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Gradall Excavator XL4100 Operator Parts Service Manual PDF

Gradall Excavator XL4100 Operator Parts Service Manual PDF

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Download Gradall Excavator XL4100 Operator Parts Service Manual PDF ( English )

Ensure maximum job-site productivity, precise maintenance, and comprehensive machine overhaul capability with the Gradall Excavator XL4100 Operator, Parts & Service Document Manual PDF. As a high-performance, heavy-duty telescopic excavator engineered with a signature multi-position tilting and extending boom for superior reach, digging depth, and grading precision across demanding construction and industrial projects, the baseline Gradall XL4100 relies on an advanced integration of robust diesel powertrains, high-pressure hydraulic circuits, planetary drive assemblies, and specialized mechanical control systems. When performing routine operator safety checks, sourcing exact replacement components, or executing complex hydraulic, transmission, and electrical repairs, having factory-authorized OEM documentation is essential to minimizing equipment downtime and preserving peak operational efficiency. www.themanualsgroup.com

MODEL COVERED :
Gradall XL4100 Highway-speed Wheeled Hydraulic Excavator

CONTENTS INCLUDED :
Introduction
Section 2 Boom Assemblies
Section 3 Cab & Related Components
Section 4 Hydraulic System Components
Section 5 Main Hydraulic Systems
Section 6 Pilot Hydraulic Systems
Section 7 Attachments
UNDERCARRIAGE
Section 1 Introduction
Section 2 Undercarriage Assembly
Section 3 Drive Line Components
Section 4 Front Axle Assembly
Section 5 Rear Tandem Axle Assembly
Section 6 Air System
Section 7 Cab & Related Components
Section 8 Steering & Component Assemblies
OPTIONS
XL4100 Service Manual 2460-4091 2007.pdf (1196 Pages)
Contents:
2460-4091 XL4100 COMBINED SERVICE MANUAL
OPERATOR INSTRUCTION
29304 Upperstructure Operation & Lube Manual
HYDRAULIC TESTING & ADJUSTMENT
8060-9015 Remote Hydraulic Schematic
RDE93010-02-R Rexroth Variable Displacement Pump Service Manual
RA64-774-S Rexroth Gear Pump Service Manual
RDE92002-30 Rexroth Swing Pump Service Manual
RDE 91001-01-R Rexroth Swing Motor/Remote Drive Motor Service Manual
RA64555 Rexroth Joystick
7-124 Char-Lynn Tilt Motor Service Manual
MECHANICAL ADJUSTMENTS
29604 Upperstructure Mechanical Adjustments & Repair Manual
F36758 Ausco Brake Technical Page
S6A Fairfield Torque-Hub Service Manual
MISCELLANEOUS
29710 XL4000/XL5000 Upperstructure Electrical System Manual
8096-9001 Upper Wiring Diagram
F114004 Donaldson Cyclopac Service Procedures
OPERATOR INSTRUCTION
29407 XL4000 6X4 & 6X6 Operator & Lubrication Manual
STEERING
WA-TRW 1108 TRW Steering Gear Service Manual
I-3143-S Vickers Vane Pumps Service Manual
CLUTCH
340186R Valeo Clutches Service Manual
MAIN TRANSMISSION
TRSM-0600RI Eaton/Fuller RT-6613 Series Service Manual
FRONT AXLE
AXSM-0037 Eaton/Fuller RT-6613 Series Service Manual
REAR TANDEM AXLE
TSA-2-113 Rockwell Drive Axle Service Manual
MM#5L Tandem Axle Service Manual
FMM#5A Meritor Single Reduction Rear Differential Carriers
MM#1 Rockwell Lubrication Manual
TP-9303 Meritor Advanced Lube Rear Drive Axles Technical Page
TP-9238 Meritor Driver-Controlled Differential Lock Technical Page
DRIVE LINES
3264-2 Spicer U-Joints & Driveshafts Service Manual
TOL-006-95 Spicer U-Joints & Driveshafts Service Manual
BRAKE SYSTEMS
8098-9002 Air Diagram
MM#4 Rockwell Cam-Master Brakes Service Manual
BW5057 Bendix Air Brake Handbook
SD-08-2403 Bendix AD-1 & AD-2 Air Dryers Service Manual
WHEEL & RIM
0009 Rim & Wheel Safety Manual
IM-298 Webb Safety Manual
MISCELLANEOUS
8098-9003 Chassis Wiring Diagram
F114005 Donaldson Air Cleaner Service Procedure
XL4100 and 4200 Upper Operators Manual 2460-4092 .pdf (46 Pages)
XL4100 Chassis Operators & Lubrication Manual 2460-4112 2002.pdf (42 Pages)
XL4100 Combined Service Manual 2460-4117 2002.pdf (1242 Pages)
Contents:
2460-4117 XL4100 COMBINED SERVICE MANUAL
OPERATOR INSTRUCTION
29304 Upperstructure Operation & Lube Manual
HYDRAULIC TESTING & ADJUSTMENT
8060-9015 Remote Hydraulic Schematic
RDE93010-02-R Rexroth Variable Displacement Pump Service Manual
RA64-774-S Rexroth Gear Pump Service Manual
RDE92002-30 Rexroth Swing Pump Service Manual
RDE 91001-01-R Rexroth Swing Motor/Remote Drive Motor Service Manual
RA64555 Rexroth Joystick
7-124 Char-Lynn Tilt Motor Service Manual
MECHANICAL ADJUSTMENTS
29604 Upperstructure Mechanical Adjustments & Repair Manual
F36758 Ausco Brake Technical Page
S6A Fairfield Torque-Hub Service Manual
MISCELLANEOUS
29710 XL4000/XL5000 Upperstructure Electrical System Manual
8096-9001 Upper Wiring Diagram
F114004 Donaldson Cyclopac Service Procedures
OPERATORS INSTRUCTION
29407 XL4000 6X4 & 6X6 Operator & Lubrication Manual
STEERING
WA-TRW 1108 TRW TAS Steering Gear Service Manual
I-3143-S Vickers Vane Pump Overhaul
CLUTCH
P.N. 340186R Valeo Clutch Installation
MAIN TRANSMISSION
TRSM-0600RI Eaton/Fuller DRRT-6613 Series Service Manual
FRONT AXLE
AXSM-0037 Eaton Steering Axle Service Manual
REAR TANDEM AXLE
TSA-2-113.pdf
MM#5L Rockwell Tandem Axle Differential Carriers Manual
FMM#5A Meritor Single Reduction Rear Differential Carriers
MM#1 Rockwell Lubrication
TP-9303 Meritor Advanced Lube Rear Drive Axles Pages
TP-9238 Meritor Driver-Controlled Diff Lock Pages
DRIVE LINES
3264-2 Spicer U-Joints & Driveshafts Service Manual
TOL-006-95 Spicer U-Joints & Driveshaft Service Manual
BRAKE SYSTEMS
8098-9002 Air Diagram
MM#4 Rockwell Cam-Master Brakes Manual
BW5057 Bendix Air Brake Handbook
SD-08-2403 Bendix Air Dryers Service Manual
MM#4B Rockwell Auto Slack Adjuster Manual
ABA-10003 Haldex Auto Brake Adjusters
4071 MGM Brakes
BRSM-0022 Dana Spicer Automatic Slack Adjuster
WHEEL & RIM
0009 Rim & Wheel Safety Manual
1M-298 Webb Wheel Products
MISCELLANEOUS
8098-9003 Wiring Diagram
F114005 Donaldson Air Cleaner Service
XL4100 CARRIER Chassis Operators Manual 2460-4133 2002.pdf (42 Pages)
Contents:
IMPORTANT SAFETY NOTICE inside front cover
INTRODUCTION
General
Related Manuals
Operator Qualifications
Orientation
Serial Number Location
SAFETY HIGHLIGHTS
INSTRUMENTS AND INDICATORS
CONTROLS
CHECKS AND SERVICES BEFORE STARTING ENGINE
ENGINE OPERATION
Starting Diesel Engine
Cold Weather Starting Aids
Normal Engine Operations
Stopping the Engine
CHECKS AFTER STARTING ENGINE
CHECKS BEFORE DRIVING
PLAN YOUR TRIP
BRAKE SYSTEM
Service Brake
Emergency Brake
Parking Brake
Digging Brake
Remote Control Braking
STEERING SYSTEM
Conventional Steering
Remote Control Steering
POWER TRAIN
Shifting Gears
Inter-Axle Differential
REMOTE CONTROL
Preparing Carrier for Remote Control Operation
Preparing Upperstructure for Remote Control Operation
Precautions for Remote Control Operation
Driving Carrier from Upperstructure for Conventional Carrier Operation
Preparing Upperstructure for Conventional Carrier Operation
Preparing Carrier for Conventional Operation
PARKING THE GRADALL
Precautions
Parking Procedure
IN CASE OF TROUBLE
Towing
IF YOU GET STUCK
LUBRICATION
6 x 4 Carrier Lubrication and Maintenance Diagram
6 x 6 Carrier Lubrication and Maintenance Diagram
Recommended Lubricants & Capacities
Torque Chart
CHECKING AUTOMATIC SLACK ADJUSTERS inside back cover
XL4100 Combined Service Manual 2460-4135 2002.pdf (1238 Pages)
Contents:
2460-4135 XL4100 COMBINED SERVICE MANUAL
OPERATOR INSTRUCTION
29618 Upperstructure Operation & Lube Manual
HYDRAULIC TESTING & ADJUSTMENTS
8060-9015 Remote Hydraulic Schematic
RDE93010-02-R Rexroth Main Pump
RDE92002-30 Rexroth Swing Pump
RA64-774-S Rexroth Gear Pump
RDE91001-01-R Rexroth Swing Motor
RA64555 Rexroth Joystick
7-124 Char-Lynn Tilt Motor
MECHANICAL ADJUSTMENTS
29604 Upperstructure Mechanical Adjustments & Repair
F36758 Ausco Swing Brake
S6A Fairfield Torque-Hub Service Manual
MISCELLANEOUS
29710 XL4000 Series Electrical Systems
8096-9001 Upper Wiring Diagram
F114004 Donaldson Cyclopac Service Procedure
OPERATORS INSTRUCTION
29612 XL4000 6X4 & 6X6 Operator & Lube Manual
STEERING
WA-TRW 1108 Ross Steering Gear
I-3143-S Vickers Vane Pumps Service Manual
CLUTCH
340186R Valeo Clutch Installation
MAIN TRANSMISSION
TRDR0500 Eaton/Fuller Driver Instructions
RTO 1190811 Eaton Lubrication Sheets
FRONT AXLE
AXSM-0037 Eaton Steering Axle Service Manual
REAR TANDEM AXLE
TSA-2-113.pdf
MM#5L Rockwell Tandem Axle Differential Carriers Manual
FMM#5A Meritor Single Reduction Rear Differential Carriers
MM#1 Rockwell Lubrication
TP-9303 Meritor Advanced Lube Rear Drive Axles Pages
TP-9238 Meritor Driver-Controlled Diff Lock Pages
DRIVE LINES
3264-2 Spicer U-Joints & Driveshafts Service Manual
TOL-006-95 Spicer U-Joints & Driveshaft Service Manual
BRAKE SYSTEMS
8098-9002 Air Diagram
MM#4 Rockwell Cam-Master Brakes Manual
BW5057 Bendix Air Brake Handbook
SD-08-2403 Bendix Air Dryers Service Manual
MM#4B Rockwell Auto Slack Adjuster Manual
ABA-10003 Haldex Auto Brake Adjusters
4071 MGM Brakes
BRSM-0022 Dana Spicer Automatic Slack Adjuster
WHEEL & RIM
0009 Rim & Wheel Safety Manual
1M-298 Webb Wheel Products
MISCELLANEOUS
8098-9003 Chassis Wiring Diagram
F114005 Donaldson Air Cleaner Service
HE92-2.pdf
2460-4161 (20013) Gradall Exc Safety.pdf
XL4100 Upper XL4200 Operators Manual 2460-4139 2002.pdf (45 Pages)
Contents:
IMPORTANT SAFETY NOTICE
INTRODUCTION
General
Related Manuals & Decals
Operator Qualifications
Orientation
PIN Location
SAFETY HIGHLIGHTS
DECALS INSIDE CAB
DECALS OUTSIDE CAB
OPERATOR’S CAB
Heater
Air Conditioner
Defrosting
Blower
Ventilation
Fire Extinguisher
12 VDC Accesory Outlets
CONTROL AND INSTRUMENT IDENTIFICATION
Electronic Monitor
CHECKS AND SERVICES BEFORE STARTING ENGINE
ENGINE OPERATION
Starting Cummins Engine
Cold Weather Starting Aids
Normal Engine Operation
Stopping the Engine
WARM-UP & OPERATIONAL CHECKS
ATTACHMENT INSTALLATION
REMOTE CONTROL
Preparing Carrier for Remote Control Operation
Preparing Upperstructure for Remote Control Operation
Precautions for Remote Control Operation
Driving Carrier From Upperstructure Cab
Preparing Upperstructure for Conventional Carrier Operation
Preparing Carrier for Conventional Operation
CRAWLER MOUNTED UNITS
Use Your Crawler Properly
Crawler Control
How To Operate the Crawler
A TYPICAL GRADALL DIGGING CYCLE
LIFTING AND POSITIONING A LOAD
Precautions
General
Positioning Machine For A Lift
Planning A Lift
SECURING BOOM & ATTACHMENT FOR TRAVEL
IF YOU GET STUCK
EXCAVATOR HAND SIGNALS
LUBRICATION & MAINTENANCE
Lubrication and Maintenance Diagram
Torque Chart
Recommended Lubricants & Capacities
XL4100 EPA Parts Manual 2460-4153 2013.pdf (361 Pages)
Contents:
2460-4153 XL4100 EPA PARTS MANUAL
UPPERSTRUCTURE
Section 1 Introduction
Section 2 Boom Assemblies
Section 3 Cab & Related Components
Section 4 Hydraulic System Components
Section 5 Main Hydraulic Systems
Section 6 Pilot Hydraulic Systems
Section 7 Attachments
UNDERCARRIAGE
Section 1 Introduction
Section 2 Undercarriage Assembly
Section 3 Drive Line Components
Section 4 Front Axle Assembly
Section 5 Rear Tandem Axle Assembly
Section 6 Air System
Section 7 Cab & Related Components
Section 8 Steering & Component Assemblies
OPTIONS
XL4100 EPA Parts Manual 2460-4153 2013.pdf (360 Pages)
Contents:
2460-4153 XL4100 EPA PARTS MANUAL
UPPERSTRUCTURE
Section 1 Introduction
Section 2 Boom Assemblies
Section 3 Cab & Related Components
Section 4 Hydraulic System Components
Section 5 Main Hydraulic Systems
Section 6 Pilot Hydraulic Systems
Section 7 Attachments
UNDERCARRIAGE
Section 1 Introduction
Section 2 Undercarriage Assembly
Section 3 Drive Line Components
Section 4 Front Axle Assembly
Section 5 Rear Tandem Axle Assembly
Section 6 Air System
Section 7 Cab & Related Components
Section 8 Steering & Component Assemblies
OPTIONS
XL4100 Combined Service Manual 2460-4158 2002.pdf (1247 Pages)
Contents:
2460-4158 XL4100 COMBINED SERVICE MANUAL
OPERATOR INSTRUCTION
29618 Upperstructure Operation & Lube Manual
HYDRAULIC TESTING & ADJUSTMENTS
8060-9015 Hydraulic Schematic
RDE93010-02-R Rexroth Main Pump
RDE92002-30 Rexroth Swing Pump
RA64-774-S Rexroth Gear Pump
RDE91001-01-R Rexroth Swing Motor
RA64555 Rexroth Joystick
7-124 Char-Lynn Tilt Motor
MECHANICAL ADJUSTMENTS
29604 Upperstructure Mechanical Adjustments & Repair
F36758 Ausco Swing Brake
S6A Fairfield Torque-Hub Service Manual
MISCELLANEOUS
29710 XL4000 Series Electrical Systems
8096-9001 Upper Wiring Diagram
F114004 Donaldson Cyclopac Service Procedure
OPERATORS INSTRUCTION
29612 XL4000 6X4 & 6X6 Operator & Lube Manual
STEERING
WA-TRW 1108 Ross Steering Gear
I-3143-S Vickers Vane Pumps Service Manual
CLUTCH
340186R Valeo Clutch Installation
CLWP-1707-4 Eaton Spicer Stamped Angle Spring Clutches
MAIN TRANSMISSION
TRDR0500 Eaton/Fuller Driver Instructions
RTO 1190811 Eaton Lubrication Sheets
FRONT AXLE
AXSM-0037 Eaton Steering Axle Service Manual
REAR TANDEM AXLE
TSA-2-113.pdf
MM#5L Rockwell Tandem Axle Differential Carriers Manual
FMM#5A Meritor Single Reduction Rear Differential Carriers
MM#1 Rockwell Lubrication
TP-9303 Meritor Advanced Lube Rear Drive Axles Pages
TP-9238 Meritor Driver-Controlled Diff Lock Pages
DRIVE LINES
3264-2 Spicer U-Joints & Driveshafts Service Manual
TOL-006-95 Spicer U-Joints & Driveshaft Service Manual
BRAKE SYSTEMS
8098-9002 Air Diagram
MM#4 Rockwell Cam-Master Brakes Manual
BW5057 Bendix Air Brake Handbook
SD-08-2403 Bendix Air Dryers Service Manual
MM#4B Rockwell Auto Slack Adjuster Manual
ABA-10003 Haldex Auto Brake Adjusters
4071 MGM Brakes
BRSM-0022 Dana Spicer Automatic Slack Adjuster
WHEEL & RIM
0009 Rim & Wheel Safety Manual
1M-298 Webb Wheel Products
MISCELLANEOUS
8098-9003 Wiring Diagram
F114005 Donaldson Air Cleaner Service
HE92-2.pdf
2460-4161 (20013) Gradall Exc Safety.pdf
XL4100 XL4100II Hydraulic Schematic 80409001.pdf (1 Pages)
XL4100 XL4100II Air Schematic 80489004.pdf (1 Pages)
XL3100EPA XL4100 XL4100II Electrical Schematic 80489008.pdf (9 Pages)
XL4100 Hydraulic Schematic 80609015 2001.pdf (1 Pages)
P XL4100 INT Parts Manual 8068-4175 2024.pdf (325 Pages)
Contents:
8068-4175 XL4100 INT. PARTS MANUAL
UPPERSTRUCTURE
Section 1 Introduction
Section 2 Boom Assemblies
Section 3 Cab & Related Components
Section 4 Hydraulic System Components
Section 5 Main Hydraulic Systems
Section 6 Pilot Hydraulic Systems
Section 7 Attachments
UNDERCARRIAGE
Section 1 Introduction
Section 2 Undercarriage Assembly
Section 3 Drive Line Components
Section 4 Front Axle Assembly
Section 5 Rear Tandem Axle Assembly
Section 6 Air System
Section 7 Cab & Related Components
Section 8 Steering & Component Assemblies
OPTIONS
XL3100 XL3100IV XL4100 XL4100IV XL5100IV to XL5130V Railgear Hydraulic Schematic 80709006.pdf (2 Pages)
XL3100IV XL3100 to XL4100 HIGHWAY WHEELED XL4100IV XL5100IV Electrical Schematic 80709007.pdf (11 Pages)
XL3100IV XL4100IV XL4100 to XL4100 XL4100IV XL4100 XL4100IV Electrical Schematic 80709014.pdf (11 Pages)
XL4100V XL3100V XL4100V XL3100V to XL3100V XL3100 XL4100V Electrical Schematic 80709015.pdf (12 Pages)
XL4100V XL4100 XL4100V to XL3100V XL3100 XL3100V XL3100 XL3100V Electrical Schematic 80709027.pdf (15 Pages)
XL4100V XL4100 XL4100V to XL3100V XL3100 XL3100V XL3100 XL3100V Electrical Schematic 80709027.pdf (15 Pages)
XL4100 XL4100IV XL5100IV Air Schematic 80789113.pdf (1 Pages)
XL4100 XL4100V XL5100 XL5100V Air Schematic 80789164.pdf (1 Pages)
XL4100 XL4100V XL5100 XL5100V Air Schematic 80789259.pdf (1 Pages)
Series V XL3100V XL4100V XL5100V XL3100 XL4100 XL5100 Illustrated Parts Manual 80884032 2026.pdf (778 Pages)
Contents:
Section 1 – Frame & Attaching Parts
Section 2 – Boom
Section 3 – Attachments
Section 4 – Engine & Attaching Parts
Section 5 – Drive Train
Section 6 – Cab
Section 7 – Controls
Section 8 – Hydraulic Circuits
Section 9 – Hydraulic Components
Section 10 – Electrical
Section 11 – Decals
Section 12 – Options
Recommended Spare Parts
Part Number Index
Series V XL3100V XL4100V XL5100V XL3100 XL4100 XL5100 Operator Safety Manual 80884033 2026.pdf (172 Pages)
Contents:
Section 1 – General Safety Practices
1.1 Hazard Classification System
1.2 General Precautions
1.3 Operation Safety
1.4 Personal Protection Equipment
Section 2 – Pre-Operation and Controls
2.1 Pre-Operation Checks & Inspection
2.2 Walk-Around Inspection
2.3 Safety Decals
2.4 Undercarriage Cab Components
2.5 Transmission Shift Selector
2.6 Undercarriage Cab Controls & Indicators
2.7 Upperstructure Cab Components
2.8 Upperstructure Cab Controls & Indicators
Section 3 – Operation
3.1 Travel Mode Engine Operation
3.2 Checks Before Undercarriage Operation
3.3 Travel Mode Brake System
3.4 Travel Mode Power Train
3.5 Travel Mode Engine Shutdown
3.6 Remote Control Preparation
3.7 Checks Before Remote Control Operation
3.8 Remote Mode Brake System
3.9 Remote Mode Power Train
3.10 Steering System
3.11 Typical Dig Cycle
3.12 Lifting & Placing a Load
3.13 Lift Capacity
3.14 Remote Mode Engine Shutdown
3.15 Return to Travel Mode
3.16 Parking the Excavator
3.17 Preservation & Storage
3.18 Parked Regeneration (Stage V Engines)
Section 4 – Attachments
4.1 Approved Attachments
4.2 Unapproved Attachments
4.3 Attachment Operation
4.4 Adapter Attachment Installation
Section 5 – Lubrication & Maintenance
5.1 Introduction
5.2 General Maintenance Instructions
5.3 Service & Maintenance Schedules
5.4 Undercarriage Lubrication Schedules
5.5 Upperstructure Lubrication Schedules
5.6 Operator Maintenance Instructions
Section 6 – Emergency Procedures
6.1 Loss Of Power
Section 7 – Specifications
7.1 Product Specifications
7.2 Torque Chart
7.3 Fuses
Index
Series V XL3100V XL4100V XL5100V XL3100 XL4100 XL5100 Service Manual 80884034 2026.pdf (1189 Pages)
Contents:
80884034_C_Series V Highway Speed Combined Service Manual_3-2026
VOLUME I
80884033_C_Series V Highway Speed Op & Safety Manual_3-2026
HYDRAULIC TEST & ADJUSTMENT
MECHANICAL ADJUSTMENT
ELECTRICAL
STEERING
MAIN TRANSMISSION
VOLUME II
FRONT AXLE
REAR AXLE
DRIVE LINES
BRAKE SYSTEMS
MISCELLANEOUS
XL4100 XL5100 Air Diagram 80989002 2001.pdf (1 Pages)
XL4100 XL5100 Chassis Electric Schematic 80989003 2001.pdf (1 Pages)

Feature Specification
Brand Gradall
Model Gradall XL4100 Highway-speed Wheeled Hydraulic Excavator
Type of Manual Air Diagram, Air Schematic, Combined Service Manual, Electric Schematic, Electrical Schematic, Hydraulic Schematic, Illustrated Parts Manual, Operator Safety Manual, Operators Manual, Parts Manual, Service Manual
Type of Machine Highway-speed Wheeled Hydraulic Excavator
Language English
Format PDF
File Size 577.39 MB

www.themanualsgroup.com
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: Download - You will receive the PDF manual in your email after the purchase

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