John Deere 410J Backhoe Loader Operation & Test Service Manual (TM10132)
Complete official service manual with Electrical Wiring Diagrams for John Deere 410J Backhoe Loader, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
TM10132 - John Deere 410J Backhoe Loader (S.N. —161616) Technical Manual (Operation & Test Manual).epub
TM10132 - John Deere 410J Backhoe Loader (S.N. —161616) Technical Manual (Operation & Test Manual).pdf
Total Pages: 933 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
Covered models: 410J (S.N. before 161616)
TABLE OF CONTENTS......1
Section 9000: General Information......18
Group 01: Safety Information......18
Recognize Safety Information......21
Follow Safety Instructions......22
Operate Only If Qualified......23
Wear Protective Equipment......24
Avoid Unauthorized Machine Modifications......25
Inspect Machine......26
Stay Clear of Moving Parts......27
Avoid High-Pressure Fluids......28
Avoid High-Pressure Oil......29
Beware of Exhaust Fumes......30
Prevent Fires......31
Prevent Battery Explosions......32
Handle Chemical Products Safely......33
Dispose of Waste Properly......34
Prepare for Emergencies......35
Use Steps and Handholds Correctly......36
Start Only From Operator's Seat......37
Use and Maintain Seat Belt......38
Prevent Unintended Machine Movement......39
Prevent Unintended Machine Movement—If Equipped With Pilot Controls......40
Avoid Work Site Hazards......41
Keep Riders Off Machine......43
Avoid Backover Accidents......44
Avoid Machine Tipover......45
Add and Operate Attachments Safely......46
Use Special Care When Operating......47
Operating or Traveling On Public Roads......48
Inspect and Maintain ROPS......49
Prevent Unintended Detonation of Explosive Devices......50
Park and Prepare for Service Safely......51
Service Cooling System Safely......52
Remove Paint Before Welding or Heating......53
Make Welding Repairs Safely......54
Drive Metal Pins Safely......55
Service Tires Safely......56
Section 9001: Diagnostics......57
Group 10: Engine Control Unit (ECU)......57
Engine Control Unit (ECU) Diagnostic Trouble Codes......62
002047.09 - Can Communication Lost with FLC......57
Group 20: Flex Load Controller (FLC)......57
Flex Load Controller (FLC) Diagnostic Trouble Codes......67
000069.07 - MFWD Logic Error......57
000070.02 - Park Brake Switch (S7) Open Circuit......57
000070.04 - Park Brake Switch (S7) Short to Ground......57
000070.07 - Park Brake Switch (S7) Logic Error......57
000117.19 - Service Brake Pressure Low......57
000234.02 - Software Revision Mismatch......57
000237.02 - Model Number in Vehicle Identification Number Not Valid......57
000525.03 - TCL/Range Switch (S5) Gear Range Input Shorted to Power......57
000525.04 - TCL/Range Switch (S5) Gear Range Input Voltage Low......57
000525.05 - TCL/Range Switch (S5) Gear Range Input Open Circuit......57
000525.12 - TCL/Range Switch (S5) Gear Range Input Logic Error......57
000629.12 - FLC Watchdog Timeout......57
000734.05 - Transmission Solenoid (Y1) Open Circuit......57
000735.05 - Transmission Solenoid (Y2) Open Circuit......57
000736.05 - Transmission Solenoid (Y3) Open Circuit......57
000737.12 - Transmission Solenoid (Y4 or Y5) Fault......57
000738.05 - Transmission Solenoid (Y5) Open Circuit......57
000739.12 - Transmission Solenoid (Y2 or Y6) Fault......57
000741.12 - Transmission Solenoid (Y1 or Y3) Fault......57
000746.07 - Differential Lock Switch (S4) Logic Error......57
000746.12 - Differential Lock Switch (S4) Short to Power or Ground......57
000757.05 - Transmission Solenoid (Y4) Open Circuit......57
000759.05 - Transmission Solenoid (Y6) Open Circuit......57
001504.05 - Seat Swivel Latch Switch (S18) Short to Ground......57
001714.04 - Seat Position Front Switch (S17) Short to Ground......57
001714.07 - Seat Position Rear Switch (S16) and Seat Position Front Switch (S17) Logic Mismatch......57
001714.10 - Seat Position Front Switch (S17) Short Circuit to Power or Stuck Closed......58
001715.04 - Seat Position Rear Switch (S16) Short to Ground......58
002000.09 - CAN Communication Lost with ECU......58
002023.09 - CAN Communication Lost with SDM......58
002228.09 - CAN Communication Lost with FHC......58
002368.12 - Left Turn Signal Driver Output Fault......58
002370.12 - Right Turn Signal Driver Output Fault......58
002580.07 - Service Brake Pressure Switch Status Error......58
002605.12 - Brake Charge Solenoid (Y59) Circuit Fault......58
002875.04 - 4-Way Flasher Switch (S31) Input Short to Ground......58
002876.12 - Conflicting Turn Signal Switch (S30) Data......58
003413.04 - Right Door Switch (S99) Input Short to Ground......58
003416.03 - Right Exit Switch (S99) Circuits Short to Power......58
003416.04 - Right Exit Switch (S99) Circuits Short to Ground......58
003416.05 - Right Exit Switch (S99) Open Circuit......58
298816.14 - Park Brake Did Not Apply When Commanded......58
522371.04 - FLC Valve Power #5 Voltage Low......58
522379.12 - Park Brake Release Solenoid (Y7) Fault......58
522398.14 - Park Brake Did Not Release When Commanded......58
522411.03 - TCL/Range Switch (S5) Input Voltage High......58
522411.04 - TCL/Range Switch (S5) Input Voltage Low......58
522411.05 - TCL/Range Switch (S5) TCL Input Open Circuit......58
523218.03 - FLC Valve Power #2 Output Stuck ON......58
523218.04 - FLC Valve Power #2 Output Stuck OFF......58
523218.05 - FLC Valve Power #2 Output Voltage Low......58
523219.04 - FLC Valve Power #1 Voltage Low......58
523702.02 - Flex Power Status Erratic......58
523702.07 - Flex Power Not Active......58
523702.08 - Flex Power Time Out......58
523702.09 - Flex Power ECU Authentication Error......58
523702.13 - Flex Power Mismatch......58
523702.10 - Flex Power Watch Dog Error......58
523911.12 - Hydraulic Pump Control Solenoid (Y56) Fault......58
523948.12 - Ride Control Solenoid 1 (Y50) or 2 (Y51) Fault......59
524070.04 - Valve Power # 6 Voltage Low......59
524075.04 - Valve Power # 5 Voltage Low......59
524172.00 - Clutch Disconnect Switch Stuck Closed......59
524172.04 - Switch Short to Ground......59
524172.07 - Clutch Disconnect Device Fault......59
524235.12 - MFWD Solenoid (Y11) Output Fault......59
Group 30: Standard Display Monitor (SDM)......59
Standard Display Monitor (SDM) Diagnostic Trouble Codes......213
000096.03 - Fuel Level Sensor (B8) Input Voltage Low......59
000096.04 - Fuel Level Sensor (B8) Input Voltage High......59
000100.01 - Engine Oil Pressure Low......59
000100.05 - Engine Oil Pressure Switch Open......59
000107.00 - Engine Air Filter Restricted......59
000117.01 - Service Brake Pressure Low......59
000158.00 - System Voltage High......59
000158.01 - System Voltage Low......59
000177.00 - Torque Converter Oil Temperature High......59
000177.03 - Torque Converter Oil Temperature Sensor (B6) Input Voltage High......59
000177.04 - Torque Converter Oil Temperature Sensor (B6) Input Voltage Low......59
000234.02 - Software Revision Mismatch......59
000629.02 - No CAN from ECU......59
000920.03 - SDM Alarm (H2) Output Voltage High......59
000920.04 - SDM Alarm (H2) Output Voltage Low......59
001196.11 - Antitheft Lock Status Not Detected From ECU......59
001201.11 - Antitheft Unlock Status Not Detected From ECU......59
001508.00 - Hydraulic Oil Temperature Moderately High......59
001508.03 - Hydraulic Oil Temperature Sensor (B10) Input Voltage High......59
001508.04 - Hydraulic Oil Temperature Sensor (B10) Input Voltage Low......59
001508.16 - Hydraulic Oil Temperature High......59
001713.00 - Hydraulic Oil Filter Restricted......59
002003.09 - CAN Communication Lost with FLC......59
002000.09 - CAN Communication Lost with ECU......59
002000.12 - No CAN from ECU......60
002228.09 - CAN Communication Lost with FHC......60
002071.09 - CAN Communication Lost with Other Controller......60
298887.13 - SDM/ECU Model Number Mismatch......60
523569.04 - FLC Switched and/or Unswitched Power Open Circuit......60
523662.04 - FHC Valve Power Circuit Voltages Low......60
523649.04 - CAN Communication Lost with Hydraulic Controllers......60
523650.04 - CAN Communication Lost with FHC......60
523653.04 - Gear Selection/Transmission Direction Circuit Voltages Low......60
523665.04 - FLC Valve Power 1 Input Voltage Low......60
523666.04 - FLC Switched Power Voltage Open Circuit......60
Section 9005: Operational Checkout Procedure......329
Group 10: Operational Checkout Procedure......329
Operational Checkout Procedure......329
Section 9010: Engine......363
Group 05: Theory of Operation......363
POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines......376
Engine Cooling System......366
Group 15: Diagnostic Information......363
POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines......376
Engine Cooling System Component Location......369
Engine Fuel System Component Location......370
Engine Intake and Exhaust Component Location......372
Group 20: Adjustments......363
POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines......376
Group 25: Tests......363
POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines......376
Fluid Sampling Procedure—If Equipped......377
Engine Speed Check......382
Intake Manifold Pressure—Turbocharger Boost......384
Air Intake System Leakage Test......387
Fuel Line Leakage Test......389
Thermal Bypass Valve Test......391
Section 9015: Electrical System......392
Group 05: System Information......392
Electrical Diagram Information......399
Electrical Schematic Symbols......403
Group 10: System Diagrams......392
Fuse and Relay Location and Specifications......410
System Functional Schematic, Wiring Diagram, and Component Location Legend......414
System Functional Schematic and Section Legend......421
JDLink™ System Functional Schematic—MIG/GTT......429
JDLink™ System Functional Schematic—MTG/SAT......430
Canopy (ROPS) Harness (W5) Component Location......432
Canopy (ROPS) Harness (W5) Wiring Diagram......434
Engine Harness (W7) Component Location......437
Engine Harness (W7) Wiring Diagram......440
Transmission Harness (W9) Component Location......443
Transmission Harness (W9) Wiring Diagram......444
Cab Harness (W10) Component Location......445
Cab Harness (W10) Wiring Diagram......447
Roof Harness (W15) Component Location......451
Roof Harness (W15) Wiring Diagram......452
Air Conditioning Harness (W16) Component Location......454
Air Conditioning Harness (W16) Wiring Diagram......456
Selective Flow Control Harness (W17) Component Location......458
Selective Flow Control Harness (W17) Wiring Diagram......460
Ride Control Harness (W18, W19) Component Location......462
Ride Control Harness (W18, W19) Wiring Diagram......464
Radio Harness (W20) Component Location......466
Radio Harness (W20) Wiring Diagram......467
Loader Coupler Harness (W21, W22) Component Location......468
Loader Coupler Harness (W21, W22) Wiring Diagram......470
Pilot Control Harness (W23, W24) Component Location (S.N. —178748)......472
Pilot Control Harness (W23, W24) Wiring Diagram (S.N. —178748)......474
Return-to-Dig Harness (W25) Component Location......476
Return-to-Dig Harness (W25) Wiring Diagram......477
JDLink™ System Harnesses Component Location—MIG/GTT......478
JDLink™ System Harnesses Component Location—MTG/SAT......480
JDLink™ System Wiring Diagrams—MIG/GTT......482
JDLink™ System Wiring Diagrams—MTG/SAT......485
Diode Suppression Harness (W33) Wire Diagram—If Equipped......488
Diode Suppression Harness (W33) Component Location—If Equipped......489
Group 15: Sub-System Diagnostics......393
Starting and Charging Circuit Theory of Operation......493
Controller Area Network (CAN) Circuit Theory of Operation......496
Engine Control Unit (ECU) Circuit Theory of Operation......498
Flex Load Controller (FLC) Circuit Theory of Operation......501
Standard Display Monitor (SDM) Circuit Theory of Operation......508
Group 16: Monitor Operation......393
Standard Display Monitor (SDM)—Service Menu......513
Standard Display Monitor (SDM)—Clear Codes......514
Standard Display Monitor (SDM)—Diagnostics......515
Standard Display Monitor (SDM)—Hide/Unhide Main Menu......518
Standard Display Monitor (SDM)—Restore Monitor Defaults......519
Standard Display Monitor (SDM)—Machine Options......520
Standard Display Monitor (SDM)—Setting Hour Meter......521
Anti-Theft Security System Enable/Disable......523
Anti-Theft Security System Configuration......525
Anti-Theft Security System Operation......529
Group 20: References......393
Service ADVISOR™ Connection Procedure......533
JDLink™ System Identification......535
JDLink™ Connection Procedure—If Equipped......538
Reading Diagnostic Trouble Codes (DTCs)......539
Intermittent Diagnostic Trouble Code (DTC) Diagnostics......542
Controller Area Network (CAN) Resistor Test......543
Controller Area Network (CAN) Circuit Test......545
Alternator Test Procedure......554
Electrical Component Specifications......555
Wire Harness Test......558
Crank Position Sensor Test......561
Throttle Position Sensor Test......562
Flex Load Controller (FLC) Output Test......563
Transmission Solenoid Circuit Test......564
Transmission Control Circuit Test......565
Transmission Control Lever (TCL) Test......567
Transmission Solenoid Check......569
Seat Position Switches Remove and Install......570
WEATHER PACK® Connector Remove and Install......571
WEATHER PACK® Contact Installation......573
DEUTSCH® Connector Remove and Install......575
DEUTSCH® Contact Installation......579
CINCH™ Connector Remove and Install......581
CINCH™ Contact Installation......583
CINCH™ CP Connector Remove and Install......585
CINCH™ CP Contact Installation......594
Metri-Pack® Connector Remove and Install......598
Section 9020: Power Train......601
Group 05: Theory of Operation......601
Power Shift Power Train Overview......606
Clutch Modulation Operation......608
Torque Converter Operation......610
Transmission Pump Operation......612
Transmission Filter Operation......613
Clutch and Mechanical Front Wheel Drive (MFWD) Operation......614
Power Shift Transmission Gear Flow......616
Power Shift Transmission Clutch Engagement And Solenoids Activated......619
Differential Operation......620
Differential Lock Operation......622
MICO Power Boost Brake Valve—Neutral Position......624
MICO Power Boost Brake Valve—Both Pedals Applied Position......626
MICO Power Boost Brake Valve—One Pedal Applied Position......628
MICO Power Boost Brake Valve—Both Pedals Applied, Engine Off Position......630
Service Brake Operation......632
Park Brake Operation......633
MFWD Differential Operation—Unequal Traction......635
MFWD Differential Operation—Equal Traction—If Equipped......637
Group 15: Diagnostic Information......601
Power Train Component Location......641
Hydraulic Circuit—Symbols......644
Power Train Schematic—Neutral......645
Power Train Schematic—First Forward Mechanical Front Wheel Drive (MFWD) Engaged......647
Power Train Schematic—First Reverse......649
Power Train Schematic—Fourth Forward......651
Diagnose Transmission Malfunctions......653
Transmission Slippage......601
Machine Lacks Power or Moves Slow......601
Transmission Overheats......601
Excessive Power Train Noise......601
Park Brake Piston Leak......601
No Power to Mechanical Front Wheel Drive (MFWD)......602
No Power to One Wheel of Mechanical Front Wheel Drive (MFWD)......602
No Differential Lock Operation......622
Differential Lock Slips or Chatters When Engaged......602
Differential Lock Will Not Release......602
Rear Axle Overfilled With Oil......602
Poor Service Brakes......602
Brake Pedal Hard to Push......602
Service Brakes Will Not Release......602
Service Brakes Chatter or Noisy......602
Park Brake Will Not Hold......602
Park Brake Will Not Release......602
Group 20: Adjustments......602
Park Brake Release for Towing......704
Brake Pedal Adjustment......706
Brake Bleeding Procedure......708
Tracking Angle Check and Adjust......712
Toe-In Check and Adjust......713
Steering Angle Check and Adjust......715
Group 25: Tests......602
Transmission Oil Warm-Up Procedure......718
Transmission Oil Sampling Procedure—If Equipped......720
Power Shift Transmission Overall Test Connections, Ports, and Locations......721
Torque Converter Stall Speed Test......723
Torque Converter Inlet Pressure Test......725
Brake Valve Leakage Test......730
Park Brake Release Pressure Test......732
Transmission System Pressure Test......734
Service Brake Boost Pressure Test......737
Clutch Pressure Test......740
Differential Lock Pressure Test......743
Mechanical Front Wheel Drive (MFWD) Pressure Test......745
Cooler In and Cooler Out Pressure Test......747
Solenoid Circuit Leakage Test......751
Transmission Pump Flow Test......752
Section 9025: Hydraulic System......754
Group 05: Theory of Operation......754
Hydraulic System Operation......759
Hydraulic Pump Operation......760
Power Limiting Valve Operation......762
Load Sense Isolator......763
Hydraulic Filter Operation......765
Steering Valve Operation......768
Ride Control Hydraulic Circuit Component Location and Valve Operation......773
Circuit Relief Valve without Anticavitation and Load Sense Relief—Loader and Backhoe......778
Circuit Relief Valve with Anticavitation—Loader and Backhoe......780
Circuit Relief Valve with Anticavitation—Backhoe Bucket Curl and Loader Bucket Dump......781
Backhoe Auxiliary Flow Control Circuit Relief Valve......783
Backhoe Control Valve Inlet Section......785
Backhoe Control Valve Selective Auxiliary Flow Section—Solenoid Energized......787
Backhoe Control Valve Swing Section—Swing Right Position......789
Backhoe Control Valve Boom Section—Boom Raise Position......791
Backhoe Control Valve Bucket Section—Bucket Curl Position......793
Backhoe Control Valve Crowd Section—Crowd In Position......795
Backhoe Control Valve Extendible Dipperstick Section (Optional)—Neutral......797
Pilot Control Valve Operation......799
Pilot Control Manifold Valve Operation......801
Pattern Select Valve Operation (S.N. —178748)......803
Loader and Stabilizer Control Valve Operation......804
Loader and Stabilizer Control Valve Steering Load Sense Isolator......824
Loader and Stabilizer Control Valve Load Sense Relief......826
Attachment Coupler Hydraulic Operation......828
Group 15: Diagnostic Information......754
Hydraulic System Schematic......837
Hydraulic System Component Location......844
Attachment Coupler Hydraulic Component Location......851
Slow Steering Hydraulics......754
No Steering Hydraulics......754
Hard Steering......755
Steering Valve Does Not Return to Neutral......755
No Response when Steering Wheel is Turned......755
Machine Turns in Opposite Direction......755
Excessive Vibration of the Steering Wheel......755
Machine Turns when Steering Valve is in Neutral......755
Steering Wheel Kickback......755
Excessive Steering Wheel Turns To Steer Machine......755
Erratic (“Spongy”) Steering......755
Steering Wheel "Locks" Up......755
Poor Centering of Steering Wheel (Wheels Continue to Move After Steering Wheel is Stopped)......755
Steering Wheel or Front Wheels Slowly Turn by Themselves When Using Backhoe or Loader......755
Steering Wheel Turns Apply Rear Axle Service Brakes......755
Steering Wheel Turns Freely With No Resistance or Action On Steered Wheels......755
Steering Wheel Turns With Slight Resistance and No Action On Steered Wheels......755
Wander—Vehicle Will Not Stay in a Straight Line......755
No Loader or Steering Hydraulics......755
No Loader Hydraulics......755
Low Loader Hydraulic Power......755
Low Hydraulic Power......755
Engine Pulls Down Excessively During Loader Operation......755
Engine Pulls Down Excessively During Backhoe Operation......755
Slow Hydraulic Functions......755
Loader or Backhoe Operates Slowly in One Function......755
No Loader or Backhoe Power in One Function......755
No Stabilizer Hydraulics......755
Slow Loader and Backhoe Hydraulics......755
Low Hydraulic Power (Low Hydraulic Pressure)......755
Hydraulic Function Makes "Chattering" Noise......755
Functions Drift......755
Control Valve Sticks or Works Hard......755
Low Hydraulic Power (Low Hydraulic Pressure)......755
Hydraulic Oil Overheats......755
Foaming Oil......756
Hydraulic Pump Leaking......756
Excessive Pump Noise......756
Attachment Coupler Not Working......756
Group 20: Adjustments......756
Loader Bucket Self-Leveling Linkage and Return-To-Dig Switch Adjustment......928
Loader Lever and Stabilizer Lever Adjustment......932
Backhoe Control Lever to Valve Linkage (Two Lever) Adjustment......936
Backhoe Control Lever to Valve Linkage (Four Lever) Adjustment—If Equipped......939
Selective Flow Valve Adjustment......942
Ride Control Accumulator Charge Procedure......944
Ride Control Accumulator Charge Check Procedure......947
Ride Control Accumulator Hydraulic Pressure Release Procedure......949
Pilot Control Pressure Adjustment......950
Pilot Control Manifold Valve Accumulator Discharge Procedure......952
Group 25: Tests......756
JT02156A Digital Pressure and Temperature Analyzer Kit Installation......954
Hydraulic Oil Warmup Procedure......955
Hydraulic Oil Sampling Procedure—If Equipped......956
Hydraulic Circuit Pressure Release......957
Hydraulic Pump High Pressure Cut-Off Test......959
Pump Load Sense Differential Pressure Test......962
Hydraulic Pump Flow Test......965
Hydraulic Return Pressure Test......969
Backhoe, Loader, and Steering Load Sense Relief Valve Pressure Test......972
Power Limiting Valve Test......976
Pilot Control Accumulator Charge Pressure Test......977
Pilot Control Pressure Test......980
Hydraulic Oil Cooler Restriction Test......981
Circuit Relief Valve Test With Remote Pump......984
Steering System Leakage Test......988
Steering Cylinder Leakage Test......991
Function Drift Test......993
Hydraulic Cylinder Leakage Test......1002
Loader and Stabilizer Control Valve Lockout Leakage Test......1005
Section 9031: Heating and Air Conditioning......1007
Group 05: Theory of Operation......1007
Proper Refrigerant Handling......1044
R134a Refrigerant Cautions......1045
R134a Refrigerant Theory Of Operation......1012
Air Conditioning Circuit—Specifications......1014
Air Conditioning Circuit Operational Information......1015
Air Conditioning Circuit Theory Of Operation......1016
Freeze Control Switch Operation......1017
Receiver/Dryer Operation......1018
Expansion Valve Operation......1020
Compressor Relief Valve Operation......1021
Heater Blower Circuit Operational Information......1022
Heater Blower Circuit Theory Of Operation......1023
Temperature Control Operation......1024
Group 15: Diagnostic Information......1007
Air Conditioning System Does Not Operate......1007
Air Conditioner Does Not Cool Interior of Cab......1007
Air Conditioner Runs Constantly, Too Cold......1007
Interior Windows Continue to Fog......1007
Heater System Does Not Operate......1007
Heater Does Not Warm Interior of Cab......1007
Air Conditioning and Heater System Component Location......1042
Group 25: Tests......1007
Proper Refrigerant Handling......1044
R134a Refrigerant Cautions......1045
R134a Air Conditioning System Test......1046
Operating Pressure Diagnostic Chart......1049
Expansion Valve Operation Test......1054
Blower Switch Test......1057
Blower Resistor Test......1058
Heater Blower Motor Test......1060
Freeze Control Switch Test......1061
Air Conditioning Switch Test......1062
Binary Pressure Switch Test......1063
Compressor Clutch Coil Test......1066
Air Conditioning System Leak Test......1067
Refrigerant Hoses And Tubing Inspection......1068
