Complete Diagnostics, Operation & Test manual with Electrical Wiring Diagrams for John Deere Backhoe Loaders 410D, 510D, with all the shop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere Backhoe Loaders 410D, 510D workshop service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM1512 - John Deere 410D, 510D Backhoe Loaders Operation & Test Technical Manual.pdf
TM1512 - John Deere 410D, 510D Backhoe Loaders Operation & Test Technical Manual.epub

Total Pages: 942 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle/iPad/iPhone/Android.
Language: English

MAIN SECTIONS
Foreword
   General Information
      Safety Information
      General Specifications
      Torque Values
      Fuels And Lubricants
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory Of Operation
      System Operational Checks
      System Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory Of Operation
      System Operational Checks
      System Diagnostic Information
      Adjustments
      Test
   Hydraulics
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Heating And Air Conditioning
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Test

tm1512 - 410D, 540D Backhoe Loaders

Table of Contents

Foreword

Section 9000: General Information

Group 01: Safety Information

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 02: General Specifications

410D Backhoe Loader With Standard Dipperstick

410D Heavy Lift Backhoe Loader

410D Backhoe Loader Specifications

410D Backhoe Specifications

410D Backhoe Loader And Backhoe Buckets

410D And 510D Backhoe Loader Drain And Refill Capacities

410D Backhoe Loader Lifting Capacities

510D Backhoe Loader With Standard 2.1 M (6 Ft 11.7 In.) Dipperstick

510D Backhoe Loader Specifications

510D Backhoe And Loader Buckets

510D Backhoe Loader Lifting Capacities

Group 03: Torque Values

Hardware Torque Specifications

Checking Wheel Fastener Torque

ROPS Torque Specifications

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Additional Metric Cap Screw Torque Values

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Check Oil Lines And Fittings

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Group 04: Fuels And Lubricants

Fuel Specifications

Low Sulfur Diesel Fuel Conditioner

Storing Fuel

Do Not Use Galvanized Containers

Fuel Tank

Engine Oil

Transaxle Oil

Hydraulic And Reverser Oil

Mechanical Front Wheel Drive Oil

Grease

Grease For Extendible Dipperstick

Alternative and Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Engine Coolant

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout Procedure

Section 9010: Engine

Group 05: Theory Of Operation

4045 John Deere Engine—Use CTM8

General Engine Description

Engine—Sectional View

Group 10: System Operational Checks

4045 John Deere Engine—Use CTM8

System Operational Checks

Group 15: System Diagnostic Information

4045 John Deere Engine—Use CTM8

Make Visual Inspection Of Engine And Supporting Systems

Diagnose Engine Malfunctions

Group 20: Adjustments

4045 John Deere Engine—Use CTM8

JT05801 Clamp-On Electronic Tachometer Installation

Fan Belt Tension Adjustment

Adjust Speed Control Lever Tension

Engine Speed Control Linkage

Slow And Fast Idle

Group 25: Tests

4045 John Deere Engine—Use CTM8

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

JT07158 TIME TRAC JT07158 TIME TRAC is a registered trademark of the Stanadyne Automotive Corp. Installation

Cooling System

Air Filter Restriction Indicator Switch

Air Intake System Leakage Test

Radiator Air Flow Test

JT05529 Air Flow Meter Test Record

Turbocharger Boost Pressure—Engine Performance Test

Injection Pump Timing

Injection Pump Static Timing Adjustment

Section 9015: Electrical System

Group 05: System Information

Visually Inspect Electrical System

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Multimeter

Seven Step Electrical Test Procedure

Wiring Diagram And Schematic Information

Reading A System Functional Schematic

Reading A Wiring Diagram

Electrical Schematic Symbols

Group 10: System Diagrams

Component Identification Table

Fuse Specifications

Wiring And Schematic Diagrams Legend

System Functional Schematic Section Legend

System Functional Schematic

Cab Roof Harness (W5) Wiring Diagram

Cab Roof Harness (W5) Component Location

Cab Side Console Harness (W6) Wiring Diagram (SN —778668)

Cab Side Console Harness (W6) Component Location (SN —778668)

Cab Floor Harness (W6) Wiring Diagram (SN —778668)

Cab Floor Harness (W6) Component Location (SN —778668)

Cab Side Console Harness (W6) Wiring Diagram (SN 778669—XXXXXX)

Cab Side Console Harness (W6) Wiring Diagram (SN XXXXXX— )

Cab Side Console Harness (W6) Component Location (SN 778669— )

Front Console Harness (W7) Wiring Diagram

Front Console Harness (W7) Component Location

Engine Harness (W8) Wiring Diagram

Engine Harness (W8) Component Location

Blower Harness (W10) Wiring Diagram

Blower Harness (W10) Component Location

Radio Harness (W12) Wiring Diagram

Radio Harness (W12) Component Location

Air Conditioning Compressor Harness (W11) Wiring Diagram

Air Conditioning Compressor Harness (W11) Component Location

Auxiliary Valve Harness (W14) Wiring Diagram

Auxiliary Valve Harness (W14) Component Location

Group 15: Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory Of Operation

Power Circuit Schematic

Start Circuit Operational Information

Start Circuit Theory Of Operation

Start Circuit Schematic

Charging Circuit Operational Information

Charging Circuit Theory Of Operation

Charge Circuit Schematic

Display Module And Logic Module Circuit Operational Information (SN —XXXXXX) With Logic Module

Display Module And Logic Module Circuit Theory Of Operation (SN —XXXXXX) With Logic Module

Display Module And Logic Module Circuit Operational Information (SN XXXXXX— ) Without Logic Module

Display Module Circuit Theory Of Operation (SN XXXXXX— ) Without Logic Module

Logic Module (SN —XXXXXX)

Indicator Circuit Specifications

Indicator Circuit Operational Information

Indicator Circuit Theory Of Operation (SN —XXXXXX) With Logic Module

Indicator Circuit Theory Of Operation (SN XXXXXX—) Without Logic Module

Indicator Circuit Schematic

MFWD Circuit Operational Information

MFWD Circuit Theory Of Operation

MFWD Circuit Schematic

Start Aid Circuit Operational Information

Start Aid Circuit Theory Of Operation

Start Aid Circuit Schematic

Fuel Shut-Off Circuit Operational Information

Fuel Shut-Off Circuit Theory Of Operation

Fuel Shut-Off Circuit Schematic

Reverse Alarm Circuit Specifications (SN —794639)

Reverse Alarm Circuit Operational Information

Reverse Alarm Circuit Theory Of Operation

Reverse Alarm Circuit Schematic

Dome Light Circuit Operational Information

Dome Light Circuit Theory Of Operation

Dome Light Circuit Schematic

Radio Circuit Operational Information

Radio Circuit Theory Of Operation

Radio Circuit Schematic

Wiper/Washer Circuit Operational Information

Wiper/Washer Circuit Theory Of Operation

Wiper/Washer Circuit Schematic

Blower Circuit Operational Information

Blower Circuit Theory Of Operation

Blower Circuit Schematic

Drive And Work Light Circuit Operational Information

Drive And Work Light Circuit Theory Of Operation

Park Brake/Clutch Disconnect Circuit Specifications

Park Brake/Clutch Disconnect Circuit Operational Information

Park Brake/Clutch Disconnect Circuit Theory Of Operation

Park Brake/Clutch Disconnect Circuit Schematic

Horn Circuit Operational Information

Horn Circuit Theory Of Operation

Horn Circuit Schematic

Turn Signal, Flasher And Brake Light Circuit Operational Information

Turn Signal, Flasher And Brake Light Circuit Theory Of Operation

Turn Signal, Flasher And Brake Light Circuit Schematic

Beacon Circuit Operational Information

Beacon Circuit Theory Of Operation

Beacon Circuit Schematic

Return-To-Dig Circuit Operational Information

Return-To-Dig Circuit Theory Of Operation

Return-To-Dig Circuit Schematic

Fuel Gauge And Hour Meter Circuit Specifications

Fuel Gauge And Hour Meter Circuit Operational Information

Fuel Gauge And Hour Meter Circuit Theory Of Operation

Gauge And Hour Meter Circuit Schematic

Auxiliary Valve Circuit Operational Information

Auxiliary Valve Circuit Theory Of Operation

Auxiliary Valve Circuit Schematic

Group 20: References

Alternators And Starting Motors—Use CTM77

JT05801 Clamp-On Electronic Tachometer Installation

Battery Operation

Battery Specifications

Diagnose Battery Malfunctions

Check Battery Electrolyte Level And Terminals

Procedure For Testing Batteries

Using Booster Batteries—12 Volt System

Alternator Operation—78 AMP Delco Remy (Serial No. —787513)

Alternator Operation—95 AMP Bosch (Serial No. 787514— )

Alternator Operation—95 AMP Bosch

Monitor Test In Machine

Logic Module Test In Machine (SN —XXXXXX)

Logic Module Bench Test (SN —XXXXXX)

Tachometer Calibration

Section 9020: Power Train

Group 05: Theory Of Operation

Reverser Hydraulic System Operation

Torque Converter Operation

Reverser Operation

Reverser Hydraulic Filter Operation

Accumulator Operation

Pressure Regulating Valve Operation

Solenoid Operation

Reverser Control Valve

Synchronizer Operation

Second Speed Operation

Third Speed Operation

Park Brake Operation

Brake Valve Operation

Service Brake Pressure Lubrication (SN —796851)

Group 10: System Operational Checks

System Operational Procedure

Group 15: System Diagnostic Information

Reverser Oil Passage Identification

Diagnose Power Train Malfunctions

Group 20: Adjustments

Adjust Brake Pedals And Equalizing Valves

Adjust Park Brake

Bleeding Brakes

Check And Adjust Toe-In

Group 25: Test

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Reverser Oil Warm-Up Procedure

Reverser System Pressure Test

Reverser Pump Flow Test (410D, SN —796854) (510D, SN —796890)

Reverser Converter-In (Cooler) Relief Valve Test

Reverser Oil Cooler Restriction Test

Torque Converter Stall Speed Test

Reverser Element Leakage Test Using Element Pressure (Three-Gauge Method)

Complete Reverser System Test

Reverser Test Procedure

Specifications And Analysis

Brake Valve Leakage Test

Brake Element Leakage Test

Mechanical Front Wheel Drive (MFWD) Clutch Pressure Test (410D SN —796854, 510D SN —796890)

Section 9025: Hydraulics

Group 05: Theory Of Operation

Charge Pump Operation

Main Hydraulic Pump Operation

Pressure Compensator Operation

Return Filter Operation

Priority Valve Operation (S.N. —801199)

Steering Valve Operation

Loader Circuit Relief Operation— GRESEN (S.N. —801199)

Loader Bucket Valve Operation—GRESEN (S.N. —801199)

Loader Boom Valve Operation—GRESEN (S.N. —801199)

Loader Auxiliary Valve Operation—GRESEN (S.N. —801199)

Loader Priority Valve Operation HUSCO (S.N. 801200— )

Loader Boom Valve Operation—HUSCO (S.N. 801200— )

Loader Bucket Valve Operation—HUSCO (S.N. 801200— )

Loader Auxiliary Valve Operation—HUSCO (S.N. 801200— )

Loader Circuit Relief Valve With Anti-Cavitation—HUSCO (S.N. 801200— )

Loader Circuit Relief Valve Without Anti-Cavitation— HUSCO (S.N. 801200— )

Backhoe Circuit Relief And Anti-Cavitation Valve Operation—GRESEN

Backhoe Boom Valve Operation—GRESEN

Backhoe Crowd Valve Operation—GRESEN

Backhoe Bucket Valve Operation—GRESEN

Backhoe Swing Valve Operation—GRESEN

Backhoe Auxiliary Valve Operation—GRESEN

Backhoe Boom Valve Operation—HUSCO

Backhoe Bucket Valve Operation—HUSCO

Backhoe Crowd Valve Operation—HUSCO

Backhoe Swing Valve Operation—HUSCO

Backhoe Auxiliary Valve Operation—HUSCO

Backhoe Circuit Relief Valve With Anti-Cavitation—HUSCO

Backhoe Circuit Relief Valve Without Anti-Cavitation—HUSCO

Backhoe System Relief Valve Operation—HUSCO 410D—(S.N. 796855—801199), 510D—(S.N. 796891—801199)

Stabilizer Valve Operation

Backhoe Solenoid Controlled Auxiliary Valve

Group 10: System Operational Checks

System Operational Procedure

Group 15: Diagnostic Information

Diagnose Steering System Malfunctions

Diagnose Main Hydraulic System Malfunctions

Main Hydraulic System Operation

Hydraulic System Schematic, 410D (S.N. —796854), 510D (S.N. —796890)

Hyd. Component Location, 410D (S.N. 796855—801199), 510D (S.N. 796891—801199)

Hydraulic Schematic, 410D (S.N. 796855—801199), 510D (S.N. 796891—801199)

Hydraulic Component Location, 410D (S.N. 801200— ), 510D (S.N. 801200— )

Hydraulic Schematic, 410D (S.N. 801200— ), 510D (S.N. 801200— )

Group 20: Adjustments

Loader Bucket Level Indicator And Return-To-Dig Switch Adjustment

Loader Control Valve Linkage Adjustment

Backhoe Valve Linkage Adjustment

Stabilizer Valve Linkage Adjustment

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Hydraulic Oil Warm-Up Procedure

Diagnostic Destroke Wire Harness Installation Procedure

Main Hydraulic Pump Flow And Stroke Control Valve Test

Charge Pump Pressure Test

Charge Pump Flow Test

Main Pump Standby Pressure Test

Priority Valve Test (S.N. —801199)

Priority Valve "LS" Port Flow Test

Hydraulic Oil Cooler Restriction Test 410D (S.N. —796854) 510D (S.N. —796890)

Hydraulic Oil Cooler Restriction Test 410D (S.N. 796855— ) 510D (S.N. 796891— )

Cycle Time Test

Relief Valve Test—with Remote Pump

Relief Valve Test Using Amplification Cylinder

Steering System Leakage Test

Steering Cylinder Leakage Test

Steering Valve Neutral Drift Test

Hydraulic Component Leakage Test

Hydraulic Cylinder Drift Test Procedure

Function Drift Test

Cylinder Leakage Test

MFWD Valve Test 410D (S.N. —796854) 510D (S.N. —796890)

Flowmeter Calibration Procedure

Section 9031: Heating And Air Conditioning

Group 05: Theory Of Operation

Proper Refrigerant Handling

R12 And R134a Refrigerant Cautions

Refrigerant Theory Of Operation

Air Conditioning Circuit Operational Information

Air Conditioning Circuit Theory Of Operation

Air Conditioning Circuit Schematic

Blower Circuit Operational Information

Blower Circuit Theory Of Operation

Blower Circuit Schematic

Receiver/Dryer Operation

Expansion Valve Operation

Compressor Relief Valve Operation

Temperature Control

Group 10: System Operational Checks

Air Conditioning Operational Checks

Group 15: Diagnostic Information

Diagnose Air Conditioning Electrical Malfunctions

Air Conditioning Component Location

Group 20: Adjustments

Proper Refrigerant Handling

R12 And R134a Refrigerant Cautions

R12 Component Oil Charge

R12 Refrigerant Recovery, Recycling Station Installation Procedure

R12 Refrigerant Evacuation And Charging Station Installation Procedure

Recover R12 System

Evacuate R12 System

Charge R12 System

R134a Compressor Oil Charge Check

R134a Compressor Oil Removal

R134a Component Oil Charge

R134a Refrigerant Recovery, Recycling And Charging Station Installation Procedure

Recover R134a System

Evacuate R134a System

Charge R134a System

Check And Adjust Compressor Belt Tension

Group 25: Test

Proper Refrigerant Handling

R12 And R134a Refrigerant Cautions

R134a Air Conditioning System Test

Pressure Diagnostic Chart

Low Pressure Switch Test

High Pressure Switch Test

Clutch Cycle Switch

Leak Testing

Refrigerant Hoses And Tubing Inspection

John Deere Backhoe Loaders 410D, 510D Technical Manual - Operation and Test (TM1512)