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JLG 4013 Service Manual

JLG 4013
136 pages
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Service Manual
Models
3507, 3508,
3509, 3512,
3513, 4007,
4008, 4009,
4012, 4013
P/N - 3121852
Revised
April 20, 2007
Courtesy of Crane.Market

Table of Contents

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JLG 4013 Specifications

General IconGeneral
BrandJLG
Model4013
CategoryConstruction Equipment
LanguageEnglish

Summary

Section 1 Safety Practices

1.5 Safety Information

Emphasizes compliance with safety messages and emergency readiness.

1.6 Safety Instructions

General safety statements to consider before performing maintenance procedures.

Section 2 General Information and Specifications

2.2 Torques

Comprehensive English and Metric fastener torque charts for various bolt sizes.

2.5 Maintenance Schedules

Detailed maintenance schedules based on operating hours (8, 50, 250, 500, 1000, 1500 hours).

2.6 Lubrication Schedules

Recommended lubrication intervals and procedures for machine components.

Section 3 Boom

3.3 Boom Assembly Maintenance

Procedures for boom removal, installation, and section-specific maintenance.

3.6 Troubleshooting

Solutions for common boom operational issues like extension, shifting, and noise.

Section 4 Cab and Covers

4.4 Cab Removal

Step-by-step instructions for safely removing the machine's operator cab.

4.5 Cab Installation

Detailed procedure for securely installing the operator cab onto the machine.

Section 5 Axles, Drive Shafts, Wheels and Tires

Section 6 Transmission

6.5 Transmission Replacement

Procedures for transmission removal, inspection, repair, and installation.

6.6 Troubleshooting

Common transmission issues with potential causes and solutions.

Section 7 Engine: Perkins 1104-42 & 1104-42T

7.9 Engine Replacement

Steps for engine removal, disassembly, inspection, service, and installation.

7.11 Troubleshooting

Common engine operating problems, their causes, and recommended remedies.

Section 8 Hydraulic System

8.2 Safety Information

Hazards of hydraulic fluid and critical safety precautions for system maintenance.

8.3 Hydraulic Pressure Diagnosis

Introduction to the JLG Pressure Test Kit for hydraulic system diagnostics.

8.5 Hydraulic Schematics

Detailed hydraulic schematics for standard and optional machine configurations.

8.7 Hydraulic System Pump

Information on pump description, failure analysis, and replacement procedures.

8.8 Valves and Manifolds

Procedures for main control valve, service brake valve, steer select valve, and ERS control valve.

8.9 Hydraulic Cylinders

Detailed steps for hydraulic cylinder removal, disassembly, cleaning, inspection, assembly, and installation.

Section 9 Electrical System

9.5 Electrical System Schematics

Comprehensive schematics for cab, engine, PCB, ESX, and chassis harnesses.

9.6 Circuit Breakdowns

Detailed breakdown of electrical circuits: battery power, start, and charging.

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