Lock to the stowed position
Check lowering circuit from Upper Controls box to Lowering valve SV-5
Clean debris, replace
Clean orifice
Check valve coils Lowers but not completely
(4191RT only)
Emergency lowering not working
Maintenance Lock in maintenance position
Lowering valve not energized
Lowering valve not shifting
Lowering orifice (ORF-3) plugged
Down valve on one cylinder inoperative
4191RT ONLY
Lowers but not completely
October 2008
Page 4-4
E-Down cable broken or frayed (2591RT/3391RT)
Lowering valve not shifting
Lowering orifice (ORF-3) plugged
E-Down battery discharged
Valve coil failed on either cylinder
Down valve on one cylinder inoperative
Replace E-Down cable
Clean debris, replace
Clean orifice
Charge, check charge diode & connections
Test, replace
Check valve coils, wiring
continued…
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
PROBLEM
Drive
No drive function
(with outriggers option)
No drive elevated
(with outriggers option)
Slow drive with Platform stowed
Drive in one direction only
No low speed (high torque mode)
PROBABLE CAUSE REMEDY/SOLUTION
Valve SVD1 not energizing Check forward/reverse LEDs lighting up at circuit board inside
Lower Controls box
Check connections at valve
Check voltage at valve
Check ground to valve
Check valve for proper functioning
Check OPL5 brake orifice for contamination
See Proportional Controller Adjustment in this section brakes not releasing
Proportional Control out of adjustment
(High Speed adjustment)
Outriggers lowered
Outrigger Retracted switch/s inoperative
Outriggers lowered
High torque enabled
Limit switch not functioning
Check Drive Enable light - raise outriggers
Check enable light on Platform Controls box
Check outrigger switches located on top of each outrigger jack for continuity
See Proportional Controller Adjustment in this section Proportional Control out of adjustment
(Low Range adjustment)
Axle out of center or Axle Center switch inoperative
Unit out of level
Lower platform and reposition o level ground. Inspect switch on level ground.
Lower and reposition the machine.
Check Level Sensor malfunction
Check Drive Enable light - raise outriggers
Check Speed/Torque switch in Platform Controls Box
Limit switch at rear center of base
Check continuity between wire 2 TAN/ORG and wire 20 RED/
WHT. Continuity = platform stowed.
12 volts to “R” terminal on circuit board in Platform Controls box = High Range
See
Proportional Controller Adjustment in this section
Upper Controls circuit board running in slow speed mode
Proportional Control out of adjustment
(Low Range adjustment)
Engine not running to full potential
Wheel motor/s not functioning correctly
RV3 or RV4 not adjusted correctly
Rev-Up or FWD-Down micro-switch failure
Drive valve SVD1 not energizing in one direction
Counterbalance valve CBV1 or CBV2 not functioning correctly
Speed/Torque selector switch inoperative
Valve SV3 not functioning
Check engine operation as per engine manufacturer guidelines
Inspect wheel motors for excessive bypass
Check and adjust relief valves
Check micro-switches on Joystick controller for function or adjustment
Check 12 volts to appropriate coil, check coil, check valve function
Swap Counterbalance valves to see if functioning direction changes.
Check for 12 volts on terminals 2 & 3 of Speed/Torque switch in Platform Controls box with drive enabled
Check for 12 volts and ground to valve
Check for faulty valve spool
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications continued…
October 2008
Page 4-5
Drive
PROBLEM
No Mid Speed
No High Speed
PROBABLE CAUSE
SV3 or SV4 powered and/or shifted
Speed/Torque selector switch malfunction
Speed/Torque selector switch inoperative
Faulty diode block DB1
Valve SV4 not functioning
REMEDY/SOLUTION
These valves should not have 12 volts, in mid-speed, check valve function
Should not have power at terminals 1 & 3 of Speed/Torque switch in Platform Controls box with drive enabled
Check for 12 volts on
all
terminals of Speed/Torque switch in
Platform Controls box with drive enabled
Test DB-1 in Platform Controls box.
Check voltage and ground to valve.
Check for faulty valve spool.
Should provide pressure to 2SP Port
Multi-Function
No drive or Lift function from
Upper Controls with steer operational
PWM circuit board in Platform Controls box not functioning correctly
Proportional valve malfunction
Check battery + and - terminals at board.
Check PWM output at A terminal.
Check connections between A terminal and Proportional valve.
Check, for 1 AMP at valve during full Joystick stroke. Replace
Proportional valve SP-1
Check, replace valve EC1
No steering With Drive operational
EC1 pressure compensation valve not functioning
SV2 not functioning
Faulty lift/drive selector switch
Faulty steer switch
Steering Cylinder/s internal leakage
RV1 steer relief valve not functioning
Check voltage and ground to valve
Check for faulty SV2 valve
Check power on wire #25A on switch
Check switch in Joystick handle
Check for internal leakage - repair
Check adjustment or replace
October 2008
Page 4-6
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications continued…
PROBLEM
Diesel Engine
Starter inoperative
PROBABLE CAUSE
Battery Cables loose or corroded
Key switch not functioning
Starter not functioning
Circuit board relay failed
No Engine start:
Starter operates
Low diesel fuel level
Fuel valve closed - located at fuel tank
Air in injector lines
Fuel filter clogged
Run solenoid not activating
Engine starts but dies when starter disengaged
Glow plugs inoperative
Faulty oil pressure switch
Faulty Fuel solenoid
REMEDY/SOLUTION
Clean, tighten cables
Check power to wire #20 at Key switch while cranking
Check power to YEL/RED #220 wire at starter,
Check ground cable to engine bell housing
Check
input
on plug A pin-17, ORG/RED wire #20 on Lower
Controls circuit board
Check
output
on plug B pin-1, YEL/RED wire #220 on Lower
Controls circuit board.
12 volts in - 0 volts out = replace circuit board
Fill diesel tank, (see Section 3 for Fuel Priming instructions)
Open valve
See
Section 3 for Fuel Priming instructions
Replace fuel filter
Check power at WHT/BLK wire #320 from starter to run solenoid while cranking (WHT/BLK pull in, GRN/WHT hold wire)
See “
Glow Plugs Inoperative” in this section
Check switch and wiring
Check 12 volts on GRN/WHT wire #116 -
Replace Fuel Solenoid
Dual Fuel Engine - Gas
Starter inoperative
No Engine start:
Starter operates
Battery Cables loose or corroded
Key switch not functioning
Starter not functioning
Circuit board relay failed
Low gas level
Fuel valve closed - located at fuel tank
Clogged Fuel Filter
Faulty fuel selector switch
Faulty fuel shut off solenoid
Faulty fuel pump
Clean, tighten cables
Check power to wire #20 at Key switch while cranking
Check power to YEL/RED #220 wire at starter,
Check ground cable to engine bell housing
Check
input
on plug A pin-17, ORG/RED wire #20 on Lower
Controls circuit board
Check
output
on plug B pin-1, YEL/RED wire #220 on Lower
Controls circuit board.
12 volts in - 0 volts out = replace circuit board
Fill gas tank
Open valve
Replace fuel filter, located on fuel hose below engine
Check power to BLK/WHT wire #23 while cranking engine
Check power and ground at gas solenoid,
Check solenoid operation located in float bowl
Check power and ground at fuel pump during engine crank.
Check fuel pump operation
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications continued…
October 2008
Page 4-7
PROBLEM
Dual Fuel Engine - LP
Starter inoperative
PROBABLE CAUSE REMEDY/SOLUTION
No Engine start:
Starter operates
Propane tank empty or valve closed
Faulty carburetor mounted Propane solenoid
Faulty propane shut off solenoid
Engine runs rough, no power, poor throttle response
Faulty fuel selector switch
Clogged Propane Filter Located under the propane tank shelf
Vapor withdrawal tank installed
Low engine coolant level
Clogged Propane Filter Located under the propane tank shelf
Propane regulator malfunction
Throttle, Choke & Glow Plugs
Throttle does not operate Maladjusted Throttle Solenoid (maladjusted throttle solenoid will result in the failure of the solenoid)
Throttle Solenoid failure
Throttle Relay (located on side of engine)
Failed diode block (Large) located in Upper
Controls box
Failed Throttle solenoid
Clean, tighten cables
Check power to wire #20 at Key switch while cranking
Check power to YEL/RED #220 wire at starter,
Check ground cable to engine bell housing
Check
input
on plug A pin-17, ORG/RED wire #20 on Lower
Controls circuit board
Check
output
on plug B pin-1, YEL/RED wire #220 on Lower
Controls circuit board.
12 volts in - 0 volts out = replace circuit board
Fill tank - open valve
Check power and ground at Proportional solenoid,
Check solenoid operation
Check power and ground at Shut-off solenoid,
Check solenoid operation
Check power to BLU/WHT wire #22 while cranking engine
Turn Off Propane valve before filter inspection or replacement
Replace tank with Liquid withdrawal type
Check, add coolant.
Turn Off Propane valve before filter inspection or replacement
Replace Propane Regulator
Adjust throttle linkage
NOTE: throttle linkage adjustment is critical on diesel engine)
Check + and - to solenoid while operating Throttle
Test for 12 volts on RED wire #00 and ORG wire # 225 while throttle is requested
Power on these wires should = 12 volts on ORG/BLK wire 325
Test and/or replace diode block
Check for Throttle LED on Upper Control board
Replace Throttle Solenoid Throttle does not remain energized
Choke does not operate
Battery Cables loose or corroded
Key switch not functioning
Starter not functioning
Circuit board relay failed
Glow Plugs inoperative
October 2008
Page 4-8
Choke Solenoid failure
Failed Choke switch
Failed Glow Plug Switch
Failed Glow Plug Relay - located on side of engine
Failed glow plugs
Check + and - to solenoid while operating Choke
Try Choke switch on opposite control panel
Check for Choke LED on Lower Controls circuit board
Try Glow Plug switch on opposite control panel,
Check for LED on Lower Controls circuit board.
Test for 12 volts on RED #00 wire and on ORG/WHT wire #124 while operating glow plugs.
Power on these wires should = 12 volts on ORG/BLU wire 224
Check for 12 volts at glow plugs while operating glow plugs.
end Trouble Table
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
HYDRAULIC PRESSURE ADJUSTMENT PROCEDURES
•
Before attempting to check and/or adjust pressure relief valves, operate the machine for
15 minutes or long enough to sufficiently warm the hydraulic fluid.
•
Insert a 0-5000 psi gauge onto the pressure test port on the valve manifold using gauge adapter fitting MEC part no. 8 434
Pressure Adjustment Table
MODEL
2591
3391RT
4191RT
MAIN (PUMP)
3000 PSI 207 bar
3000 PSI 207 bar
3000 PSI 207 bar
LIFT (MANIFOLD RV1)
2500 PSI 172 bar
2650 PSI 183 bar
2500 PSI 172 bar
STEER (MANIFOLD RV2)
1500 PSI 103 bar
1500 PSI 103 bar
1500 PSI 103 bar
STAND-BY (PUMP)
500-550 PSI 35-38 bar
500-550 PSI 35-38 bar
500-550 PSI 35-38 bar
RV1
Lift Relief
RV2
S teer Relief
LEFT S IDE
G au ge Port
(Te s t Port)
M a in Relief
S t a nd-By
Pre ssu re Relief
LIFT CYLINDER MANIFOLD
33 91RT & 4191RT
RV4
Overpre ssu re Relief
(not a dj us t ab le)
PUMP
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_2071
October 2008
Page 4-9
Pump Adjustment
The Hydraulic Pump used in this model is a Variable Displacement, Pressure Compensated,
Piston type pump. Proper adjustment is critical for normal operation of the machine. The following paragraphs will guide you through the various steps however, you must perform all steps, in their listed sequence, in order to achieve proper adjustment and machine performance.
Main Relief and Standby Pressure Adjustments
1. Start engine and operate the unit for 15 minutes or until the hydraulic fluid is warm.
2. Insert a 0 – 5000 PSI (0-345 bar) gauge onto the manifold pressure gauge port.
3. Remove the acorn nut from the Main Relief adjustment screw. Loosen the jam nut and turn the screw counterclockwise 3 turns. Tighten the jam nut and install the acorn nut.
4. Remove the acorn nut from the Standby adjustment screw and loosen the jam nut. Turn the screw clockwise 3 turns or until the needle on the gauge stops climbing. At this point the gauge is reading full main relief pressure.
5. Access the Main Relief screw again and adjust it until the gauge settles at 2 8 00 PSI
(193.5 bar). Tighten the jam nut and install the acorn nut.
6. Check the gauge reading again to ensure the setting did not change.
7. Turn the Standby adjustment screw counterclockwise until the gauge reads 550 PSI
(3 8 bar). Tighten the jamb nut and install the acorn nut.
8 . Check the gauge reading again to ensure the setting did not change.
Pump Displacement Adjustment
This adjustment is set at the factory and should not be tampered with. The Displacement adjustment controls the maximum amount of fluid flow that the pump will produce per revolution.
Excessive flow will result in severe engine loading and stalling. Reduced flow will result in slower functions with no engine loading. If you suspect that the sitting is incorrect, please call MEC
Product Support at ( 8 00) 3 8 7-4575 for assistance.
Lift Relief (RV1)
The Lift Relief valve is located on the left-side, center of the valve manifold. It will be necessary to remove the cap from the relief valve if adjustment is necessary. REMOVING THE CAP WHILE
THE ENGINE IS RUNNING WILL RESULT IN FLUID LEAKAGE.
To check Lift Relief valve setting, park the machine on a firm level surface free from overhead obstructions. Using the lift switch on the lower panel, elevate the platform to full elevation. While maintaining the lift command, record the reading on the gauge.
Steering Relief (RV2)
The steering Relief valve is located on the left side, lower of the valve manifold. It will be necessary to remove the cap from the relief valve if adjustment is necessary. REMOVING THE
CAP WHILE THE ENGINE IS RUNNING WILL RESULT IN FLUID LEAKAGE.
To check Steering Relief valve setting, operate steer in one direction. While maintaining the steer command, record the reading on the gauge.
October 2008
Page 4-10
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Lift Cylinder Overpressure Valves (RV4) 4191RT Only
The Lift Cylinder Overpressure valves are located on each of the lift cylinder valve blocks on the
4191RT model only.
Proper valve adjustment is not possible by the consumer. Considering their importance to the safe operation of the machine, they must not be tampered with. If the valve is suspected to be out of adjustment or tampered with, it must be replaced.
Setting Counterbalance Valves
1. Loosen the locknut on one of the valves.
2. Turn the adjustment screw clockwise (to the right) until it reaches the internal stop and the screw will turn no further.
3. Tighten the locknut while holding the adjustment screw in position to prevent it from rotating.
4. Repeat steps 1 through 4 on the other Counterbalance valve.
5. Adjustment is complete.
Co u nter ba l a nce
V a lve s
ART_2072
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 4-11
PROPORTIONAL SPEED ADJUSTMENT
Proportional Circuit Board Adjustment should only be performed after all other components are deemed to be in proper working order.
There are many factors that may contribute to excessively fast or slow drive speeds. Proportional
Circuit Board Adjustment should only be performed after all other components are deemed to be in proper working order and not contributing to abnormal driving speeds. Failure to do so may result in incorrect speeds once the offending component has been repaired.
Circuit Board Setting Test Procedure
Before you begin, ensure there are no overhead obstructions preventing lift to full height. Lay out a course measured at 20 feet (6 meters) long. Ensure there are no obstructions preventing a straight travel over the distance of the course including leading up to and away from the course.
Try not to steer while driving the timed course.
RUN-IN 20 FT (6m) RUN-OUT
ART_2073
High Speed Drive Test:
With the platform fully lowered, drive the machine over the course, crossing the start line at full speed. Record the time it takes for a (predetermined) point on the machine to cross both lines and compare with the chart below using the ‘High Range’ column figure.
Elevated Speed Drive Test:
Elevate the platform above 12 feet (3.6 meters). Drive the machine over the course, crossing the start line at full speed. Record the time it takes for a (predetermined) point on the machine to cross both lines and compare with the chart below using the ‘Low Range’ column figure.
Speed Adjustment Table: 20 ft. (6 m) Course
TRIM POT
High Range
Low Range
TRAVEL TIME
IN SECONDS
3.5 to 4.0
27 to 33
October 2008
Page 4-12
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Adjustment Procedure
Note:
Proportional Controller adjustments should only be made when the possibility of unauthorized tampering exists or after the Proportioning Valve or Proportional Circuit board was replaced. Though testing the proportional output should be part of routine maintenance, adjustments should not be necessary as a routine maintenance procedure.
The Trim Pots are located in the Platform Controls box (see illustration).
PLATFORM
CONTROL S
ADJU S TMENT
S CREW
1. Turn the RAMP trim pot counterclockwise until a clicking noise is heard.
HI RANGE
2. Ensure there are no overhead obstructions preventing lift to full height. Select LIFT mode, pull the enable and move the Joystick in reverse slowly to the point that the engine accelerates and hold it at that point. While holding the Joystick in that position, adjust the THRESH trim pot until the platform does NOT lift. Once adjusted, slight additional reverse motion of the Joystick should result in very slow and controlled lift action.
THRE S H
LO RANGE
RAMP
ART_2074
•
Counterclockwise trim pot adjustment increases the amount of Joystick travel before platform movement.
•
Clockwise trim pot adjustment will allow platform movement sooner in the
Joystick travel.
3. If the machine was slow in the High Speed portion of the test, turn the HI RANGE trim pot clockwise until a clicking noise is heard.
4. If the Elevated Speed Drive Test resulted in speeds other then those listed, turn the LO
RANGE trim pot clockwise to increase elevated drive speed or counterclockwise to decrease elevated drive speed to the proper speed. Repeat the Elevated Speed Drive
Test.
5. The RAMP trim pot controls the smoothness of the motion start-up and linear ramp-up response. Turn the RAMP trim pot clockwise until the slowest machine start-up can be achieved while maintaining good proportional ramp-up through the travel of the Joystick.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 4-13
CONTROLS AND SWITCHES
Power Rel a y
Engine
S t a rt / S top
MicroS witche s
S teering
En ab le S witch
Rever s e/Down
Rocker S witch
Forw a rd/Up
Rocker S witch
Potentiometer
ART_2075
Lift / Drive
S peed / Tor qu e
Emergency S top
Choke / Glow Pl u g
Gener a tor (Option a l)
Horn (Option a l)
Drive En ab led Indic a tor
(Option a l)
O u trigger Extend/Retr a ct
(Option a l)
R a i s e
(Green)
Lower
(Green)
Throttle
(Green)
Engine S top
(Red)
Pl a tform /
B as e
Emergency S top
Ho u r Meter
Circ u it Bre a ker
G as oline/Prop a ne (D ua l F u el)
Engine S t a rt
(Green)
Choke/Prehe a t
(Bl a ck)
October 2008
Page 4-14
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION 5:
SCHEMATICS
SECTION 5:
SCHEMATICS .............................................................................................. 5-1
Hydraulic Schematic ............................................................................................................ 5-2
Main Hydraulic Manifold .................................................................................................... 5-4
Optional Outriggers ........................................................................................................... 5-5
Electric Schematics ............................................................................................................. 5-6
Wire Harness Connections ............................................................................................... 5-6
Main Wiring Harness ......................................................................................................... 5-7
Circuit Board Schematic ................................................................................................... 5-8
Upper Controls .................................................................................................................5-10
Upper Controls - With Outriggers .....................................................................................5-11
Lower Control Box ............................................................................................................5-12
Diesel Engine ...................................................................................................................5-13
Dual Fuel Engine .............................................................................................................5-14
Optional Outriggers ..........................................................................................................5-15
Optional Generator ..........................................................................................................5-16
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 5-1
HYDRAULIC SCHEMATIC
Callout
CYL2
MA3
SV5
ORF3
Description
Lift Cylinder Components (2591RT/3391RT)
Cylinder
Manifold, Lift Cylinder
Solenoid Valve - 12V Cable Attach
Orifice - 0.093
CYL3
MA5
SV6
RV4
ORF4
CYL4
MA4
SV6
RV4
ORF6
LF
LR
RF
RR
P1
Lift Cylinder Components (4191RT)
Cylinder, Upper
Manifold, Lift Cylinder, Upper
Solenoid Valve - 12V Dual Coil
Relief Valve - 3200 PSI
Orifice - 0.093
Cylinder, Lower
Manifold, Lift Cylinder, Lower
Solenoid Valve - 12V Dual Coil
Relief Valve - 3200 PSI
Orifice - 0.047
Wheel Motor Components
Wheel Motor - Dual Displacement (Left Front)
Wheel Motor - Dual Displacement (Left Rear)
Wheel Motor - Dual Displacement (Right Front)
Wheel Motor - Dual Displacement (Right Rear)
Pump - Variable Displacement
Pressure Compensated
FL1
CYL1
Return Filter - 10 Micron
Cylinder, Steering
CYL6
SV10
Oscillating Axle Components
Axle Lock Cylinder
Solenoid Valve, Poppet N.C.
MA6
CV1 - CV2
CYL5
SV7
SV8
SV9
Optional Outriggers Components
Manifold, Outriggers
Check Valve
Outrigger Cylinder
Solenoid Valve, Poppet N.C.
Solenoid Valve, Poppet N.C.
Spool Valve, 4-way - 3-Position
Callout
MA1
SVD1
SV1
SV2
SV3
SV4
SP1
RV1
RV2
RV3
RV4
PD1 - PD2
EP1 - EP2 - EP3
LS1 - LS2 - LS3
CBV1 - CBV2
CL1
CL2
CL3
FD1 - FD2
EC1
CV1 - CV2
CV3 - CV7
CV8
OPL5
OPL1
OPL2 - OPL3
OPL4
Description
Main Manifold Components
Manifold, Main Valve Block
Spool Valve, Drive, 4 Way - 3 Position
Spool Valve, Lift, 3 Way
Spool Valve, Steer, 4 Way - 3 Position
Spool Valve, Series Parallel, 4 Way - 2 Position
Spool Valve, High Speed, 3 Way - 2 Position
Proportional Valve - 12V
Relief Valve, Lift - 2500 PSI
Relief Valve, Steer - 1500 PSI
Relief Valve, Front Drive Motors - 2800 PSI
Relief Valve, Rear Drive Motors - 2800 PSI
Piloted Spool Valve, 4 Way - 3 Position
Piloted Poppet Valve, Flow Divider Bypass
Load Sense Shuttle Check Valve
Counter Balance Valve
Coil, Series 8 - 12V
Coil, Series 10 - 12V
Coil, Series 10 E-Coil - 12V
Flow Divider / Combiner
Pressure Compensator
Check Valve, Load Sense
Check Valve, Anti Cavitation
Check Valve, Tank Return
Orifice Plug, Brake - 0.035
Orifice Plug, Steer - 0.080
Orifice Plug, Flow Divider Bleed - 0.040
Orifice Plug, Compensator Bleed - 0.093
October 2008
Page 5-2
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
CYL1
NOTE:
O u trigger Option connect s from -
M a in M a nifold port s
ORL S , ORR a nd OR S
− to −
O u trigger M a nifold port s
ORL S , ORR a nd OR S
(O u trigger s chem a tic s hown s ep a r a tely)
STEERING
CYL1
MA-5
RV4
SV6
CYL3
UPPER LIFT CYLINDER
MA-4
RV4
SV6
CYL4
LOWER LIFT CYLINDER
ø.093
ORF4
ø.047
ORF6
MA-3
SV5
ø.093
ORF3
CYL2
LIFT CYLINDER
2591RT AND 3391RT ONLY
4191RT ONLY
BRAKES
LF
RF
RR
LR
STR STL LFT
MA-1
LFB
CV3
LFA RFA RFB RRA RRB LRB
RV3
PD1
2800
PSI
1
CV4 CV5 CV6
PD2
1
CV7
ORL S
CV1
S2
CV2
S1
SV2
EP2
OPL2
ø.025
4
FD1
3
2
4
2
6
5
3
ø.080
OPL1
RV1
2500
PSI
SV1
ORR
SP1
OR S
GST
EC1
P1
PUMP
4
2
3
P GP
1
FL1
RV2
1500
PSI
OPL4
ø.040
GLS
LS1
LS
LS3
EP3
SVD1
SV4
CBV1 a
2 S P
4
2
6
5
3
LS2
A B
P T
FD2
2
CBV2 b
TANK
SV10
CYL6
B
OPL3
ø.025
3
4
OPL5
ø.035
LRA
RV4
2800
PSI
SV10
CYL6
OSCILLATING
AXLE
CYLINDERS
ART_2076
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
EP1
4 2
SV3
1
3
CV8
T
0A
October 2008
Page 5-3
Main Hydraulic Manifold
CV8
PD1
PD2
PLG4
TOP BOTTOM
PLG4
MOUNTING
HOLE
PLG4
EP3
FRONT BACK
PLG4
EP1
EP2
PLG4
EC1
PLG8
RV3
CV4
OPL2
CV3
RV1
RV2
S V3 CL1
CBV2
S VD1
L S 3
S V1 CL2
L S 2
S V2
CL1 CL1
LEFT RIGHT
PLG4
CV5
FD1
OPL3
CL1
S V4
S P1 CL3
PLG4
OPL1
CV2
ART_2077
October 2008
Page 5-4
CV1
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
CBV1
FD2
CV7
RV4
CV6
L S 1
ORF5
ORF4
PLG4
PLG4
PLG6
Optional Outriggers
S V1 CL1 CL1
CAV1 PLG10
CV8
ORA
ORB
ORR
PLG4
ORL S
OR S
CV9
RIGHT
OPTIONAL OUTRIGGERS
CYL5
SV7 SV7
CYL5
LEFT
ORA
SV9
SV8
SV8
BOTTOM
ORS ORR ORLS
ORS ORR ORLS
Mai n Ma n ifold
MA-1
ART_2078
ORB
MA-6
CYL5
SV7
SV8
FRONT
SV8
SV7
CYL5
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 5-5
ELECTRIC SCHEMATICS
Wire Harness Connections
Located on the circuit board in the lower control box.
A
October 2008
Page 5-6
ART_2079
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
B
C
D
B
C
C
Main Wiring Harness
MAIN HARNE SS - AN S I
A
A
TILT
S EN S OR
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_2080
October 2008
Page 5-7
Circuit Board Schematic
The Circuit Bard schematic is broken into two pages for clarity. The cable connections are shown on this page. Match the numbers to line-up the traces.
ART_2081
October 2008
Page 5-8
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_2082
October 2008
Page 5-9
Upper Controls
38 PNK/WHT
104 BLU/RED
13 WHT/BLK
71 RED/WHT
PC BOARD
October 2008
Page 5-10
ION #2
S
S TAT
DT06-6
UPPER
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
N TATIO
S A
S
DT06-12
UPPER
Upper Controls - With Outriggers
104 BLU/RED
13 WHT/BLK
71 RED/WHT
38 PNK/WHT
PC BOARD
35 BLK/RED
35 BLK/RED
ION #2
S
S TAT
DT06-6
UPPER
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
N TATIO
S A
S
DT06-12
UPPER
October 2008
Page 5-11
Lower Control Box
October 2008
Page 5-12
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Diesel Engine
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 5-13
Dual Fuel Engine
October 2008
Page 5-14
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Optional Outriggers
UPPER CONTROL S TATION
RETRACT EXTEND
4
6
1
3
2
5
PLATFORM
POWER
RELAY
IN S IDE
UPPER
CONTROL BOX
BLK/RED
4 3
4 3
2 1
CABLE
A SS EMBLIE S
2 1
RED/BLU 301
PLATFORM DOWN
S WITCH
RED/WHT
LR
PPL PPL PPL
RR RF
OUTRIGGER PRE SS URE S WITCHE S
LF
PPL
OUTRIGGER
CYLINDER S
GRN/RED 67
GRY/WHT 66
GRY/RED 65
GRY/BLK 64
BRN/YEL 63
BRN/RED 62
GRN 61
BRN/BLK 60
RETRAC LR
EXTEND LR
RETRACT RR
EXTEND RR
RETRACT RF
EXTEND RF
RETRACT LF
EXTEND LF
LR
BLK/ORG BLK/ORG BLK/ORG
LR LR
OUTRIGGER S TOWED S WITCHE S
BLK 15
LR
PNK/WHT 69
YEL 68
111 FWD
110 REV
HYDRAULIC MANIFOLD
GRY 57
P29
1 × ¼ Male Di s co nn ect
IN S IDE LOWER CONTROL S
PCB TERMINAL S 17
B+ (VCC1)
ALARM TERMINAL
THROTTLE S WITCH
TERMINAL 4
PCB TERMINAL S 5
LOWER CONTROL BOX
1 YEL/WHT 304
2 RED/WHT 201
3 ORG/BLU 125
4 BLK/ORG 125
P4-9
P2-6
P2-5
P2-1
P2-2
P2-3
P2-4
GP106
P2-12
P4-1
P4-2
P4-3
P4-4
P4-5
P4-6
P4-7
P4-8
GRY/WHT 66
GRY/BLK 64
BRN/RED 62
BRN/BLK 60
GRN/RED 67
GRY/RED 65
BRN/YEL 63
GRN 61
P2-10
EXTEND OUTPUT
P2-7
P2-8
RETRACT OUTPUT
ALL LEG S DOWN OUTPUT
P2-9
P2-11
THROTTLE UP OUTPUT
BLK 15
BLK/ORG 125
YEL/BLK 168
PPL/WHR 169
BRN 156
ORG/BLU 125
86
87
LIFT ENABLE
RELAY 30 87
BLK 15
OUTRIGGER
MANIFOLD
EXTEND VALVE
RETRACT VALVE
BLK 15
ART_2088 R1
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page 5-15
Optional Generator
3 0
8 5
RED/WHT
BLK
8 7 N.O.
GENERATOR
VALVE
RED/WHT 71
EXI S TING UPPER CONTROL CABLE
8 7 a ORG/GRN
8 6
TO: PIN 5
ON 12 PIN
CONNECTOR
ORG
ORG
WHT
GRN
BLK
CONTROL
MODULE
WHT/RED
GENERATOR
TOGGLE
S WITCH
UPPER
CONTROL S
GENERATOR
THROTTLE
S OLENOID
AT ENGINE
ORG
TO: ENGINE
THROTTLE
S OLENOID
POWER
MODULE
ART_2089
October 2008
Page 5-16
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Table of Contents
Parts Section
SECTION A: CONTROL BOXES
U
PPER
C
ONTROLS
, ANSI ............................................................................................ A-3
U
PPER
C
ONTROL
B
OX
C
OVER
A
SSEMBLY
........................................................................ A-5
U
PPER
C
ONTROL
J
OYSTICK
.......................................................................................... A-7
B
ASE
C
ONTROL
B
OX
................................................................................................... A-9
SECTION B: PLATFORM AND RAILS
P
LATFORM
A
SSEMBLY
.................................................................................................. B-3
R
OLLOUT
L
OCK
P
IN
A
SSEMBLY
...................................................................................... B-5
R
OLLER
A
SSEMBLY
...................................................................................................... B-7
E
NTRY
C
HAIN
............................................................................................................. B-9
S
WING
G
ATE
(O
PTION
) .............................................................................................. B-11
C
ONTROL
C
ABLE
/H
ORN
I
NSTALLATION
........................................................................... B-13
P
OWER TO
P
LATFORM
................................................................................................ B-15
A
IRLINE
T
O
P
LATFORM
(O
PTION
) ................................................................................. B-15
L
ANYARD
A
TTACHMENT
(O
PTION
) ................................................................................. B-17
SECTION C: SCISSORS
84001B
EAM
A
SSEMBLY
, 2591RT .................................................................................C-3
84002B
EAM
A
SSEMBLY
- 3391RT ...............................................................................C-5
84003B
EAM
A
SSEMBLY
- 4191RT ...............................................................................C-7
C
ABLE
R
OUTING
, S
CISSORS
.........................................................................................C-9
L
IMIT
S
WITCH
I
NSTALLATION
........................................................................................C-11
SECTION D: AXLES
R
EAR
A
XLE
A
SSEMBLY
.................................................................................................D-3
F
RONT
A
XLE
A
SSEMBLY
...............................................................................................D-7
D
RIVE
H
UB WITH
B
RAKE
(R
EAR
) ................................................................................. D-11
D
RIVE
H
UB
(F
RONT
) .................................................................................................D-13
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Table of Contents
Parts Section
SECTION E: HYDRAULICS
91410M
ANIFOLD
A
SSEMBLY
......................................................................................... E-3
M
ANIFOLD
A
SSEMBLY
– H
ARDWARE
................................................................................ E-5
M
ANIFOLD
- O
UTRIGGER
(O
PTION
)................................................................................. E-7
H
OSE
K
IT
- D
RIVE
...................................................................................................... E-9
H
OSE
K
IT
: P
UMP AND
T
ANK
R
ETURN
............................................................................ E-11
H
OSE
K
IT
: B
RAKE
& O
SCILLATING
A
XLE
....................................................................... E-11
H
OSE
K
IT
: S
TEERING
................................................................................................. E-13
H
OSE
K
IT
: W
HEEL
M
OTOR
C
ASE
D
RAIN
....................................................................... E-13
H
OSE
K
IT
: O
UTRIGGER
O
PTION
................................................................................... E-15
H
OSE KIT
- G
ENERATOR
O
PTION
................................................................................. E-17
L
IFT
C
YLINDER
, 2591RT, 3391RT ............................................................................ E-19
L
IFT
C
YLINDER
, L
OWER
, 4191RT ............................................................................... E-21
L
IFT
C
YLINDER
, U
PPER
, 4191RT ............................................................................... E-23
S
TEERING
C
YLINDER
................................................................................................. E-25
F
LOATING
A
XLE
L
OCK
C
YLINDER
.................................................................................. E-27
O
UTRIGGER
C
YLINDER
(O
PTION
) ................................................................................. E-29
SECTION F: BASE
B
ASE
A
SSEMBLY
......................................................................................................... F-3
C
ONTROL
M
ODULE
...................................................................................................... F-5
P
OWER
M
ODULE
......................................................................................................... F-9
P
OWER
M
ODULE
: E
NGINE
M
OUNT
- D
IESEL
................................................................... F-13
E
NGINE
, D
UAL
F
UEL
.................................................................................................. F-17
E
NGINE
, D
IESEL
....................................................................................................... F-21
W
IRE
H
ARNESS
........................................................................................................ F-25
O
UTRIGGER
I
NSTALLATION
(O
PTION
) ............................................................................. F-27
G
ENERATOR
- O
PTION
............................................................................................... F-29
SECTION G: DECALS
D
ECAL
K
IT
, C
ONTROLS
............................................................................................... G-3
D
ECAL
K
IT
, B
ASE
....................................................................................................... G-5
D
ECAL
K
IT
, S
CISSORS
................................................................................................ G-7
D
ECAL
K
IT
, P
LATFORM
................................................................................................ G-9
D
ECAL
K
IT
, A
NCHORAGE
P
OINTS
O
PTION
..................................................................... G-11
D
ECAL
K
IT
, O
UTRIGGER
O
PTION
................................................................................ G-11
October 2008 "2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION A:
CONTROL BOXES
U
PPER
C
ONTROLS
, ANSI ............................................................................................................ A-3
U
PPER
C
ONTROL
B
OX
C
OVER
A
SSEMBLY
....................................................................................... A-5
U
PPER
C
ONTROL
J
OYSTICK
.......................................................................................................... A-7
B
ASE
C
ONTROL
B
OX
................................................................................................................... A-9
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page A-1
LIFT/ DRIVE
GRN/WHT
PPL
BLU/RED
25A
3
104
4
1
2
3
BLK
PPL
BLU
PWM
14 3 15 - 55
A + – X R
No Connection
ORG/GRN
18 19 20
To Potentiometer
17
15
1
ORG/BLK
PNK/WHT
WHT/BLK
SPEED/
TORQUE
6
3 8
1 3
1
2
3
6
E-STOP
WHT
1
WHT/YEL 1A
7
2
No Connection
ORG/RED
3
KEY
SWITCH 20
YEL/WHT
JUMPER
8
1A
1
4
3
2
101
YEL/WHT
WHT/RED
BLK/WHT
11
101
24
CHOKE/
PREHEAT
1
2
3
WHT/RED
No Connection
POWER RELAY
RED
BLK/RED
101A
3 5
86
87
87A
3 0
85
15
101
14
21
28
BLK
1 3
WHT/RED
BLK
PNK/WHT
WHT/RED
TIME DELAY
101 3 8 15
1 2
3
6
3
12
PPL
27
22
RED/GRN
24
DRIVE
INDICATOR
45 45A
RED WHT
RED/BLK
25
26
2 3
OUTRIGGER
PNK/WHT
RED/BLU
YEL
69
3 01
68
1 4
2 5
3 6
57
3 01
57
GRY
JUMPER
RED/BLU
WHT/RED
9
101
7 3
HORN
BUTTON
10
GENERATOR
BLK/WHT/RED
WHT/RED
71
101
1
2
OPTION
ART_2090
October 2008
Page A-2
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
17 91107
1 8 90 8 14
19 90 8 33
20 5364
21 9102 8
22 91294
23 5694
24 907 8 9
25 16312
26 90 8 33
27 5364
2 8 9102 8
ITEM PART NO.
QTY DESCRIPTION
U
PPER
C
ONTROLS
, ANSI
9110 8
1 16242
2 13 8 65
3 6350
4 6234
-
1
1
.5FT
1
CONTROL BOX ASSEMBLY, ANSI
WELDMENT, CONTROL BOX
BRACKET, CONTROL BOX HOLDER
TAPE, FOAM
SWITCH, TOGGLE, LIFT/DRIVE
6 6905
7 7 8 00
8 91619
9 8 044
10 5630
11 7423
12 911 8 6
13 911 8 4
14 91375
15 91027
1
1
1
1
1
1
1
1
1
1
SWITCH, TOGGLE, SPEED/TORQUE
SWITCH, EMERGENCY STOP
START SWITCH
SWITCH, HORN BUTTON (OPTION)
SWITCH, TOGGLE, GENERATOR (OPTION)
SWITCH, TOGGLE, CHOKE/PREHEAT
RELAY, TIME DELAY
WIRE HARNESS, CONTROL BOX
RELAY, POWER
DIODE BLOCK, 2 POSITION
2
2
1
2
1
2
2
1
1
1
1
1
PWM CARD
SPACER
SCREW, 6-32 X 3/4"
NUT, 6-32
DIODE BLOCK, 4 POSITION
OUTRIGGER OPTION
HARNESS, OUTRIGGER CONTROL
SWITCH, TOGGLE
LED, GREEN, DRIVE ENABLED
PLATE, MOUNTING, OUTRIGGER PLUG
SCREW, 6-32 X 3/4"
NUT, 6-32
DIODE BLOCK, 4 POSITION
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page A-3
ART_2091
October 2008
Page A-4
1
2 3
4 5 6
7
8
9
10
11
12
1 3
14
15
29
16 17
18 19 20
28
27
26
28
27
26
25 2 3 22 24
TO CONTROL BOX
21
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
U
PPER
C
ONTROL
B
OX
C
OVER
A
SSEMBLY
1 13647
2 3772
3 7 8 75
4 7 88 2
5 HDW376 8
6 7 8 19
7 8 435
8 100/ 8 34 8
9 HDW7 88 7
10 13502
11 3763
12 13402
13 HDW 8 531
14 HDW7 88 1
15 37 8 2
16 13403
1 WASHER, FLAT
1
2
1
1
1
1
1
1
1
1
1
1
1
1
CONTROL BOX COVER ASSEMBLY
CONTROL ARM COVER
1 COVER
GASKET
O-RING, 7/ 8 " ID X 1 1/
CAM. DIRECTIONAL
PLATE, BOTTOM
8 " OD
BEARING, BRONZE, FLANGED
SPRING, JOYSTICK, CENTERING
PIN, HOLD DOWN
SCREW, #6-32, 1/2" LG
BRACKET, CENTERING
SPACER, STEP
GEAR, LARGE
WASHER, FLAT
WASHER, BEVEL
17 6917
1 8 7 8 1 8
19 HDW3771
20 5736
21 HDW 8 399
22 HDW 8 567
23 8 3 8 9
24 91522
1
1
1
1
4
2
1
1
CLAMP, CABLE 1/4"
BEARING, BRONZE, FLANGED
WASHER, FLAT
RING, RETAINING, 1/2"
SCREW, #4 - 40, 5/
WASHER, FLAT
GEAR, SPUR
POTENTIOMETER
8 " LG
25 HDW7 888 12 SCREW, #10 - 32, 1/2" LG
26 3764 2 PLATE, SPACER
27 8 696
2 8 3765
29 3766
2
2
1
SWITCH, LIMIT, MICRO V7
PLATE, STRAP
PLATE, TOP
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page A-5
1
2
8
11
4
3
1 3
12
5
7
6
ART_2092
October 2008
Page A-6
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
U
PPER
C
ONTROL
J
OYSTICK
13647
1 8 750
2 8 453
3 HDW 8 455
4 8 752
5 8 751
6 1363 8
7 8 74 8
8 8 456
7476
8 630
8 761
8 0 8 9
7777
4
1
1
1
1
CONTROL ARM ASSEMBLY, JOYSTICK
PIN (SERVICE ONLY)
SWITCH ACTUATOR (SERVICE ONLY)
SCREW, 6-1/2" LG (SERVICE ONLY)
GRIP-TOP HALF (SERVICE ONLY)
GRIP-BOTTOM HALF (SERVICE ONLY)
1
5
1
1
1
CONTROL ARM WITHOUT WIRE
TRIGGER (SERVICE ONLY)
ROCKER BOOT (SERVICE ONLY)
AMP PINS
HANDLE, GRIP
SWITCH ASSEMBLY (NOT SHOWN)
1' WIRE, BLK 1 8 GA 300 V
2 TERMINAL, PUSH ON, 3/16"
11 8 447
12 8 753
13 8 44 8
1
1
2
SWITCH SEPARATOR (SERVICE ONLY)
MOTION SWITCH, ON-OFF (SERVICE ONLY)
SWITCH (SERVICE ONLY)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page A-7
1 Emergency S top
Raise (Green)
3
Lower (Green)
3
Throttle (Green) 3
Engine S top (Red) 5
2
3
4
Hour Meter
Engine S tart (Green)
Choke/Preheat (Black)
1
Platform/Chassis 16
9
Circuit Breaker
6
Gasoline/Propane (Dual Fuel)
7
Plug (Diesel)
2
Green
3
Black
4
Dual Fuel
6
Diesel
7
16
9
Red 5
Green 3
Mounting Plate
Platform/Base - N.O.
14
15
Raise - N.O. 10
12
1 3
Circuit Board
Alarm
Hardware supplied with Alarm
9
Circuit Breaker
11
Propane/Gasoline - N.C.
(Dual Fuel)
9 Circuit Breaker
10 Engine
S tart - N.O.
10 Choke/Preheat - N.O.
11 Engine
S top- N.C.
10 Throttle - N.O.
11 Emergency
S top - N.C.
10 Lower - N.O.
ART_2093
October 2008
Page A-8
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
B
ASE
C
ONTROL
B
OX
91169
1 7 8 00
2 7909
3 91533
4 91534
5 91535
6 91536
7 91329
8 91536
9 7235
10 91537
91537
11 9153 8
12 91539
13 91370
14 90714
15 8 0 8 2
16 9549
17 9169 8
1
4
-
1
1
1
4
1
6
8
1
2
1
1
1
1
2
1
1
BASE CONTROL PANEL - COMPONENTS
SWITCH, EMERGENCY STOP
HOUR METER
SWITCH, BUTTON, GREEN
SWITCH, BUTTON, BLACK
SWITCH, BUTTON, RED
SWITCH, 2-POSITION
PLUG (DIESEL)
SWITCH, 2-POSITION (DUAL FUEL)
CIRCUIT BREAKER, 15 AMP
BLOCK, CONTACT, N.0. (DIESEL)
BLOCK, CONTACT, N.0. (DUAL FUEL)
BLOCK, CONTACT, N.C.
ALARM, 107DB
CIRCUIT BOARD
BASE, CONTACT MOUNT
BLOCK, CONTACT, N.O.
SWITCH, 3-POSITION, KEYED
DIODE, 25 AMP (NOT SHOWN)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Update: October 2008
October 2008
Page A-9
THIS P
AGE IS LEFT INTENTIONALL
Y BLANK
October 2008
Page A-10
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION B:
PLATFORM
AND RAILS
P
LATFORM
A
SSEMBLY
.................................................................................................................. B-3
R
OLLOUT
L
OCK
P
IN
A
SSEMBLY
..................................................................................................... B-5
R
OLLER
A
SSEMBLY
..................................................................................................................... B-7
E
NTRY
C
HAIN
............................................................................................................................. B-9
S
WING
G
ATE
(O
PTION
) .............................................................................................................. B-11
C
ONTROL
C
ABLE
/H
ORN
I
NSTALLATION
.......................................................................................... B-13
P
OWER TO
P
LATFORM
................................................................................................................ B-15
A
IRLINE
T
O
P
LATFORM
(O
PTION
) ................................................................................................. B-15
L
ANYARD
A
TTACHMENT
(O
PTION
) ................................................................................................. B-17
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page B-1
2 3
7
8
1
25
6
5
26
3 0
27
28
4
21
24
20
19
17
22
27
24
9
16
18
2 3
29
14
1 3
15
11
10
12
3 1
ART_2094
October 2008
Page B-2
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
P
LATFORM
A
SSEMBLY
1 16436
2 7 8 05
3 704 8
4 HDW7119
5 HDW5217
6 HDW 8 304
1
2
1
1
4
6
REAR RAIL WELDMENT
PADDING, RAIL (OPTIONAL)
COVER, RAIL PADDING (OPTIONAL)
SCREW, 5/16” - 1 8 , 2 ¼” LG, GR 5
FLAT WASHER, .343 ID × .6
88 OD × .063 THK
NUT, 5/16” - 1 8
7 HDW7593
8 16433
9 14301
10 16435
11 8 909
12 HDW5723
13 HDW 8 294
14 HDW 8 267
6
1
1
1
1
8 SCREW, ¼” - 20, ½” LG
4
4
PIN, WIRE LOCK, SQUARE, 3/ 8 ” × 2 ¼” LG
SIDE RAIL WELDMENT, LH
SIDE RAIL WELDMENT - EXTENSION
FRONT RAIL WELDMENT
MANUAL ENCLOSURE
FLAT WASHER, .32
NUT, ¼” - 20
8 ID × 1.000 OD × .100 THK
15 14415 2 BRACKET, EXTENSION STOP
16 HDW5724 20 SCREW, 5/16” - 1 8 , ¾” LG, GR 5
17 14152 2 CHANNEL, EXTENSION
1 8 16429
19 16437
20 HDW 88 56
21 HDW 8 457
22 14313
23 HDW 8 974
24 6 8 23
25 16434
1
1
2
2
1
1
2
1
EXTENSION PLATFORM WELDMENT
MAIN PLATFORM WELDMENT
SCREW, ½”-13, 5” LG
NUT, ½” - 13
RIGHT SIDE RAIL WELDMENT - EXTENSION
PIN, WIRE LOCK, SQUARE, 3/
CAP PLUG, 1 ¼"
SIDE RAIL WELDMENT, RH
26 HDW 8 279 10 SCREW, 3/ 8 -16, 2½" LG
27 HDW 8 26 8 10 NUT, 3/ 8 -16
8 ” × 3” LG
2 8 20552
29 912 8 4
1
1
COVER, PLATFORM CORD
PIN HITCH 3/ 8 " × 4
30 HDW5355 20 WASHER, FLAT, .43
8 ID×1.00 OD×.07
8 THK
31 HDW6434 3 SCREW, 3/ 8 -16×2" LG
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page B-3
4
5
8
3
6
9
8
7
1
ART_2133
October 2008
Page B-4
Roll-out Deck Lock Pin Assembly
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
R
OLLOUT
L
OCK
P
IN
A
SSEMBLY
1 13737
2 71 8 4
3 88 14
4 20235
5 HDW 8 303
6 HDW 8 304
7 740 8
8 HDW7031
9 HDW 8 513
1 PIN, EXTENSION LOCK
3.7 FT CABLE, COATED AND ROLLED
2
1
SLEEVE, ALUMINUM OVAL
HANDLE
1
1
SCREW, 5/16” - 1 8 , 2” LG
LOCKNUT, 5/16” - 1 8
1
1
1
SPRING, DECK LOCK
WASHER, FLAT, ½” ID 7/ 8 ” OD
PIN, SPRING, 1/ 8 ” DIA. ¾” LG
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page B-5
4
5
3
2
1
ART_2095
October 2008
Page B-6
Reference: ART_687
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Roll-out Deck Roller
ITEM PART NO.
QTY DESCRIPTION
R
OLLER
A
SSEMBLY
1 591 8
2 HDW 8 370
3 13230
4 14062
5 HDW5724
1
1
1 RETAINING RING, HEAVY DUTY 1”
1 WASHER, FLAT, 1.015 ID × 1.375 OD × .062 THK
4
ROLLER
ROLLER PLATE WELDMENT
SCREW, 5/16” - 1 8 , ¾” LG
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page B-7
1
2
3
ART_2096
October 2008
Page B-8
Reference: ART_13850
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Entry Chain
ITEM PART NO.
QTY DESCRIPTION
E
NTRY
C
HAIN
1
2
3
13
5239
8 7
8
8
46
1
1
2
1
CHAIN CLOSURE
CHAIN
S-HOOK, CONNECTING LINK
SNAP, CHAIN LINK
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page B-9
1
2
3
4
17
14
16
7
15
6
5
7
8
1 3
12
5
10
11
9
ART_2097
October 2008
Page B-10
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
S
WING
G
ATE
(O
PTION
)
1 40003
2 7055
3 40006
4 HDW6434
5 8 1 8 7
6 40014
7 HDW 8 294
8 HDW 8 4 8 6
9 6 8 23
10 8 300
11 13272
12 40015
13 40017
14 30 8 14
15 HDW 8 303
16 HDW7120
17 HDW 8 26 8
1
1
1
1
1
1
6
4
2
2
1
1
1
1
1
2
1
LATCH PIN, REAR GATE
SPRING, LATCH, .4
8 0 DIA. OD × 1.5” LG
ROD, LATCH LEVER, REAR GATE
SCREW, 3/ 8 -16 × 2” LG
BEARING, NYLINER, 5/ 8 ” ID × 5/ 8 ” LG
MOUNTING BRACKET, UPPER
WASHER, .32
8 ” ID × 1” OD × .100” THK
SCREW, 5/16” - 1 8 , 1 7/ 8 ” LG, GR 5
CAP PLUG, 1 ¼” SQUARE
SPRING, TORSION, 1” DIA. OD × 4” LG
BLOCK, PIVOT, REAR GATE
MOUNTING BRACKET, LOWER
SWING GATE WELDMENT
STRIKE PLATE
SCREW, 5/6”-1 8 , 2” LG, GR 5
NUT, 5/16”-1 8 , GR 5
NUT, 3/ 8 -16
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page B-11
8
9
3
5
6
3
2
7
1
10
3
11
ART_2098
October 2008
Page B-12
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
C
ONTROL
C
ABLE
/H
ORN
I
NSTALLATION
1 9716
2 HDW5217
3 HDW6455
1
2
5
HORN, 12-4 8 V (OPTION)
WASHER, FLAT, .343 ID × .6
88 OD × .063 THK
SCREW, ¼”-20, ½” LG, GR 5
5 HDW5363
6 HDW5364
7 6947
8 6964
9
10 164 8 5
11 5 8 63
3
3
SCREW, #6-32, 1” LG, GR 5
NUT, KEPS, #6-32 , GR 5
1
4
TERMINAL STRIP
CLAMP, CABLE, 1” DIA.
REF CABLE, UPPER CONTROL
1 COVER, TERMINAL STRIP
1 GROMMET, 1.5 ID × 1.75 OD × .1
8 7 THK
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page B-13
4
7
8
9
1
5
10
11
12
6
2
3
1 3
ART_2099
October 2008
Page B-14
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
P
OWER TO
P
LATFORM
1 90 8 27
2 90 8 2 8
3 HDW5636
4 HDW6455
5 HDW 8 267
6 53 8 1
7 8 20 8
8 8 209
9 8 479
10 88 33
11 16221
12 HDW5724
13 HDW 8 304
1
2
2
1
1
1
1
1
2
1
1
2
1
BOX, RECEPTACLE
DUPLEX RECEPTACLE COVER
SCREW #6 - 32 × 0.25"
SCREW, ¼" - 20, ½" LG
LOCKNUT ¼" - 20
RECEPTACLE, DUPLEX
CONDUIT, 3/ 8 " FLEXIBLE
FERRULE, 3/ 8 "
BUSHING, ¾" ID
CONNECTOR, OUTLET BOX 3/ 8 " CONDUIT
BRACKET
SCREW, 5/16–1 8 × ¾"
NUT, 5/16–1 8
HDW 8 501
9441
2
*
CLIP, SELF RETAINING
WIRE, 14 GA
*2591RT = 50 FT.
*3391RT = 5 8 FT.
*4191RT = 6 8 FT.
HDW5217 2 FLAT WASHER 11/32" ID
5351
91399
1
*
A
IRLINE
T
O
P
LATFORM
(O
PTION
)
NOT SHOWN
CABLE TIE
HOSE, 3/ 8 " AIRLINE
*2591RT = 49 FT.
* 3391RT = 57 FT.
*4191RT = 67 FT.
8 559 2
HDW91500 2
5 88 2 2
CLAMP, HOSE
FITTING, ¼" MALE, MALE HOSE BARB
CABLE CLAMP
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page B-15
5
3
4
1
2
ART_2100
October 2008
Page B-16
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
L
ANYARD
A
TTACHMENT
(O
PTION
)
145 8 3 LANYARD ATTACHMENT
1 HDW6433 10 SCREW, 3/ 8 ” - 16, 1” LG, GR 5
2 HDW 8 26 8 10 NUT, 3/ 8 ” - 16, GR 5
3 8 605 5 DECAL, LANYARD ATTACH POINT
4 3923
5 8 606
5
1
BRACKET, ATTACH POINT
DECAL, WARNING, POS RESTRAINTS
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page B-17
THIS P
AGE IS LEFT INTENTIONALL
Y BLANK
October 2008
Page B-18
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION C:
SCISSORS
B
EAM
A
SSEMBLY
, 2591RT .............................................................................................. C-3
B
EAM
A
SSEMBLY
- 3391RT ............................................................................................ C-5
B
EAM
A
SSEMBLY
- 4191RT ............................................................................................ C-7
C
ABLE
R
OUTING
, S
CISSORS
............................................................................................. C-9
L
IMIT
S
WITCH
I
NSTALLATION
........................................................................................... C-11
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page C-1
A
26
ALL OUTER BEAMS HAVE 6 BEARINGS:
2 AT EACH PIVOT POINT
23
24
25
5
23
21
13
2
23
1
27
A
A
17
7
6
A
B
26
8
9
23
17
22
29
23
ART_2101-R1
October 2008
Page C-2
2591RT
13
19
20
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
28
23
Scissor Assembly
15
3
16
18
B
10
11
12
3
14
3
4
ITEM PART NO.
QTY DESCRIPTION
B
EAM
A
SSEMBLY
, 2591RT
1 20141
2 16468
2
1
BLOCK, SLIDE - PLATFORM
BEAM, SINGLE CYLINDER MOUNT
3 HDW6455 14 SCREW, 1/4" - 20,1/2" LG
4 20913 1 GUARD, CONTROL CORD, SHORT
5 20948
6 HDW7783
2
8
BEAM WELDMENT, 3 X 6
WASHER, SPLIT, LOCK, 3/8"
7 HDW8277
8 20365
9 8340
10 HDW5724
11 20223
12 20224
13 20932
14 20839
15 20778
16 21133
17 6688
8
2
1
8
4
2
4
1
1
2
4
SCREW, 3/8" - 16, 1 3/4" LG
SCISSORS MOUNT ASSEMBLY
PIN, ROLLER - PLATFORM
SCREW, 5/16"–18, 3/4" LG
PLATE, CYLINDER PIN LOCK
PIN, CYLINDER
BEAM, OUTER, 3 X 8
GUARD, CONTROL CORD
LOCK, MAINTENANCE
BRACKET, MAINTENANCE LOCK
CLIP RING, 2" SHAFT
18 20429
19 HDW8856
20 HDW6463
21 16460
22 20142
23 6701
24 91403
25 20937
26 6669
27 20413
28 25429
29 6670
4
1
2
4
BLOCK, FIXED - BASE
SCREW, 1/2" -13, 5" LG
NUT, 1/2" - 13, NYLON
BEAM, SINGLE CYLINDER MOUNT
2 BLOCK, SLIDE - BASE
18 RING, RETAINING, 2" SHAFT
1
1
CYLINDER, LIFT
BEAM, INNER, CENTER
38 BEARING
1 PIN-SLIDE, BASE
16 SPACER BLOCK
2 BEARING
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Update: October 2008
October 2008
Page C-3
A
13
3
25
2
25
1
21
8
25
22
8
25
24
27
11
ALL OUTER BEAMS HAVE 6 BEARINGS:
2 AT EACH PIVOT POINT
A
8
A
17
B
7
6
A
11
5
25
26
19
20
ART_2102-R1
October 2008
Page C-4
3391RT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
4
25
17
B
14
15
16
18
28
25
Scissor Assembly
9
10
12
ITEM PART NO.
QTY DESCRIPTION
B
EAM
A
SSEMBLY
- 3391RT
1 20141
2 20957
3 20939
4 8340
5 20365
6 HDW7783
7 HDW8277
8 20932
9 HDW5724
10 20223
11 6669
12 20224
13 16469
14 20778
15 HDW6455
16 21133
17 6688
18 20429
19 HDW8856
20 HDW6463
21 20937
22 16460
23 20142
24 91403
25 6701
26 6670
27 20413
28 25429
2
1
2
1
2
8
BLOCK, SLIDE - PLATFORM
BEAM, INNER, 3 X 6
BEAM, OUTER, 3 X 6
PIN, ROLLER - PLATFORM
SCISSORS MOUNT ASSEMBLY
WASHER, SPLIT, LOCK, 3/8"
4
2
4
8
4
8
6
SCREW, 3/8"-16, 1 3/4" LG
BEAM, 3 X 8
SCREW, 5/16"–18, 3/4" LG
PLATE, CYLINDER PIN LOCK
50 BEARING
2 PIN, CYLINDER
1
1
BEAM, INNER, CYLINDER MOUNT
LOCK, MAINTENANCE
SCREW, 1/4"- 20, 1/2" LG
BRACKET, MAINTENANCE LOCK
CLIP RING, 2" SHAFT
4
1
2
4
BLOCK, FIXED - BASE
SCREW, 1/2" - 13, 5" LG
NUT, 1/2" - 13, NYLON
BEAM, INNER, CENTER
1
2
BEAM, SINGLE CYLINDER MOUNT
BLOCK, SLIDE - BASE
1 CYLINDER, LIFT
24 RING, RETAINING, 2" SHAFT
2
1
BEARING
PIN, SLIDE, BASE
24 SPACER BLOCK
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page C-5
A
10
22
1 3
26
25
3 0
1 3
2
26
1
12
3
26
14
10
26
27
2 3
3 2
ALL OUTER BEAM S HAVE 6 BEARING S :
2 AT EACH PIVOT POINT
A
A
17
A
B
7
6
3 2
5
4
26
1 8
24
33
ART_2103-R1
October 2008
Page C-6
4191RT
20
21
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
3 1
19
26
Scissor Assembly
2 8
16
B
8
9
11
15
16
17
8
9
11
29
16
ITEM PART NO.
QTY DESCRIPTION
B
EAM
A
SSEMBLY
- 4191RT
18 6688
19 20429
20 HDW8856
21 HDW6463
22 16460
23 20937
24 20142
25 91404
26 6701
27 91405
28 20913
29 20839
30 20413
31 25429
32 6669
33 6670
1 20141
2 20935
3 20939
4 8340
5 20365
6 HDW7783
2
1
2
1
2
8
BLOCK, SLIDE - PLATFORM
BEAM, SINGLE CYLINDER MOUNT
BEAM, OUTER, 3 X 6
PIN, ROLLER - PLATFORM
SCISSORS MOUNT ASSEMBLY
WASHER, SPLIT, LOCK, 3/8"
7 HDW8277 8 SCREW, 3/8" - 16, 1 3/4" LG
8 HDW5724 16 SCREW, 5/16"–18, 3/4" LG
9 20223
10 20938
8
4
PLATE, CYLINDER PIN LOCK
BEAM, OUTER, 3 X 8
11 20224
12 16467
13 20932
14 20933
4
1
4
1
PIN, CYLINDER
BEAM, INNER, CENTER
BEAM WELDMENT
BEAM, DOUBLE CYLINDER MOUNT
15 20778 1 LOCK, MAINTENANCE
16 HDW6455 14 SCREW, 1/4" - 20, 1/2" LG
17 21133 2 BRACKET, MAINTENANCE LOCK
2
1
1
1
4
4
4
2
CLIP RING, 2" SHAFT
BLOCK, FIXED - BASE
SCREW, 1/2" - 13, 5" LG
NUT, 1/2" - 13, NYLON
BEAM, ¼", SINGLE CYLINDER MOUNT
BEAM WELDMENT
BLOCK, SLIDE - BASE
CYLINDER, LIFT - LOWER
30 RING, RETAINING, 2" SHAFT
1 CYLINDER, LIFT - UPPER
1
1
GUARD, CONTROL CORD, SHORT
GUARD, CONTROL CORD
1 PIN, SLIDE, BASE
32 SPACER BLOCK
62 BEARING
2 BEARING
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page C-7
2591RT
33 91RT
October 2008
Page C-8
ART_2062
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
4191RT
ITEM PART NO.
QTY DESCRIPTION
C
ABLE
R
OUTING
, S
CISSORS
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page C-9
1
2
7
6
5
3
4
ART_2104
October 2008
Page C-10
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
L
IMIT
S
WITCH
I
NSTALLATION
1 20924
2 HDW6455
3 HDW8482
4 HDW5251
5 90996
6 7594
7 20838
2
2
1
4
1
1
1
COVER, LIMIT SWITCH
SCREW, 1/4"- 20, 1/2" LG
SCREW, #8-32, 1 1/2" LG
NUT, #8-32
SWITCH, LIMIT, 3-POLE
CONNECTOR, CORD
CAM, SLOW SPEED
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page C-11
THIS P
AGE IS LEFT INTENTIONALL
Y BLANK
October 2008
Page C-12
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION D:
AXLES
R
EAR
A
XLE
A
SSEMBLY
................................................................................................................ D-3
F
RONT
A
XLE
A
SSEMBLY
............................................................................................................... D-7
D
RIVE
H
UB WITH
B
RAKE
(R
EAR
) ................................................................................................. D-11
D
RIVE
H
UB
(F
RONT
) ................................................................................................................. D-13
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page D-1
26
5
6
7
8
19
20
21
28
22
2 3
4
12
2
1
3
3 2
9
14
15
16
10 11 12
1 3
14
17
18
25
24
27
DRIVE HUB
ART_2105 R1
October 2008
Page D-2
MOTOR
29
3 1
3 0
TORQUE TABLE
Part # Desc
27 Fitting
28 Fitting
29 Fitting
30 Fitting
Ft-lbs
80 - 85
25 - 30
5 - 10
5 - 10
Nm
110 - 118
34 - 41
9 - 12
9 - 12
2591RT - 3391RT - 4191RT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Rear Axle Assembly
ITEM PART NO.
QTY DESCRIPTION
R
EAR
A
XLE
A
SSEMBLY
1 10423
2 HDW5204
3 69 8 4 2
4 HDW13339 3
1
2
5 10424
6 90531
2
1
7 HDW 8 4 8 2
8 HDW5251
9 91406
10 1647 8
11 HDW 8 273
12 HDW 8 267
13 16479
14 HDW5723
15 164 8 2
16 164 8 4
17 91402
2
2
2
6
2
2
PIVOT PIN WELDMENT
SCREW, 5/16-1
BEARING, 1 3/ 8
8 × 1"
× 1 5/
WASHER, FLAT NYLON, 1 3/
AXLE GUIDE, NYLON
8 " LG
LIMIT SWITCH, AXLE CENTER POSITION
2 SCREW, # 8 -32 × 1.5" LG
2 NUT, # 8 -32
2
2
2
AXLE LOCK CYLINDER
CLEVIS PIN WELDMENT, 5/
SCREW, ¼–20 ×
NUT, ¼–20
CLEVIS PIN WELDMENT, 5/
SCREW, ¼–20 × ¾"
COVER, REAR AXLE
BRACKET, AXLE COVER
8
8
MOTOR, HYDRAULIC DRIVE
8 ID × 2¼ OD × .030 THK
" × 5¼"
" × 2 1/ 8 "
91560
1 8 91400 2
SEAL KIT
DRIVE HUB W/BRAKE
19 HDW 8 2 8 3
20 HDW5012
4
4
21 HDW907 8 4 4
(SERVICE PARTS - SEE PAGE D-10 & D-11)
SCREW, ½–13 × 1½" GR
LOCK WASHER, ½"
8
WASHER, FLAT, .531 ID × 1.063 OD × .104 THK
22 HDW91407 12 SCREW, 5/ 8 –11 × 1½ SOCKET HEAD GR 8
23 HDW5994 12 WASHER, LOCK, 5/ 8 "
CONTINUED . . .
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page D-3
26
5
6
7
8
19
20
21
28
22
2 3
4
12
2
1
3
3 2
9
14
15
16
10 11 12
1 3
14
17
18
25
24
27
DRIVE HUB
ART_2105 R1
October 2008
Page D-4
MOTOR
29
3 1
3 0
TORQUE TABLE
Part # Desc
27 Fitting
28 Fitting
29 Fitting
30 Fitting
Ft-lbs
80 - 85
25 - 30
5 - 10
5 - 10
Nm
110 - 118
34 - 41
9 - 12
9 - 12
2591RT - 3391RT - 4191RT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Rear Axle Assembly
ITEM PART NO.
QTY DESCRIPTION
R
EAR
A
XLE
A
SSEMBLY
(
CONTINUED
)
24 HDW91420 1 8 NUT, LUG, 5/ 8 –1 8
25 91411 1 WHEEL TIRE ASSY, RH, AIR FILLED
91413
91432
91445
1
1
1
WHEEL TIRE ASSY, RH, FOAM FILLED OPTION
WHEEL TIRE ASSY, RH, NON-MARKING AIR OPTION
WHEEL TIRE ASSY, RH, NON-MARKING FOAM OPTION
26 91412
91414
91433
91446
1
1
1
1
WHEEL TIRE ASSY, LH, AIR FILLED
WHEEL TIRE ASSY, LH, FOAM FILLED OPTION
WHEEL TIRE ASSY, LH, NON-MARKING AIR OPTION
WHEEL TIRE ASSY, LH, NON-MARKING FOAM OPTION
27 HDW 8 9 8 4
2 8 HDW 8 0 8 1
2 FITTING, MB–MJ–12– 8
1 FITTING, MB–MJ90– 8 –6
29 HDW9142 8 1 FITTING, MB–MJ45–4–4
30 HDW 888 1 1 FITTING, MB–MJ–4–4
31 91419
32 16400
2 O-RING (NOT SHOWN)
— AXLE REAR WELDMENT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page D-5
18
10
11
9
Part # Desc
27 Fitting
28 Fitting
29 Fitting
TORQUE TABLE
Ft-lbs
80 - 85
25 - 30
5 - 10
Nm
110 - 118
34 - 41
9 - 12
26
24
16
17
12
11
1 3
25
5
7
4
8
6
3
21
RIGHT MOTOR
12
11
1 3
1
2
14
15
19
10
3 1
22
2 3
20
28
27
3 1
29
LEFT MOTOR
27
29
ART_2106 R1
October 2008
Page D-6
28
2591RT - 3391RT - 4191RT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Front Axle Assembly
ITEM PART NO.
QTY DESCRIPTION
F
RONT
A
XLE
A
SSEMBLY
1 HDW5920 2
2 HDW90770 2
3 91019
90990
1
4 16407
5 HDW7326
1
2
17 7 8 96
1 8 16425
19 HDW 8 457
20 16471
21 16470
22 91402
91560
PIN, COTTER, .12 × 1"
PIN, CLEVIS, ½ × 1 3/ 8 "
CYLINDER, STEERING
SEAL KIT, STEERING CYLINDER (NOT SHOWN)
BAR, STEERING
SCREW, 5/ 8 –11 × 4" GR5
6 HDW9219
7 7292
8 HDW6633
9 1640 8
4
2
WASHER, .656 ID × 1.312 OD × .093 THK
BEARING, BRONZE
2 NUT, 5/ 8 –11 LOCK
4 KING PIN WELDMENT
10 HDW6211 16 SCREW, ½–13 × 1¼" GR5
11 HDW5012 16 LOCK WASHER, ½"
12 HDW 8 2 8 3 4 SCREW, ½–13 × 1½" GR 8
13 HDW907 8 4 4 WASHER, FLAT, .531 ID × 1.063 OD × .104 THK
14 HDW5994 12 WASHER, LOCK, 5/ 8
15 HDW91047 12 SCREW, 5/ 8 –11 × 1½ SOCKET HEAD GR 8
16 9140 8 4 THRUST BEARING, 1¾ ID × 2 5/ 8 OD × 1/ 8 THK
4
1
4
2
1
2
BEARING, 1¾ ID × 1" LG
STEERING KNUCKLE WELDMENT
LOCK NUT, ½–13
HOSE GUARD WELDMENT, LH
HOSE GUARD WELDMENT, RH
MOTOR, HYDRAULIC DRIVE
SEAL KIT
23 91401 2 DRIVE HUB
(SERVICE PARTS - SEE PAGE D-12 & D-13)
CONTINUED . . .
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page D-7
18
10
11
9
Part # Desc
27 Fitting
28 Fitting
29 Fitting
TORQUE TABLE
Ft-lbs
80 - 85
25 - 30
5 - 10
Nm
110 - 118
34 - 41
9 - 12
26
24
16
17
12
11
1 3
25
5
7
4
8
6
3
21
RIGHT MOTOR
12
11
1 3
1
2
14
15
19
10
3 1
22
2 3
20
28
27
3 1
29
LEFT MOTOR
27
29
ART_2106 R1
October 2008
Page D-8
28
2591RT - 3391RT - 4191RT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Front Axle Assembly
ITEM PART NO.
QTY DESCRIPTION
F
RONT
A
XLE
A
SSEMBLY
(
CONTINUED
)
24 HDW91420 1 8 NUT, LUG, 5/ 8 –1 8
25 91411 1 WHEEL TIRE ASSY, RH, AIR FILLED
91413
91432
91445
1
1
1
WHEEL TIRE ASSY, RH, FOAM FILLED OPTION
WHEEL TIRE ASSY, RH, NON-MARKING AIR OPTION
WHEEL TIRE ASSY, RH, NON-MARKING FOAM OPTION
26 91412
91414
91433
91446
1
1
1
1
WHEEL TIRE ASSY, LH, AIR FILLED
WHEEL TIRE ASSY, LH, FOAM FILLED OPTION
WHEEL TIRE ASSY, LH, NON-MARKING AIR OPTION
WHEEL TIRE ASSY, LH, NON-MARKING FOAM OPTION
27 HDW 8 9 8 4
2 8 HDW 8 0 8 1
2
1
FITTING, MB–MJ–12–
FITTING, MB–MJ90– 8
8
–6
29 HDW9142 8 1 FITTING, MB–MJ45–4–4
31 91419 2 O-RING (NOT SHOWN)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page D-9
3 B
3 A
2A
1B
4
1D
2D
2E
2B
2C
4
10
7
6
9
1E
8
1C
1F
5
1A
ART_2107 R1
October 2008
Page D-10
9
7
10
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Drive Motor with Brake
ITEM PART NO.
QTY DESCRIPTION
D
RIVE
H
UB WITH
B
RAKE
(R
EAR
)
91400 DRIVE HUB
1 91562
1A
1B
1C
1D
1E 91569
1F
2 91563
2A
2B
2C
2D
2E
1
2
SEAL KIT
SEAL, LIP
SCREW, SET-SOCKET
3 BOLT, FLAT HEAD - HEX SOCKET
1 O–RING
1 O–RING, END COVER (AVAILABLE SEPARATE FROM KIT)
1 NUT, BEARING
1
1
BRAKE SEAL KIT
RETAINER, RING - INTERNAL
O-RING
1 O-RING, BACK-UP
1 O-RING, BACK-UP
1 O-RING
3 91564
3A
3B
BRAKE LINING KIT (INCLUDES SEAL KIT 91563)
8 REACTION DISC, BRAKE ROTOR
9 FRICTION DISC, BRAKE, STATOR
4 91565
5 91566
6 91567
7 9156 8
8 91569
9 91571
10 HDW5633
1
2
2
9
BEARING ASSEMBLY
WHEEL STUD
1 DISENGAGE ROD
1 DISENGAGE CAP
END CAP O-RING
END COVER PLUG
2 SCREW ¼–20 × ½" LG
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page D-11
8
5
4
1B
2
1D
2
7
ART_2108 R1
October 2008
Page D-12
1E
6
1C
1F
3
4
7
5
8
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
1A
Drive Motor
ITEM PART NO.
QTY DESCRIPTION
D
RIVE
H
UB
(F
RONT
)
91401 DRIVE HUB
1 91562
1A
1B
1C
1D
1E 91569
1F
1
2
SEAL KIT
SEAL, LIP
SCREW, SET-SOCKET
3 BOLT, FLAT HEAD - HEX SOCKET
1 O–RING
1 O–RING, END COVER (AVAILABLE SEPARATE FROM KIT)
1 NUT, BEARING
4 91565
5 91566
6 91567
7 9156 8
8 91569
9 91571
10 HDW5633
1
2
2
2
9
BEARING ASSEMBLY
WHEEL STUD
1 DISENGAGE ROD
1 DISENGAGE CAP
END CAP O-RING
END COVER PLUG
SCREW ¼–20 × ½" LG
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page D-13
THIS P
AGE IS LEFT INTENTIONALL
Y BLANK
October 2008
Page D-14
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION E:
HYDRAULICS
91410 M
ANIFOLD
A
SSEMBLY
.................................................................................................... E-3
M
ANIFOLD
A
SSEMBLY
– H
ARDWARE
............................................................................................... E-5
M
ANIFOLD
- O
UTRIGGER
(O
PTION
) ................................................................................................ E-7
H
OSE
K
IT
- D
RIVE
...................................................................................................................... E-9
H
OSE
K
IT
: P
UMP AND
T
ANK
R
ETURN
........................................................................................... E-11
H
OSE
K
IT
: B
RAKE
& O
SCILLATING
A
XLE
....................................................................................... E-11
H
OSE
K
IT
: S
TEERING
................................................................................................................ E-13
H
OSE
K
IT
: W
HEEL
M
OTOR
C
ASE
D
RAIN
....................................................................................... E-13
H
OSE
K
IT
: O
UTRIGGER
O
PTION
.................................................................................................. E-15
H
OSE KIT
- G
ENERATOR
O
PTION
................................................................................................ E-17
L
IFT
C
YLINDER
, 2591RT, 3391RT ............................................................................................ E-19
L
IFT
C
YLINDER
, L
OWER
, 4191RT ............................................................................................... E-21
L
IFT
C
YLINDER
, U
PPER
, 4191RT ............................................................................................... E-23
S
TEERING
C
YLINDER
................................................................................................................. E-25
F
LOATING
A
XLE
L
OCK
C
YLINDER
................................................................................................. E-27
O
UTRIGGER
C
YLINDER
(O
PTION
) ................................................................................................. E-29
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-1
14
16
LEFT
FR
ONT
17 21
19
8 3
9
10
16
17 20
18
19
17 21
26
1
16
ART_2109
October 2008
Page E-2
12
7
1
4
2
5
1 3
6
1
11
27
12
16
14
16
15
25
1 3
2 3
24
17
RIGHT
BA
CK
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
TORQUE TABLE
Part # Desc Ft-lbs
4-5
5-7
Nm
4.5-6.8
6.8-9.5
3 E-Coil, 7-10 9.5-13.6
4 Valve, 6-8 8.5-10.5
5 Valve, 25-27 34.0-36.7
6 Valve, 18-20 24.5-27.2
7 Valve, 18-20 24.5-27.2
8 Valve, 25-27 34.0-36.7
9 Valve, 18-20 24.5-27.2
10 Valve, 18-20 24.5-27.2
11 Valve, 33-37 44.9-50.3
12 Valve, 25-27 34.0-36.7
13 Valve, 18-20 24.5-27.2
14 Valve, 18-20 24.5-27.2
15 Valve,
Counterbalance 18-20 24.5-27.2
16 Valve, 12-14 16.3-19.0
17 Plug
18 Plug
10-20 13.5-27.2
10-20 13.5-27.2
19 Flow Div, FD10 25-27
20 Orifice N/A
21 Orifice N/A
23 Orifice N/A
34.0-36.7
N/A
N/A
N/A
24 Orifice N/A N/A
25 Comp, 25-27 34.0-36.7
26 Valve, 18-20 24.5-27.2
27 Valve, 33-37 44.9-50.3
ITEM PART NO.
QTY DESCRIPTION
91410 M
ANIFOLD
A
SSEMBLY
1 91141
2 91142
3 91143
4 91144
5 91145
6 91146
1
1
4
1
1
1
COIL, SERIES 8 , 12V
COIL, SERIES 10, 12V
COIL, SERIES 10 E-COIL, 12V
VALVE, DRIVE, 4 WAY 3 POSITION
VALVE, LIFT SPOOL, 3 WAY 2 POSITION
VALVE, STEER, 4 WAY 3 POSITION
7 91147
8 9114 8
9 91149
10 91150
11 91151
12 91152
13 91153
14 91476
1
1
1
1
2
3
3
2
VALVE, TORQUE, SPOOL, 4 WAY 2 POSITION
VALVE, PROPORTIONAL, 12 V
VALVE, RELIEF, LIFT
VALVE, RELIEF, STEER
VALVE, PILOTED SPOOL 4 WAY 3 POSITION
VALVE, PILOTED POPPET
VALVE, LOAD SHUTTLE CHECK
VALVE, RELIEF, DRIVE
15 91350
16 91477
2
7
VALVE, COUNTERBALANCE
VALVE, CHECK
17 HDW7314 12 PORT PLUG M ¼", O-RING, RBG-4
1 8 74 8 4
19 91351
20 91355
21 91356
1
2
2
2
PORT PLUG M 0.3
8 " O-RING, RBG-6
FLOW DIVIDER / COMBINER
ORIFICE PLUG, STEER
ORIFICE PLUG, FLOW DIVIDER BLEED
23 91474
24 91475
25 91352
26 91472
27 91473
1
1
1
1
1
ORIFICE PLUG, BRAKE
ORIFICE PLUG, COMPENSATOR
PRESSURE COMPENSATOR
VALVE, SPEED SPOOL 3 WAY 2 POSITION
CHECK VALVE, TANK RETURN
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-3
29
3 8
3 4
LEFT
FR
ONT
28
3 5
3 9
40 w/ Outriggers w/o Outriggers
(Plug)
29
28
3 6
3 7
3 2
TORQUE TABLE
Part # Desc
28
29
Elbow, ½˝
Elbow, ½˝
Ft-lbs
25-30
25-30
Nm
34-41
34-41
5-10
5-10
6.8-13.6
6.8-13.6
85-90 115-122
85-90 115-122
35 Adapter, 3 /
8
˝ 10-20 14-27
5-10
N/A
6.8-13.6
N/A
5-10 6.8-13.6
39 Elbow,
3
/
8
˝ 10-20 14-27
40 Plug
41 Plug
10-20
10-20
14-27
14-27
3 8
3 1
ART_2110
October 2008
Page E-4
3 0 w/ Outriggers
41 w/o Outriggers
(Plug)
RIGHT
BA
CK
3 0
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
M
ANIFOLD
A
SSEMBLY
– H
ARDWARE
2 8 HDW9124 8 4
29 HDW90764 4
30 HDW 88 77 2
31 HDW910 8 1 1
32 HDW91244 1
ELBOW, 90°, MALE, ½", O-RING, MALE, ½", MB-MJ90LL8 8
ELBOW, 90°, MALE, ½", O-RING, MALE, ½", MB-MJ908 8
ELBOW, 90°, MALE ¼” O-RING, MALE ¼”, MB-MJ90-4-4
ELBOW, 90°, MALE ¼” O-RING, MALE ¼”, MB-MJ90LL-4-4
ELBOW, 90°, MALE ¾” O-RING, MALE ¾”, MB-MJ90-12-12
34 HDW91245 1
35 HDW743 8 1
36 HDW7971 1
37 HDW91243 1
3 8 HDW 888 1 3
ELBOW, 90°, M ¾” O-RING, M ¾”,MB-MJ90LL-12-12
ADAPTER, MALE 3/ 8 O-RING, MALE 3/ 8 JIC, MB-MJ-6-6
FITTING, MALE DISCONNECT, ¼" NPT
ADAPTER MALE ¼" ORNG M ¼" NTP, MP-MB-4-4
ADAPTER, MALE ¼”, O-RING, MALE ¼” 37° MB-MJ-4-4
39 HDW7601
40 74 8 4
41 HDW7314
2
2
1
ELBOW, 90°, MALE 3/ 8 O-RING, MALE 3/ 8 JIC, MB-MJ90-6-6
PLUG (WITHOUT OUTRIGGER OPTION)
PLUG (WITHOUT OUTRIGGER OPTION)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-5
MAIN MANIFOLD
LEFT
FR
ONT
RIGHT
BA
CK
OUTRIGGER EXTEND
OUTRIGGER RETRACT
5
6
2
1
2
TO
OUTRIGGER S
CYLINDER S
ORB
OR S
ORR
ORL S
ORA
3
4
TO
OUTRIGGER S
CYLINDER S
ART_2111
October 2008
Page E-6
TO
MAIN MANIFOLD
OR S
TO
MAIN MANIFOLD
ORR
TO
MAIN MANIFOLD
ORL S
TORQUE TABLE
Part # Desc
1 Manifold
Ft-lbs
N/A
Nm
N/A
2 Elbow, 3 /
8
˝ 10-20 14-27
5-10 6.8-14
4 Adapter,
3
/
8
˝ 10-20 14-27
5-7 6.8-9.5
6 Valve, 25-27 34.0-36.7
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
M
ANIFOLD
- O
UTRIGGER
(O
PTION
)
1 9126 8
2 HDW7601
3
4 HDW743 8
5
HDW 888
91142
6 9100 8
1
SEE HOSE KIT FOR HOSES
1 MANIFOLD ASSEMBLY
3
1
1
2
1
ELBOW 90° MALE 3/ 8 " O-RING - MALE 3/
ADAPTER MALE ¼" O-RING - MALE ¼" JIC
ADAPTER MALE 3/
COIL
8 " O-RING - MALE 3/
VALVE SPOOL 4-WAY 3-POSITION
8
8 " JIC
" JIC
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-7
8
A
B
2
1
A
B
7
4
6
5
9
10
2SP
LIFT
B
A
3
2
ART_2112
October 2008
Page E-8
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
B
A
`
ITEM PART NO.
QTY DESCRIPTION
H
OSE
K
IT
- D
RIVE
8 4020 HOSE KIT
1 91425
2 91426
3 91427
4 HDW9557
5 HDW90332 1
6 90275 1
7 9393
8 9 8 47
1
2
9 888 4
10 91256
3
3
2
4
2
4
HOSE ASSY, ½"×74", 8 M3K8 FJX8 FJX45-74"
HOSE ASSY, ½"×116", 8 M3K8 FJX8 FJX45-116"
HOSE ASSY, ½"×14 8 ", 8 M3K8 FJX8 FJX45-14 8 "
TEE, M ¼ JIC M ¼ JIC
TEE, FEMALE ¼ JIC × MALE ¼ JIC
HOSE ASSY, ¼" × 17", 4G1-4FJX-4FJX-17
HOSE ASSY, ¼" × 4 8 ", 4G1-4FJX-4FJX-4 8
HOSE ASSY, ¼" × 76", (4G1-4FJX-4FJX)
HOSE ASSY, ¼" × 106", 4G1-4FJX-4FJX-106
HOSE ASSY, ¼"×42", 4G1-4FJX-4FJX90S
LIFT HOSES
SEE CYLINDER ART
CONTINUED…
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-9
3
9
5
8
1
PUMP
CA S E
DRAIN
S UCTION
LOAD S EN S E
14
1 3
10
11
PRE SS URE
12
ART_2113
October 2008
Page E-10
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
3
4
5
LS
BRAKE
OA
TANK
5
6
PUMP
7
ITEM PART NO.
QTY DESCRIPTION
H
OSE
K
IT
: B
RAKE
& O
SCILLATING
A
XLE
8 4020 HOSE KIT (CONTINUED)
1 HDW9557
2 91256
3 9227
4
3
4
TEE, M ¼ JIC M ¼ JIC
HOSE ASSY, ¼"×42", 4G1-4FJX-4FJX90S
HOSE ASSY, ¼"× 8 3", 4G1-4FJX-4FJX90S
H
OSE
K
IT
: P
UMP AND
T
ANK
R
ETURN
2 HOSE ASSY, ¼" × 76", (4G1-4FJX-4FJX) 4 9 8 47
5 HDW91246 2 FITTING FEMALE ¾" JIC MALE ¾" HOSE BARB
6 91247
7 91423
8 91265
9 90276
8 FT HOSE ASSY, ¾", 12LOLA BULK
1 HOSE ASSY, ¾" × 8 2", (12M3K-12FJX-12FJX45)
1 HOSE ASSY, 1" × 22", (16GMV-16FJX-16FJX-22")
HOSE ASSY, ¼"×24",( 4G1-4FJX-6FJX-24)
10 91161
11 91162
1 FLANGE KIT #16
1 FLANGE KIT #12
12 91163 1 ADAPTER ¾" FLANGE, MALE ¾" JIC 90°
13 HDW91176 1 ADAPTER 1" FLANGE, MALE 1" JIC
14 HDW 88 77 2 ELBOW, 90°, MALE ¼" O-RING, MALE ¼" JIC
CONTINUED…
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-11
5
6
7 FT.
4 FT.
6
5
5
7 FT.
5
6
5 FT.
4
5
4
5
5
2
STEER LEFT
STEER RIGHT
1
3
ART_2114
October 2008
Page E-12
5
6
9 FT.
9 FT.
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
6
5
ITEM PART NO.
QTY DESCRIPTION
H
OSE
K
IT
: S
TEERING
8 4020 HOSE KIT (CONTINUED)
1 888 4
2 9755
3 91421
3 HOSE ASSY, ¼" × 106", 4G1-4FJX-4FJX-106
1
2
HOSE ASSY, ¼" × 8 4", 4G1-4FJX-4FJX8 4
HOSE ASSY, ¼" × 25", 4G1-4FJX90S-4FJX90S-25
H
OSE
K
IT
: W
HEEL
M
OTOR
C
ASE
D
RAIN
4 HDW7391 2 TEE, MALE 3/ 8 JIC
5 HDW91436 12 ADAPTER, FEMALE 3/ 8 JIC × MALE 3/ 8 HOSE BARB
6 91435 41FT HOSE, CASE DRAIN 3/ 8 "
CONTINUED…
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-13
5
4
1
3
3
2
6
ORLS
7
7
8
8
ORR
ORS
5
ART_2115
October 2008
Page E-14
1
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
4
ITEM PART NO.
QTY DESCRIPTION
H
OSE
K
IT
: O
UTRIGGER
O
PTION
8 4020 HOSE KIT (CONTINUED)
1 HDW9557 4 TEE, MALE ¼" JIC
2 HDW7391 2 TEE, MALE 3/ 8 " JIC
3 91422
4 91459
5 902 8 1
6 91424
7 903 8
8 8 31 8
4
1
4
4
2
2
HOSE ASSY, ¼"×74" (4G1-4FJX-6FJX)
HOSE ASSY, ¼"×44" (4G1-4FJX-4FJX90 S)
HOSE ASSY, ¼"×73" (4G1-4FJX-4FJX90 S)
HOSE ASSY, ¼"×26" (4G1-4FJX-4FJX)
HOSE ASSY, 3/ 8 "×46" (6M3K-6FJX-6FJX)
HOSE ASSY 3/ 8 "×24" (6M3K-6FJX-6FJX90)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-15
HYDRAULIC TANK
3/4” TEE
3/4” X 1/2”
9
5
2 1/2” X 21”
EXISTING HOSE
P
FILTER
TANK RETURN
MAIN HYDRAULIC
MANIFOLD
LEFT S IDE
BACK
1 1/4” X 35”
TO: ORL S ON
RIGHT S IDE
6
1/4” X 1/4” X 90°
3
1/2” X 84”
3/4” X 1/2”
9
PRESSURE
PORT
EXISTING HOSE
P
4
3/4” TEE
GENERATOR
& GEAR PUMP
7 1/2” X 1/2”
8
5/8” X 1/2”
HYDRAULIC PUMP
ART_2116
October 2008
Page E-16
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
H
OSE KIT
- G
ENERATOR
O
PTION
1 91346
2 90315
3 91259 1
4 HDW91467 1
1
1
5 HDW91466 1
6 HDW 88 77 1
HOSE ASSY, ¼" × 35" (4GI–4FJX–4FJX90S)
HOSE ASSY, ½" × 21" (
HOSE ASSY, ½" × 8 4" ( 8
8 M3K–
M3K– 8
8 FJX–
FJX– 8
8 FJX90S)
FJX45)
ADAPTER, TEE, ¾" W/SWIVEL FEMALE
ADAPTER, TEE, ¾" MALE O-RING, ¾" MALE JIC
ADAPTER, MALE ¼" O-RING, MALE ¼" JIC 90°
7 HDW90764 1
8 HDW90967 1
ADAPTER, MALE ½" O-RING, MALE ½" JIC 90°
ADAPTER, MALE 5/ 8 " O-RING, MALE ¼" JIC 90°
9 HDW9146 8 2 ADAPTER, FEMALE ¾" JIC, MALE ½" JIC
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-17
S eal Kit
S tatic S eal Groove
Rod
Rod Wiper
Rod S eal
S eal Retainer
S tatic S eal
Rod Wear Rings
Barrel
Piston Wear Ring
Piston S eal
Piston Wear Ring
Piston
5
5
14
8
To Hydraulic Manifold
12
1
5
15
2
October 2008
Page E-18
3
4
16
7
6
5
9140 3 LIFT CYLINDER WITH BEARING S
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
To Hydraulic Reservoir
ART_2117
ITEM PART NO.
QTY DESCRIPTION
L
IFT
C
YLINDER
, 2591RT, 3391RT
1 91403
2 91437
3 HDW7601
4 9767
5 6669
6 91051
7 91141
8 HDW6727
1
1
1
1
4
1
1
1
CYLINDER, LIFT
HOSE ASSEMBLY, 3/ 8 "× 320"
FITTING, ELBOW ADAPTOR
ORIFICE
BEARING
VALVE, 2 WAY, N.C. CABLE ATTACH
COIL, 12 VOLT, DEUTSCH
FITTING, PIPE 90°, MALE BARB
12 645 8 21 FT HOSE, RETURN LINE
14 77 88
15 91442
16 HDW91240 1
1
1
CLAMP, HOSE
CABLE, E-DOWN
NUT, COUPLING 10-32 × ¾"
91461
N/A 9144 8
REF KIT, SEAL-LIFT CYLINDER (SERVICE)
1 HARNESS, WIRE DOWN, VALVE (NOT SHOWN)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-19
S eal Kit
S tatic S eal Groove
Rod
Rod Wiper
Rod S eal
S eal Retainer
S tatic S eal
Rod Wear Rings
Barrel
Piston Wear Ring
Piston S eal
Piston Wear Ring
Piston
1
5
14
8
12
5
5
7
3
5
6
16
4
15
2
10
To Hydraulic Manifold
To Upper Lift Cylinder
October 2008
Page E-20
12
18
17
18
To Hydraulic Reservoir
91404 LIFT CYLINDER WITH BEARING S
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_2118
ITEM PART NO.
QTY DESCRIPTION
L
IFT
C
YLINDER
, L
OWER
, 4191RT
1 91404
2 91437
3 HDW7601
4 9767
5 6669
6 91462
7 9143 8
8 HDW6727
1
1
4
1
1
1
1
1
CYLINDER, LOWER LIFT
HOSE ASSEMBLY, LIFT CYLINDER 3/ 8 "×320"
FITTING, ELBOW 90° ADAPTOR
ORIFICE
BEARING, 2" ID × 2" LG
VALVE, 2 WAY, N.C. POPPET DUAL COIL
HOSE ASSEMBLY, 3/ 8 "×352"
FITTING, PIPE 90°, MALE BARB
10 HDW 8 699 1 FITTING, TEE 3/ 8 " JIC
12 645 8 21 FT HOSE, RETURN LINE
14 77 88
15 90969
16 91141 2
17 HDW90943 1
1 8 HDW90945 2
1
1
CLAMP, HOSE
RELIEF VALVE
COIL, 12 VOLT, DEUTSCH CONNECTOR W/DIODE
FITTING, TEE ADAPTOR
FITTING, FEMALE SWIVEL
91449
N/A 91440
REF KIT, SEAL-LIFT CYLINDER - LOWER (SERVICE)
1 HARNESS, WIRE DOWN, VALVE (NOT SHOWN)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-21
Barrel
S eal Kit
S eal Retainer
Rod
Piston
Piston Wear Rings
Rod S eal
Rod Wiper
5
5
1
5
16
2
6
5
4
3
15
8
14
12
To Lower Lift Cylinder
To Hydraulic Reservoir
91405 LIFT CYLINDER WITH BEARING S
October 2008
Page E-22
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ART_2119
ITEM PART NO.
QTY DESCRIPTION
L
IFT
C
YLINDER
, U
PPER
, 4191RT
1 91405
2 9143 8
3 HDW7601
4 90439
5 6669
6 91462
1
1
1 CYLINDER, UPPER LIFT
1 HOSE ASSEMBLY, LIFT CYLINDER 3/ 8 " × 352"
4
FITTING, ELBOW ADAPTOR
ORIFICE
BEARING, 2" ID × 2" LG
1 VALVE, 2 WAY, N.C. DUAL COIL
8 HDW6727 1 FITTING, PIPE 90°, MALE BARB
12 645 8
14 77 88
15 90969
16 91141
40 FT HOSE, 5/16", RETURN LINE
1 CLAMP, HOSE
1 RELIEF VALVE
2 COIL, 12 VOLT, DEUTSCH CONNECTOR W/DIODE
91450 REF KIT, SEAL-LIFT CYLINDER (SERVICE)
N/A 91441 1 HARNESS, WIRE DOWN, VALVE (NOT SHOWN)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-23
1
2
PI S TON
PI S TON S EAL
WEAR RING
S EAL KIT
S TATIC S EAL
ROD S EAL
ROD WIPER
S EAL
RETAINER
ART_2120
October 2008
Page E-24
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
3
4
ITEM PART NO.
QTY DESCRIPTION
S
TEERING
C
YLINDER
1 91019 2 STEERING CYLINDER
1 HDW 888 1
2 HDW 88 76
3 HDW5925
4 7293
1
1
1 ADAPTER MALE ¼" O-RING-MALE ¼" JIC
1 ADAPTER MALE ¼ O-RING-MALE ¼" JIC TEE
JAMNUT 5/
ROD END
8 -1 8
90990 REF SEAL KIT (SERVICE)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-25
S eal Kit
S tatic S eal Groove
Wear Ring Groove
Barrel
Rod
Rod Wiper
Rod S eal
S eal Retainer
S tatic S eal Backup
S tatic S eal
Piston Wear Ring
Piston
4
2
3
5
1
5
7
5
6
ART_2121
October 2008
Page E-26
91406 AXLE LOCK WITH BEARING S
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
F
LOATING
A
XLE
L
OCK
C
YLINDER
1 91406 2 AXLE LOCK CYLINDER
2 91499
3 91142
4 HDW 88 77
5 9149 8
6 91497
7 91105
1 VALVE, POPPET
1 COIL, 12V
1 FITTING, ELBOW ADAPTOR
3 BEARING, 5/ 8 X 1
1 BLEEDER FITTING
1 GREASE FITTING
91496 REF SEAL KIT (SERVICE)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-27
11
9
8
10
1
2
7
6
4
5
WEAR RING
PI S TON S EAL
S TATIC S EAL
ROD S EAL
ROD WIPER
PI S TON
S EAL
RETAINER
ART_2122
October 2008
Page E-28
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
O
UTRIGGER
C
YLINDER
(O
PTION
)
1 91443
2 912 8 1
4
1
CYLINDER, OUTTRIGGER
SWITCH, OUTRIGGER PRESSURE N.O.
4 10907
5 HDW 8 476
6 HDW9761
7 91277
8 91464
9 91141
10 HDW91465 2
2
2
1
1
1
1
11 90439 1
WASHER ACTUATOR
NUT JAM ¼-20
SCREW, SOCKET HEAD ¼-20 × 2½
SWITCH, OUTRIGGER RETRACT LIMIT N.O.
VALVE N.C. POPPET
COIL 12V DEUTSCH
ADAPTER 3/ 8 MALE O-RING, ¼ MALE JIC
ORIFICE
91451 REF SEAL KIT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page E-29
THIS P
AGE IS LEFT INTENTIONALL
Y BLANK
October 2008
Page E-30
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION F:
BASE
B
ASE
A
SSEMBLY
......................................................................................................................... F-3
C
ONTROL
M
ODULE
...................................................................................................................... F-5
P
OWER
M
ODULE
........................................................................................................................ F-9
P
OWER
M
ODULE
: E
NGINE
M
OUNT
- D
IESEL
.................................................................................. F-13
E
NGINE
, D
UAL
F
UEL
................................................................................................................. F-17
E
NGINE
, D
IESEL
....................................................................................................................... F-21
W
IRE
H
ARNESS
........................................................................................................................ F-25
O
UTRIGGER
I
NSTALLATION
(O
PTION
) ............................................................................................. F-27
G
ENERATOR
- O
PTION
............................................................................................................... F-29
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-1
ART_2123-R1
October 2008
Page F-2
2591RT | 3391RT | 4191RT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Base Assembly
ITEM PART NO.
QTY DESCRIPTION
B
ASE
A
SSEMBLY
1 16410
2 16455
16454
16453
1
1
1
1
BASE WELDMENT
LADDER WELDMENT, 2591RT
LADDER WELDMENT, 3391RT
LADDER WELDMENT, 4191RT
3 HDW6211 8 SCREW, ½-13, 1 ¼" LG, GR5
4 HDW8498
5 16153
6 16480
7 16213
1
1
4
1
SCREW, ¼-13, 4" LG GR5
CABINET WELDMENT, CONTROL MODULE
COVER, HOSE TRAY
CABINET WELDMENT, POWER MODULE
8 16156
9 16220
1
1
DOOR WELDMENT, CONTROL MODULE
DOOR WELDMENT, POWER MODULE
10 8386 4 CATCH TRIGGER
11 HDW8457 12 NUT, ½" - 13, GR 5
12 HDW5723
13 16834
14 90749
6
1
1
SCREW, ¼–20 × ¾"
BRACKET, POWER TO PLATFORM
RECEPTICAL, POWER TO PLATFORM
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-3
40
44
16
16
3
33
3
4
0
4 3
41
16
42
46
29
5
2 8
3 2
5 3
4 8
5 8
56
55
16
52
16
57
5
54
5
17
45
47
16
51
12
1 3
10
49
50
7
1
8 9
15
5
1 3
14
1 8
5
16
2
4 5
20
6
ART_2124
October 2008
Page F-4
3
19
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
C
ONTROL
M
ODULE
1 16153
2 14896
3 HDW8273
4 HDW5217
1
4
4
4
CONTROL MODULE WELDMENT
BLOCK, SLIDE, DOOR
SCREW, ¼–20, 1" LG
WASHER, .343 ID × .680 OD × .063 THK
5 HDW8267 18 NUT, ¼–20, GR 5
6 16154 1 BRACKET, CROSS SUPPORT
7 HDW5724
8 90749
4
1
SCREW, 5/16–18, ¾" LG, GR 5
POWER TO PLATFORM (EARLY MODELS)
(SEE PAGE F-3 FOR CURRENT CONFIGURATION)
10 25429
12 91410
13 HDW6433
14 HDW7783
4
4
2 PAD
1 HYDRAULIC MANIFOLD
SCREW, 3/8 × 1"
LOCK WASHER, 3/8
15 16225 1 BRACKET, FUEL TANK
16 HDW5723 18 SCREW, ¼-20 × ¾"
17 16152 1 BULKHEAD
18 HDW8268
19 91023
20 91091
6919
1
1
5
1
NUT, 3/8
FUEL TANK, PLASTIC
FUEL TANK CAP
FUEL SHUTOFF (NOT SHOWN)
HDW91279 1
7788 1
ADAPTER, MALE 1/8 NPT, 5/16 HOSE BARB (NOT SHOWN)
CLAMP (NOT SHOWN)
6458 90" HOSE, FUEL LINE (NOT SHOWN)
HDW91233 1 PLUG (DUAL FUEL) 1/8 NPT, 3/19 HOSE BARB (NOT SHOWN)
HDW91320 1 ADAPTER (DIESEL)
28 16226
29 HDW7888
30 91169
91170
32 91375
1
1
2
4
1
BRACKET, CONTROL BOX
SCREW, 10-32 × ½"
LOWER CONTROL BOX
HARNESS, MAIN (NOT SHOWN)
RELAY, SPEED/TORQUE, DRIVE
CONTINUED …
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-5
40
44
16
16
3
33
3
4
0
4 3
41
16
42
46
29
5
2 8
3 2
5 3
4 8
5 8
56
55
16
52
16
57
5
54
5
17
45
47
16
51
12
1 3
10
49
50
7
1
8 9
15
5
1 3
14
1 8
5
16
2
4 5
20
6
ART_2124
October 2008
Page F-6
3
19
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
C
ONTROL
M
ODULE
C
ONTINUED
33 16229
34 8841
9438
9012
9013
7172
7173
1
1
1
1
1
1
1
BATTERY DISCONNECT BRACKET
BATTERY DISCONNECT
BATTERY CABLE, RED, 15 INCH LONG (NOT SHOWN)
BATTERY CABLE, RED, 72 INCH LONG (NOT SHOWN)
BATTERY CABLE, BLACK, 72 INCH LONG (NOT SHOWN)
BOOT, BLACK (NOT SHOWN)
BOOT, RED (NOT SHOWN)
40 6854
41 2987
42 HDW6110
43 3436
44 91174
2
1
1
2
1
BATTERY, 12VDC
HOLD DOWN ROD
WING NUT
HOLD DOWN BAR
LEVEL SENSOR
45 91280 1
46 HDW90880 4
47 HDW90803 4
48 91375 1
49 91268 1
50 HDW91332 2
51 HDW8304 2
OUTRIGGER OPTION
CONTROL MODULE (OUTRIGGER OPTION)
SCREW, 10-32 × 1"
NUT, 10-32 NYLOCK
RELAY (OUTRIGGER OPTION)
OUTRIGGER MANIFOLD, (OPTION)
SCREW, 5/16-18 × 3½"
NUT, 5/15-18
52 16620
53 16619
54 90898
55 25480 1
56 HDW90833 2
57 HDW5364
58 7423
2
1
91378
91379
1
1
1
1
1
4191RT EMERGENCY LOWERING
BATTERY SHELF
BATTERY BRACKET
BATTERY, 12VDC
BRACKET, EMERGENCY DOWN SWITCH
SCREW, 6–32 × ¾" LG
NUT, 6 –32
SWITCH, TOGGLE, 1 POLE 2 POS
HARNESS, E-DOWN TO BATTERIES (NOT SHOWN)
HARNESS, E-DOWN W/DIODE (NOT SHOWN)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-7
11
5
7
6
19
3 5
3
4
20
1 3
14
8
9
10
16
17
15
2
12
1
ART_2125
October 2008
Page F-8
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
P
OWER
M
ODULE
1 16213
2 16247
3 25429
4 40620
5 14896
6 14826
7 HDW8273
8 HDW5217
9 HDW8267
10 HDW5724
4
4
4
4
REF WELDMENT, POWER MODULE
1 GUARD, ENGINE MODULE
2 PAD
2 SPACER, INSULATOR, 1.59" LG
4
1
BLOCK, SLIDE, DOOR
BRACKET, CROSS SUPPORT
SCREW, ¼–20, 1" LG
WASHER, .343 ID × .680 OD × .063 THK
NUT, ¼–20, GR 5
SCREW, 5/16–18, ¾" LG, GR 5
11 9370
12 HDW9200
13 HDW6727
14 HDW7500
15 91164
1
3
1
1
1
HYDRAULIC TANK INSTALLATION
LEVEL GAUGE
PLUG, ¼ NPT
ELBOW, 90° ¼ NPT – 5/16 BARB
ELBOW, 90° ¼ NPT – 3/8 JIC
ELBOW, 90° 1 1/8 NPT – 1 JIC
16 91417
91418
91570
1
1
1
FILTER ASSEMBLY (INCLUDES 91418 AND 91570)
FILTER CARTRIDGE
FILTER PRESSURE GAUGE
17 HDW9268
18 HDW9268
19 9367
20 6655
1
1
1
6
ELBOW, 90° ¾ NPT – ¾ JIC
BOLT, 32 × 1.57
FILLER/STRAINER
TEE, ¼ NPT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-9
17
2
12
14
15
1 3
12
3
9
10
7
8
11
ART_2126
October 2008
Page F-10
16
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
P
OWER
M
ODULE
: E
NGINE
M
OUNT
- D
UAL
F
UEL
2 16211
3 16210
2
2
ENGINE MOUNT, DUAL FUEL
SPACER
6 91131
7 91127
8 HDW5723
9 HDW8267
10 6458
11 16295
HDW5723
HDW8267
12 7736
13 40620
14 HDW8567
15 HDW8279
16 HDW8268
1
1
RADIATOR BRACKET KIT
COOLANT OVERFLOW TANK
3 FT HOSE
1 AIR INTAKE WELDMENT
4
4
8
4
2
4
2
2
4
SCREW, ¼-20 × ¾
NUT, ¼-20
SCREW, ¼-20 × ¾"
NUT, ¼–20, GR 5
INSULATOR RUBBER
SPACER ISOLATOR
WASHER, 3/8 FLAT
SCREW, 3/8-16 × 2 ½ GR8
NUT, 3/8-16
17 HDW91234 12 SCREW, M10-1.25 × 25 8.8
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-11
14
12
15
4
3
17
1 3
12
2
7
8
9
10
16
5
1 8
19
8
11
20
16
6
ART_2127
October 2008
Page F-12
16
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
6
ITEM PART NO.
QTY DESCRIPTION
P
OWER
M
ODULE
: E
NGINE
M
OUNT
- D
IESEL
Engine components found later in this section
2 16209
3 16210
4 16207
5 16345
6 HDW6432
1
2
2
3
5
ENGINE MOUNT, DIESEL
SPACER
BRACKET, SOLENOID MOUNT
RADIATOR MOUNT BRACKET
SCREW, 3/8 - 18 × ¾
7 91127
8 HDW5723
9 HDW8267
10 6458
11 16295
12 7736
13 40620
14 HDW8567
2 NUT, ¼-20
3 FT HOSE
4
4
1
8
1
4
COOLANT OVERFLOW TANK
SCREW, ¼-20 × ¾
AIR INTAKE WELDMENT
INSULATOR RUBBER
SPACER ISOLATOR
WASHER, 3/8 FLAT
15 HDW8279
16 HDW8268
4
9
SCREW, 3/8-16 × 2 ½ GR8
NUT, 3/8-16
17 HDW91234 12 SCREW, M10-1.25 × 25 8.8
18 91591
19 16346
20 945407
1
1
1
VIBRATION ISOLATOR
RADIATOR BRACE
NUT, M6 × 1
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-13
3
5
2
1
10
5
4
11
6
8
7
9
ART_2128
October 2008
Page F-14
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
LP T
ANK
I
NSTALLATION
, D
UAL
F
UEL
1 6859
2 6868
3 6890
4 7406
5 HDW6894
6 6861
7 6860
8 16246
9 HDW6433
10 HDW8268
11 6938
1
1
1
1
3
1
6
6
1
1
1
LP TANK
QUICK DISCONNECT
HOSE ASSEMBLY, 30"
HOSE ASSEMBLY, 90"
ELBOW, BRASS, NPT TO SAE
BULKHEAD FILTER
BRACKET, TANK MOUNT
TANK SUPPORT WELDMENT
SCREW, 3/8-16 × 1"
LOCKNUT, 3/8
RELIEF VALVE
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-15
4 8
24
22
2 3
20
47
9
19
10
12
8 50
25
46
21
26 27
Coil
15 16
17 1 8
11
1 3
5
4
6
3
42
41
7
14
54
45
3 2
33
1
3 1
4 3
3 0
2 8 29
44
49
40
52
5 3
3 9
3 5
3 6
3 7
ART_2129-R2
October 2008
Page F-16
2591RT | 3391RT | 4191RT
Dual Fuel Engine, Kubota DF752
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
E
NGINE
, D
UAL
F
UEL
2
4
91035
1 91125
90239
3 20212
9502
5 9498
1
1
1
1
1
1
Additional attaching engine parts found earlier in this section
ENGINE SUBASSEMBLY, DUAL FUEL
ENGINE, KUBOTA DF752
MUFFLER
CHOKE BRACKET
CHOKE SOLENOID
CHOKE LINKAGE
6 20204 1
7 HDW91283 1
8 91133
9 91188
1
1
10 21020
11 91119
12 91177
13 91375
1
1
1
1
14 9252
15 HDW9247
16 HDW91231 2
1
1
SPACER
SCREW, M6–1.0 × 25
CARBURETOR FLANGE
INTAKE HOSE
BRACKET, COMPONENTS
SOLENOID, THROTTLE
FUEL PUMP
RELAY, THROTTLE
THROTTLE LINKAGE
SCREW, CAP SOCKET HEAD, ¼–28 × 1.0"
JAMNUT, ¼–28
17 HDW5723
18 HDW8267
19 6458
20 7788
21 HDW8303
22 HDW8304
23 91132
24 HDW6894
25 91197
26 91198
27 91232
28 91175
29 HDW91187 1
30 90227 1
6
1
1
1
2
2
6
6
SCREW, ¼-20 × ¾"
NUT, ¼–20
REF HOSE, FUEL, 5/16
5 HOSE CLAMP, 5/16
SCREW, 5/16–18 × 2
NUT, 5/16–20
VALVE, LOCKOFF
ELBOW, 90° BRASS
10 IN LP HOSE, ½"
60 IN RADIATOR HOSE, 3/8"
HOSE CLAMP, #8
OIL PRESSURE SWITCH
FITTING, 1/8 NPT, M-F
ALTERNATOR, 40 AMP
CONTINUED . . .
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-17
4 8
24
22
2 3
20
47
9
19
10
12
8 50
25
46
21
26 27
Coil
15 16
17 1 8
11
1 3
5
4
6
3
42
41
7
14
54
45
3 2
33
1
3 1
4 3
3 0
2 8 29
44
49
40
52
5 3
3 9
3 5
3 6
3 7
ART_2129-R2
October 2008
Page F-18
2591RT | 3391RT | 4191RT
Dual Fuel Engine, Kubota DF752
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
E
NGINE
, D
UAL
F
UEL
(
CONTINUED
)
31 91129
32 91340
33 7545
1
1
2
KTR HOUSING KIT, DF752
HOSE, 2.00" I.D. FLEX
HOSE CLAMP
35 91134
36 9696
37 9868
38 40620
39 HDW8279
40 HDW8268
41 91130
42 91160
43 HDW6433
44 8516
45 8472
46 9833
47 8514
48 7406
49 91136
50 91617
51 8365
52 91765
53 91766
54 91799
1
2
EXHAUST PIPE
MUFFLER HANGER
2
1
1
1
1
1
2
1
MUFFLER CLAMP
SPACER
SCREW, 3/8–16 × 2 ½"
NUT, 3/8–16
HUB
HYDRAULIC PUMP
SCREW, 3/8-16 × 1"
OIL FILTER
1 RADIATOR
1 LPG REGULATOR
1 FUEL FILTER
REF HOSE ASSEMBLY, LP
1 AIR FILTER ELEMENT
1
1
CARBURETOR ASSEMBLY
STARTER (NOT SHOWN)
1
1
1
RING GEAR
FLYWHEEL
BREATHER CAP
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-19
Note:
Improved a ir cle a ner mo u nt repl a ce s old s tyle.
Refer to S E-0 8 1.
27
4 3
2 3
33
2
27
44
2 8
33
24
45
27
3
3 6
38
3 7
1
15
14
1 3
16
1 8
2 3 24
3 9
19
Throttle Rel a y
22
21
40
20
41
42
26
Glow Pl u g Rel a y
25
3 4
11
3 5
3 0
3 2
4
29
5
6 7
3 1
ART_2130-R2
October 2008
Page F-20
2591RT - 3391RT - 4191RT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Diesel Engine, Kubota D1105
ITEM PART NO.
QTY DESCRIPTION
E
NGINE
, D
IESEL
84036
1 91429
2
3
91113
9831
91111
8667
1
1
1
Additional attaching engine parts found earlier in this section
ENGINE SUBASSEMBLY, DIESEL
ENGINE KIT, D1105
RADIATOR KIT
RADIATOR
AIR CLEANER KIT
AIR FILTER ELEMENT
4 91115
9830
5
6
91118
9696
1
7 9868
8 40620
9
10
HDW8279
HDW8268
11 91175 1
12 HDW91187 1
13 91116
1
1
1
1
1
1
1
MUFFLER KIT
MUFFLER
EXHAUST PIPE
MUFFLER HANGER
MUFFLER CLAMP
SPACER
SCREW, 3/8–16 × 2 ½"
NUT, 3/8–16
OIL PRESSURE SWITCH
FITTING, 1/8 NPT, M–F
FUEL FILTER ASSEMBLY
91123
14 6458
15 91199
16 91114
17 7788
18 91589
19 16207
20 16347
8 FT
6 FT
1
5
1
1
2
FUEL FILTER ELEMENT
HOSE, FUEL, 5/16
HOSE, FUEL, 3/16
VALVE, CHECK
HOSE CLAMP
SOLENOID, THROTTLE
BRACKET, SOLENOID
THROTTLE LINK
21 91117 1 YOKE
22 HDW91231 1 JAMNUT, ¼–28
23 HDW5723
24 HDW8267
25 91112
4
4
1
SCREW, ¼–20 × ¾"
NUT, ¼–20
KTR HOUSING KIT, D905
CONTINUED…
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-21
Note:
Improved a ir cle a ner mo u nt repl a ce s old s tyle.
Refer to S E-0 8 1.
27
4 3
2 3
33
2
27
44
2 8
33
24
45
27
3
3 6
38
3 7
1
15
14
1 3
16
1 8
2 3 24
3 9
19
Throttle Rel a y
22
21
40
20
41
42
26
Glow Pl u g Rel a y
25
3 4
11
3 5
3 0
3 2
4
29
5
6 7
3 1
ART_2130-R2
October 2008
Page F-22
2591RT - 3391RT - 4191RT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Diesel Engine, Kubota D1105
ITEM PART NO.
QTY DESCRIPTION
E
NGINE
, D
IESEL
(
CONTINUED
)
26 91375
27 7545
2
5
RELAY
HOSE CLAMP
28 16720
29 91130
30 91160
31 HDW6433
32 91630
1
1
1
2
1
BRACKET
HUB
HYDRAULIC PUMP
SCREW, 3/8-16 × 1"
RING GEAR
33 HDW5217
34 8665
35 8413
36 8001
37 90227
38 9832
39 91588
40 HDW5217
41 HDW91590 1
42 HDW5290 1
43 91799 1
1
1
-
-
-
-
2
-
44 946640
45 16721
2
1
FLAT WASHER
OIL FILTER
STARTER
FUEL SOLENOID
ALTERNATOR
GLOW PLUGS
WASHER, ¼" RUBBER
WASHER, FLAT, 5/16"
CLEVIS PIN, 5/16 × 1"
COTTER PIN, 1/8" × 1"
BREATHER CAP
SCREW,
TUBE, INTAKE EXTENSION
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-23
THIS P
AGE IS LEFT INTENTIONALL
Y BLANK
October 2008
Page F-24
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
W
IRE
H
ARNESS
— 91430
— 91185
HARNESS, MAIN [CONTROL MODULE - BASE & VALVES]
CONTROL CABLE, 2591RT
—
91321
91439
91184
CONTROL CABLE, 3391RT
CONTROL CABLE, 4191RT
[CONTROL MODULE TO DECK THROUGH SCISSOR BEAMS]
HARNESS, CONTROL BOX (UPPER)
[INSIDE UPPER CONTROL BOX]
— 91294 CABLE, OUTRIGGER OPTION, UPPER CONTROLS
[INSIDE UPPER CONTROL BOX]
— 91295
—
—
—
—
91296
91121
91447
91444
91448
91440
CABLE, OUTRIGGER OPTION, CONTROL, PLATFORM
[DECK TO UPPER CONTROL BOX]
CABLE, OUTRIGGER OPTION, CONTROL, 2591RT
CABLE, OUTRIGGER OPTION, CONTROL, 3391RT
CABLE, OUTRIGGER OPTION, CONTROL, 4191RT
[CONTROL MODULE TO DECK THROUGH SCISSOR BEAMS]
HARNESS, OUTRIGGER OPTION
[CONTROL MODULE TO OUTRIGGERS]
HARNESS, LIFT CYLINDER DOWN VALVE, 2591RT, 3391RT
[CONTROL MODULE TO LIFT CYLINDER]
HARNESS, LOWER LIFT CYLINDER DOWN VALVE, 4191RT
[CONTROL MODULE TO LIFT CYLINDER]
— 91441
—
—
—
—
—
—
—
91379
91378
91171
91543
91172
91173
91189
91557
91595
HARNESS, UPPER LIFT CYLINDER DOWN VALVE , 4191RT
[CONTROL MODULE TO LIFT CYLINDER]
HARNESS, E-DOWN WITH DIODE, 4191RT
HARNESS, E-DOWN TO BATTERIES, 4191RT
HARNESS, ENGINE, INTERMEDIATE
[CONTROL MODULE TO ENGINE MODULE]
HARNESS, ENGINE INTERMEDIATE, GENERATOR OPTION
[CONTROL MODULE TO ENGINE MODULE]
HARNESS, ENGINE, DUAL FUEL
[ENGINE MODULE]
HARNESS, ENGINE, DIESEL [ENGINE MODULE]
CABLE, UPPER CONTROLS, REMOVABLE
CABLE, UPPER CONTROLS, FIXED
HARNESS, LOWER CONTROLS
[INSIDE LOWER CONTROL BOX]
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-25
1 3
16
15
20
17
21
14
7
19
1 8
5
12
14
11
10
4
7
7
1
2
3
2
9
ART_2131
October 2008
Page F-26
3
5
7
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
O
UTRIGGER
I
NSTALLATION
(O
PTION
)
1 16490 1
2 HDW91457 8
WELDMENT, OUTRIGGER MOUNT, REAR
SCREW, ¾–10 × 10" LG
3 HDW91458 8 LOCKNUT, ¾–10
4 16451 4 WELDMENT, OUTER OUTRIGGER
5 HDW7052 8 SCREW, ½–13 × 3 ½" LG
7 HDW8457 16 NUT, ½–13
9 16491
10 21170
1
4
WELDMENT, OUTRIGGER MOUNT, FRONT
COVER, OUTRIGGER CYLINDER
11 HDW6455 20 SCREW, ¼–20 × ½"
12 HDW91328 4 SHOULDER SCREW, 5/8 × 4.75"
13 91443
14 90663
15 16448
16 HDW5916
17 20998
4
4
4
4
CYLINDER, OUTRIGGER
64 SPACER
TUBE, INNER OUTRIGGER
SCREW, ½–13 × 4.0"
BRACKET PIVOT
18 HDW91395 4
19 HDW9219 4
20 HDW5920
21 21002
4
4
CLEVIS PIN, 5/8 × 5.0"
WASHER, FLAT
PIN, COTTER, 1/8 × 1"
PAD WELDMENT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-27
TO:
BASE
CONTROL BOX
9
8
7
12
11
10
4
5
6
1
2
3
10
11
12
8
9
6
7
3
4
5
1
2
00
00
16
15
220
15
124
PLUGGED
225
116
23
22
RED
RED
FUSE
RED
BATTERY
ORG/GRN
BLK
3
4
1 2
1
5
16
ROTATE 90°
85 86 87a 30
85 87a
87
7
6
RED/WHT 71
YEL/RED
BLK
ORG/WHT
ORG
GRN/WHT
BLK/WHT
BLU/WHT
ORG/GRN
RED/GRN
BLK
220
15
124
PLUGGED
225
116
23
22
PLUGGED
PLUGGED
16
15
10
11
12
8
9
6
7
3
4
5
1
2
4
5
6
1
2
3
TO:
ENGINE
HARNESS
9
8
7
12
11
10
15
BLK 15
ORG/GRN 171
Upper
Control s
2
ORG/GRN 171
BLK 15
RED/WHT
11
1 2
1 3
14
9
8
Control
Mod u le
ART_2135
October 2008
Page F-28
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
12
11
ITEM PART NO.
QTY DESCRIPTION
G
ENERATOR
- O
PTION
1
3
5
91550
2 5630
91551
4 91002
91546
6 91375
1
1
1
1
1
1
REFER TO SECTION 5 FOR HOSE KIT
GENERATOR, 2000 WATT
SWITCH, TOGGLE
VALVE, SOLENOID, 2-WAY, N.C.
COIL, 12V 10 SERIES
NEEDLE VALVE
RELAY, SPDT
7 91544
8 91545
9 7594
11
12
13
14
15
16
7617
91556
9502
91119
91469
91543
16369
1
1
1
2
PLUG, MALE, 3 PRONG
RECEPTACLE, FEMALE
STRAIN RELIEF
LOCKNUT, ½" NPT
6 FT WIRE, 14GA, 3 CONDUCTOR
1 LABEL, AC GENERATOR
1
1
SOLENOID, GENERATOR-THROTTLE, GAS ENGINE
SOLENOID, GENERATOR-THROTTLE, DIESEL ENGINE
2 FT CHAIN, SASH #8
1 HARNESS, ENGINE INTERMEDIATE, GENERATOR OPTION
1 BRACKET, GENERATOR MOUNT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page F-29
THIS P
AGE IS LEFT INTENTIONALL
Y BLANK
October 2008
Page F-30
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
SECTION G:
DECALS
D
ECAL
K
IT
, C
ONTROLS
................................................................................................................ G-3
D
ECAL
K
IT
, B
ASE
....................................................................................................................... G-5
D
ECAL
K
IT
, S
CISSORS
................................................................................................................. G-7
D
ECAL
K
IT
, P
LATFORM
................................................................................................................. G-9
D
ECAL
K
IT
, A
NCHORAGE
P
OINTS
O
PTION
..................................................................................... G-11
D
ECAL
K
IT
, O
UTRIGGER
O
PTION
................................................................................................. G-11
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page G-1
Controls Decals
91190
3
90729
1
7156
7156
5
7155
LOCATE CONTROL BOX HERE
FOR NORMAL OPERATION OF THI S UNIT
7155
6
7156
71 55
FO
LO
CA
R
NO
R
TE
C
MA
O
NT
L O
PE
RO
RA
TIO
N
L B
O
F
TH
H
S
U
ER
N
IT
E
DRIVE
ENAB
LED
RETRACT
AUTOMA
TIC
S
EXTEND
OUTRIGGER
DESIRED
ITCH IN
913
49
2
91158
91 3 49 (OPTION)
DRIVE
ENABLED
4
AUTOMATIC
OUTRIGGERS
RETRACT
EXTEND
HOLD SWITCH IN
DESIRED DIRECTION
91349
91109
9
W PLUGS
DIAGNOSTICS LED’S
LED INDICATES FUNCTION ENABLED
TIL
T AL
ARM
T
ARD
SE
LE
REVER THROTT
91109
91221 Diesel
7
8
91157 Dual Fuel
ART_2137
October 2008
Page G-2
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
D
ECAL
K
IT
, C
ONTROLS
1 90729
2 9115 8
3 91190
4 91349
5 7156
6 7155
7 91221
8 91157
9 91109
1
1
1
1
1
1
1
1
1
DECAL, UPPER CONTROL BOX, SIDE
DECAL, UPPER CONTROLS
DECAL, CONTROL BOX MODEL
DECAL, OUTRIGGER CONTROLS
DECAL, FRONT
DECAL, LOCATE CONTROL BOX HERE
DECAL, LOWER CONTROLS, DIESEL
DECAL, LOWER CONTROLS, DUAL FUEL
DIAGNOSTIC LABEL
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page G-3
1
9 3 78
2
6872
Dual Fuel
90751
17
Early Models: Located on Control Module
Current Models: Located on Top of Frame
3
8519
4
8502
Rear
907 3 2
5
7
4191RT only
90918
9052
6
6948
Dual Fuel
Inside
Control
Module
8
Front
11
91455 - 2591RT
12
91454 - 33 91RT
1 3
99 3 2 - 4191RT
EMERGENCY LOWERING
SWITCH INSIDE
9155 3
687 3
HYDRAULIC OIL
687 3
Inside Power Module
14
H
YD
R AU
LIC
O
IL
16
Front
15
9108 3
2591RT &
33 91RT only
10
10
91266
9
4191RT only
91 3 74
EMERGENCY LOWERING
SWITCH INSIDE
91 3 74
Control S ide
Power S ide
Rear
ART_2140-R1
October 2008
Page G-4
2591RT - 3391RT - 4191RT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Decals: Base Assembly
ITEM PART NO.
QTY DESCRIPTION
D
ECAL
K
IT
, B
ASE
1 937 8
2 6 8 72
3 8 519
4 8 502
5 90732
6 9052
7 9091 8
8 694 8
9 91374
10 91266
11 91455
12 91454
13 9932
14 6 8 73
15 910 8 3
16 91553
17 90751
1
1
4
4
1
1
1
1
1
2
1
1
1
1
1
1
1
DECAL, DIESEL ONLY
DECAL, GASOLINE ONLY
DECAL, WARNING, TIRE REPLACEMENT
DECAL, INFLATE TIRE
DECAL, WARNING, PRESSURE WASH
DECAL, BATTERY DISCONNECT AND LOCK
DECAL, EMERGENCY LOWERING SWITCH, 4191RT
WARNING, LPG, DUAL FUEL ONLY
DECAL, EMERGENCY LOWERING SWITCH INSIDE, 4191RT
DECAL, QUAD TRAX 4WD
DECAL, PLATFORM CAPACITY, SMALL, 2591RT
DECAL, PLATFORM CAPACITY, SMALL, 3391RT
DECAL, PLATFORM CAPACITY, SMALL, 4191RT
DECAL, HYDRAULIC OIL
EMERGENCY LOWERING, 2591RT, 3391RT
SERIAL PLATE
POWER TO PLATFORM
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page G-5
2
2591RT
S cissors
2591RT, 3391RT, 4191RT
S cissors Assembly Decals
Maintenance Lock
S towed
2
9910
9910
2
3391RT
S cissors
1
90717
Maintenance Lock
Rear
October 2008
Page G-6
Po wer
S ide
2
4191RT
S cissors
Contr ol
S ide
Rear
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Maintenance Lock
Engaged
ART_2143
ITEM PART NO.
QTY DESCRIPTION
D
ECAL
K
IT
, S
CISSORS
1 90717
2 9910
1
4
DECAL, MAINTENANCE LOCK
DECAL, PINCH POINT
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page G-7
2591RT, 3391RT, 4191RT
Platform Assembly Decals
91456
1
9 3 7 3
10
9 3 72
11
9 3 71
12
Front
9
8402
Front
90721
90721
2
907 3 0
3
90721
8911
4
8911
Front
907 3 9
8
Rear
2591RT 9145 3
5
33 91RT 91452
6
4191RT 91548
7
8402
ART_2146
October 2008
Page G-8
1 3
90719
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
9 3 7 3
9 3 72
9 3 71
ITEM PART NO.
QTY DESCRIPTION
D
ECAL
K
IT
, P
LATFORM
1 91456
2 90721
3 90730
4 8 911
5 91453
6 91452
7 9154 8
8 90739
9 8 402
10 9373
11 9372
12 9371
13 90719
1
1
1
1
2
2
2
1
2
2
2
2
1
DECAL, WARNING PANEL
DECAL, DANGER, ELECTRIC - TIPOVER - WIND RATING
DECAL, WARNING, SHEET LOADING
DECAL, MANUAL CASE
DECAL, CAPACITY, 2000 LB, 2591RT
DECAL, CAPACITY, 1500 LB, 3391RT
DECAL, CAPACITY, 1000 LB, 4191RT
DECAL, MADE IN USA
DECAL, RAIL STRIPE
DECAL, MEC 2591RT
DECAL, MEC 3391RT
DECAL, MEC 44191RT
DECAL, MEC OVAL
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page G-9
1
8605
90721
2
8606
ART_2149
October 2008
Page G-10
3
9465
(EACH OUTRIGGER)
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
D
ECAL
K
IT
, A
NCHORAGE
P
OINTS
O
PTION
1 8 605
2 8 506
4
1
CERTIFIED LANYARD ANCHORAGE POINT
DECAL, WARNING, POS RESTRAINTS
1 9465
D
ECAL
K
IT
, O
UTRIGGER
O
PTION
4 DECAL, DANGER, KEEP CLEAR OUTRIGGERS
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications October 2008
Page G-11
THIS P
AGE IS LEFT INTENTIONALL
Y BLANK
October 2008
Page G-12
"2591RT / 3391RT / 4191RT" Service & Parts Manual - ANSI Specifications
Service Parts Order Form
Fax to 559-263-9631
Please fill out completely
Date: ______________________________
Account: ___________________________
Bill to: _____________________________
__________________________________
__________________________________
__________________________________
__________________________________
Purchase Order Number _____________
**All orders MUST have a Purchase Order Number
Part Number Description
Ordered By: ________________________
Your Fax No.: _______________________
Ship to: ____________________________
__________________________________
__________________________________
__________________________________
__________________________________
Ship VIA __________________________
**Fed Ex shipments require Fed Ex account number
Quantity Price
All backordered parts will be shipped when available via the same ship method as original order unless noted below:
• Ship complete order only - no backorders
• Ship all available parts and contact customer on disposition of backordered parts
• other (please specify)
___________________________________________________________________
___________________________________________________________________
THIS P
AGE IS LEFT INTENTIONALL
Y BLANK
Limited Owner Warranty
MEC Aerial Platform Sales Corp. warrants its equipment to the original purchaser against defects in material and/or workmanship under normal use and service for one (1) year from date of registered sale or date the unit left the factory if not registered. MEC Aerial
Platform Sales Corp. further warrants the structural weldments of the main frame and scissor arms to be free from defects in material or workmanship for five (5) years from date of registered sale or date unit left the factory if not registered. Excluded from such warranty is the battery(s) which carries a ninety (90) day warranty from described purchase date. Warranty claims within such warranty period shall be limited to repair or replacement, MEC Aerial Platform Sales Corp’s option, of the defective part in question and labor to perform the necessary repair or replacement based on MEC Aerial Platform
Sales Corp’s then current flat rate, provided the defective part in question is shipped prepaid to MEC Aerial Platform Sales Corp. and is found upon inspection by MEC Aerial
Platform Sales Corp. to be defective in material and/or workmanship. MEC Aerial
Platform Sales Corp. shall not be liable for any consequential, incidental or contingent damages whatsoever. Use of other than factory authorized parts; misuse, improper maintenance, or modification of the equipment voids this warranty. The foregoing warranty is exclusive and in lieu of all other warranties, express or implied. All such other warranties, including implied warranties of merchantability and of fitness for a particular purpose, are hereby excluded. No Dealer, Sales Representative, or other person purporting to act on behalf of MEC Aerial Platform Sales Corp. is authorized to alter the terms of this warranty, or in any manner assume on behalf of MEC Aerial Platform Sales
Corp. any liability or obligation which exceeds MEC Aerial Platform Sales Corp’s obligations under this warranty.
Aerial Platforms Sales Corp.
1775 Park Street, Suite 77 • Selma, CA 93662 USA
Ph: 1-800-387-4575 • 559-891-2488 • Fax: 559-891-2448
E-mail:[email protected] • Web:www.mecawp.com

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Key features
- High reach and capacity for handling challenging jobs
- Precision and maneuverability for delicate tasks
- Optional outriggers for increased stability
- Emergency systems and procedures for safety
- Kubota diesel engine for reliable performance
- Intuitive controls for ease of operation
- Compact size for easy transport and storage
- Durable construction for long-lasting use
- Versatile platform for a variety of applications