JLG 4013PS Service Manual - Manual (Page 107)

7-11 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T
7.9.3 Engine Installation
1. Attach a lifting chain to the front and rear engine lift
brackets, and lift engine clear of the ground.
Note: Apply Loctite ® 243 TM threadlock to the engine
mount bracket capscrew threads before installation.
2. Inspect the front engine mounting bracket isolator.
Replace isolator if cracked or worn.
3. Install two guide studs in the bell housing holes.
4. Lift the engine and slowly push and lower into the
engine bay. Have an assistant ensure that the
engine clears all frame, hose and harness
components during engine installation. Position
engine brackets over the front frame mounts.
5. Push the engine towards the transmission aligning
the guide studs and the torque converter shaft with
the corresponding holes.
6. Push the engine against the transmission and install
eight of the ten bolts and washers. Remove both
guide studs and replace with the remaining two bolts
and washers. Tighten bolts.
7. Torque the transmission bolts to 63 Nm (46 lb-ft)
AFTER engine is lowered and secured with the front
motor mount bolts installed and torqued.
8. Remove the support from under the transmission
and lower the engine the remainder of the way onto
the frame. Align the motor mount holes and install
the bolts. Apply Loctite
® 243 TM threadlock to the
motor mount bolts and torque to 210 Nm (155 lb-ft).
9. Turn the engine over slowly by hand and align each
of the eight flex plate bolts through the access plug
in the bell housing. Install them one at a time. DO
NOT fully tighten until all of the capscrews and
locknuts are in place. Torque to 35-39 Nm
(26-29 lb-ft). Replace access plug.
10. Install the exhaust pipe. Refer to Section 7.7.2,
“Exhaust System Installation.”
11. Install the complete air cleaner assembly. Refer to
Section 7.8.2, “Air Cleaner Assembly Installation.”
12. Install and tighten the jam nuts on the throttle cable
at the throttle cable mount.
13. Connect the throttle cable at the engine throttle
lever.
14. Connect the fuel inlet line to the fuel filter head.
15. Connect the fuel return line to the fuel filter head.
16. Connect all the labeled wire harness connections on
the engine.
17. Install the hood latch plate. Align the mark on the
plate to help with hood adjustment.
18. Secure the return hydraulic oil filter plate to the
frame.
19. Install both heater hoses to the engine and tighten
clamps.
20. Install the complete radiator assembly. Refer to
Section 7.4.3, “Radiator/Oil Cooler and Coolant
Heater Replacement.”
21. Install the hose clamp on the bottom radiator hose
and work onto the engine. Tighten the clamp.
22. Install the hose clamp on the top radiator hose and
work onto the engine. Tighten the clamp.
23. Connect the transmission inlet and outlet hoses on
the oil cooler. Install the clamp holding the top
transmission cooler hose and the three bolts holding
the fan screen.
24. Install the engine cover and adjust.
25. Install the battery and reconnect the (+) positive and
(-) negative cables.
26. Open the radiator cap and fill the radiator completely
with coolant. Replace and tighten the radiator cap.
Add coolant to the overflow bottle until the bottle is 1/
4 to 1/2 full. This overfilling will compensate for any
air trapped in the cooling system.
27. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
connections are correct and connected tightly.
28. From within the cab, lightly depress the throttle pedal
to full-throttle position. As needed, adjust the limit-
stop screw until it touches the pedal. Tighten the
locknut to 13,6-14,1 Nm (120-125 lb-in).
Note: Have an assistant stand by with a Class B fire
extinguisher.
29. Start the engine and run to normal operating
temperature then shut off the engine. While the
engine is cooling, check for leaks.
30. Allow the engine to cool. Check the radiator coolant
level, and top off with coolant. Replace the radiator
cap.
31. Check for leaks from the engine, main hydraulic
pump and lines, transmission, hydraulic reservoir
and fuel tank. Check the levels of all fluids and
lubricants. Fill as required.
Note: During the full throttle check:
• DO NOT operate any hydraulic function.