JLG TOUCAN DUO Service Manual page 83

VI-5 REMOVAL - INSTALLATION PROCEDURES
6.5.5 Mast power unit removal
Before any maintenance of the power unit,
disconnect the battery and the charger plug
and ensure the power unit is off. Failure to
comply could result in death or serious
injuries.
1- Remove the rear cover from the machine.
2- Disconnect the charger from the power supply,
disconnect the battery (quick release plug).
3- Tag and disconnect the electrical cables and
the connector from the power unit.
4- Disconnect and cap the hydraulic line from the
power unit.
5- Drain the oil from the reservoir (refer to the
Operator's and Safety Handbook).
6- Remove the power unit and move it to a clean
work area. It is not necessary to remove the
hydraulic fittings if there is no leakage.
6.5.6 Mast power unit disassembly -
Assembly
1- Remove the mast power unit from the chassis
(voir § 6.5.5.).
2- Remove the clips securing the reservoir and
remove the reservoir.
3- Remove the bolts securing the pump and remove
the pump.
4- Remove the pressure relief valve.
5- Remove the filter / check valve (torque value
20 ±0.2 N.m)
6- Remove the solenoid (torque value
30 ± 0.5 N.m).
7- Loosen the nut securing the solenoid to the
solenoid valve and remove the solenoid (torque
value 5 N.m).
8- Clean all parts that were removed.
9- Replace the seals, clean the filters and
reassemble the power unit respecting the torque
values indicated below.
10- Install the reservoir on the power unit with the
clips.
11- Install the power unit on the chassis.
Models
TOUCAN Duo
Updated 06-2015
Fig. 6.18.
DANGER
Cap
P r e s s u r e
plug
Fig. 6.10
Check valve
and filter
Clip
Fig. 6.11
NOTE
Ensure the breather cap is positionned
opposite the solenoid valve.
6.5.7 Mast power unit installation
1- Secure the mast power unit on the chassis of
the machine.
2- Fill the reservoir with new hydraulic oil to the
correct level.
3- Connect the hydraulic hose and the electrical
cables to the power unit as tagged during
removal (see § 6.5.5.).
4-Set the machine to perform some tests (raise
the platform several times by 2 metres
maximum). Bleed the cylinder if necessary
(refer to § 4.8).
5- Check for proper functionning and any leakage.
6- Install the rear cover.
VI-5
Relay
P r e s s u r e
relief valve
Breather
plug
Coil
83