Worldwide Construction And Forestry Division 410J User manual
410J
Backhoe Loader
Repair
TECHNICAL MANUAL
410J Backhoe Loader
TM10147 08JUN07 (ENGLISH)
For complete service information also see:
410J Backhoe Loader Operation and
Test ................................ TM10132
410J Backhoe Loader Operator’s Manual . . OMT211053
Alternators and Starting Motors .......... CTM77
POWERTECH
4.5 L & 6.8 L Diesel
Engines—Base Engine ................. CTM104
POWERTECH
4.5L & 6.8L Diesel Engines—
Level 12 Electronic Fuel Systems with
Stanadyne DE10 Pump ................. CTM331
Front Wheel Drive Axles AS and MS
Series ............................... CTM4687
100 Series Hydraulic Cylinders .......... TM-H100A
120 Series Hydraulic Cylinders .......... TM-H120A
125 Series Hydraulic Cylinders .......... TM-H125A
Super Caddy Oil Cleanup Procedure ...... CTM310
Specifications Manual .................. SP458
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
TX03399,0001836 –19–01SEP06–1/1
Foreword
This manual is written for an experienced technician.
Essential tools required in performing certain service
work are identified in this manual and are
recommended for use.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions presented
throughout the text of the manual.
This is the safety-alert symbol. When you see this
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of all
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
testing, and repair.
Fundamental service information is available from
other sources covering basic theory of operation,
fundamentals of troubleshooting, general maintenance,
and basic type of failures and their causes.
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Introduction
TX,TM,FAX –19–03JUL01–1/1
Technical Information Feedback Form
We need your help to continually improve our technical
publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO: John Deere Dubuque Works
P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538
FAX NUMBER: 563-589-5800
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Contents
00
SECTION 00—General Information SECTION 17—Frame or Supporting Structure
Group 1740—Frame InstallationGroup 0001—Safety Information
Group 0003—Torque Values Group 1749—Chassis Weights
SECTION 18—Operator’s Station
SECTION 01—Wheels
01
Group 1800—Removal and Installation
Group 0110—Powered or Non-Powered Wheels
Group 1810—Operator Enclosure
and Fastenings
Group 1821—Seat and Seat Belt
Group 1830—Heating and Air Conditioning
SECTION 02—Axles and Suspension Systems
Group 0225—Input Drive Shafts and U-Joints
SECTION 19—Sheet Metal and Styling
Group 0230—Non-Powered Wheel Axles
Group 1910—Hood and Engine Enclosure
Group 0240—Powered Wheel Axle (MFWD)
Group 1913—Miscellaneous Shields
Group 0250—Axle Shaft, Bearings, and Reduction
Group 1921—Grille and Grille Housing
Gears
Group 1927—Fenders
SECTION 03—Transmission
02
SECTION 20—Safety, Convenience and
Group 0300—Removal and Installation
Miscellaneous
Group 0315—Controls Linkage
Group 2001—Radio
Group 0350—Gears, Shafts, and Power Shift
Group 2004—Horn and Warning Devices
Clutches
Group 0360—Hydraulic System
SECTION 21—Main Hydraulic System
Group 2160—Hydraulic System
SECTION 04—Engine
Group 0400—Removal and Installation
SECTION 31—Loader
Group 3100—Loader
SECTION 05—Engine Auxiliary Systems
Group 3102—Bucket
Group 0505—Cold Weather Starting Aid
03
Group 3104—Attachment Coupler
Group 0510—Cooling System
Group 3115—Control Linkages
Group 0515—Speed Controls
Group 3160—Hydraulic System
Group 0520—Intake System
Group 0530—Exhaust System SECTION 33—Backhoe
Group 0560—External Fuel Supply System Group 3302—Bucket
Group 3315—Control Linkage
SECTION 06—Torque Converter
Group 3340—Frames
Group 0651—Turbine, Gears and Shaft
Group 3360—Hydraulic System
SECTION 09—Steering System SECTION 99—Dealer Fabricated Tools
Group 0960—Hydraulic System
04
Group 9900—Dealer Fabricated Tools
SECTION 10—Service Brakes
Group 1011—Active Elements
Group 1060—Hydraulic System
SECTION 11—Park Brake
Group 1111—Active Elements
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
05
COPYRIGHT
2007
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION
Manual
06
09
10
11
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00
Section 00
General Information
Contents
Page Page
Group 0001—Safety Information
Additional Metric Cap Screw Torque
Safety and Operator Convenience
Values ............................00-0003-2
Features ..........................00-0001-1
Torque Value
Recognize Safety Information ............00-0001-2
Unified Inch Bolt and Cap Screw ........00-0003-4
Follow Safety Instructions ...............00-0001-2
Service Recommendations for 37°Flare
Operate Only If Qualified................00-0001-3
and 30°Cone Seat Connectors .........00-0003-5
Wear Protective Equipment..............00-0001-3
Service Recommendations for O-Ring
Avoid Unauthorized Machine
Boss Fittings .......................00-0003-6
Modifications .......................00-0001-3
Service Recommendation
Inspect Machine ......................00-0001-4
O-Ring Boss Fittings In Aluminum
Stay Clear of Moving Parts ..............00-0001-4
Housing—Excavators ...............00-0003-8
Avoid High-Pressure Fluids ..............00-0001-4 Service Recommendations For Flared
Avoid High-Pressure Oil ................00-0001-5
Connections—Straight or Tapered
Beware of Exhaust Fumes ..............00-0001-5
Threads ..........................00-0003-10
Prevent Fires.........................00-0001-6
Service Recommendations For Flat Face
Prevent Battery Explosions ..............00-0001-6
O-Ring Seal Fittings.................00-0003-11
Handle Chemical Products Safely .........00-0001-7
Service Recommendation
Dispose of Waste Properly ..............00-0001-7
O-Ring Face Seal Fittings with SAE
Prepare for Emergencies................00-0001-7
Inch Hex Nut and Stud End for High
Use Steps and Handholds Correctly .......00-0001-8
Pressure........................00-0003-12
Start Only From Operator’s Seat ..........00-0001-8
O-Ring Face Seal Fittings with Metric
Use and Maintain Seat Belt..............00-0001-8
Hex Nut and Stud End for Standard
Prevent Unintended Machine Movement ....00-0001-9
Pressure........................00-0003-14
Prevent Unintended Machine Movement—
O-Ring Face Seal Fittings with Metric
If Equipped With Pilot Controls .........00-0001-9
Hex Nut and Stud End for High
Avoid Work Site Hazards ..............00-0001-10
Pressure........................00-0003-16
Keep Riders Off Machine ..............00-0001-10
Service Recommendations for Metric
Avoid Backover Accidents ..............00-0001-11
Series Four Bolt Flange Fitting ........00-0003-18
Avoid Machine Tipover ................00-0001-11 Service Recommendations For Inch
Add and Operate Attachments Safely .....00-0001-12 Series Four Bolt Flange Fittings........00-0003-19
Use Special Care When Operating .......00-0001-12
Service Recommendation
Operating or Traveling On Public Roads . . .00-0001-13 Inch Series Four Bolt Flange For High
Inspect and Maintain ROPS ............00-0001-13
Pressure........................00-0003-20
Park and Prepare for Service Safely ......00-0001-14
Service Recommendations For
Service Cooling System Safely ..........00-0001-14
Non-Restricted Banjo (Adjustable)
Remove Paint Before Welding or
Fittings...........................00-0003-21
Heating ..........................00-0001-15
Service Recommendations For O-Ring
Make Welding Repairs Safely ...........00-0001-15
Boss Fittings With Shoulder...........00-0003-23
Drive Metal Pins Safely ................00-0001-16
Service Recommendation
Safety Signs ........................00-0001-17
Metric 24°O-Ring Seal DIN 20078 .....00-0003-26
Safety Signs—Backhoe Coupler (If
Equipped) ........................00-0001-19
Group 0003—Torque Values
Torque Value
Metric Bolt and Cap Screw ............00-0003-1
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Group 0001
Safety Information
00
0001
1
VD76477,0001270 –19–15DEC06–1/1
Safety and Operator Convenience Features
1
23
5
6
13
12
11
14
15
17
16
10 9
8
7
4
T145296
T145296 –UN–05SEP01
Please remember, the operator is the key to
preventing accidents.
1. Headlights/Taillights. Two front halogen
driving/work lights and two rear halogen work lights.
2. Signal/Warning Lights. Roof mounted turning
signal lights and warning lights for on-road use.
3. ROPS Protection. Certified rollover protection
structure surrounds the operator. Integral roof
provides overhead protection.
4. Seat Position Sensor. An audio/visual warning
alerts operator when Transmission Control Lever
(TCL) is in forward/reverse and the seat turned
toward the backhoe position.
5. Interior Rearview Mirror. Offers the operator a
view of activity behind him.
6. Handholds. Large and conveniently placed
handholds, make it easy to enter or exit the
operator’s station.
7. Loader Boom Service Lock. Provided for working
on or around this machine with the boom raised.
8. Engine Fan Guard. A secondary engine fan guard
inside engine compartment encloses rotating fan
blades.
9. Bypass Start Protection. Shielding over the starter
solenoid helps prevent dangerous bypass starting.
10. Ground-Level Fueling, Daily Service Checks.
Ground-level fueling feature eliminates the need to
climb on the machine to fuel it.
11. Steps. Wide, skid-resistant steps provide excellent
footing for getting in/out of operator’s station.
12. Independent Parking/Secondary Brake.
Independent, electrically controlled, parking brake
electrically engages when the engine is stopped.
13. Neutral Start. The machine will not move until the
Transmission Control Lever (TCL) is cycled back
to neutral and the park brake is released,
regardless of TCL position at startup.
14. Backup Alarm. Alerts bystanders when the
machine is shifted into reverse.
15. Seat Belt Retractors. Seat belt retractors help
keep belts clean and convenient to use.
16. Exceptional Visibility. Views to either side and
front or rear working tools are unrestricted.
17. Operator Manual Holder. A sealed manual holder
keeps manual clean and dry.
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Safety Information
00
0001
2
TX03679,00016CC –19–04DEC06–1/1
Recognize Safety Information
T133555 –UN–28AUG00T133588 –19–28AUG00
This is the safety alert symbol. When you see this
symbol on your machine or in this manual, be alert
for the potential of personal injury.
Follow the precautions and safe operating practices
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is
used with the safety alert symbol. DANGER identifies the
most serious hazards.
On your machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.
TX03679,00016F9 –19–07SEP06–1/1
Follow Safety Instructions
T133556 –UN–24AUG00
Read the safety messages in this manual and on the
machine. Follow these warnings and instructions carefully.
Review them frequently. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your authorized John Deere dealer.
Be sure all operators of this machine understand every
safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.
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Safety Information
00
0001
3
TX03679,00016FA –19–03JAN07–1/1
Operate Only If Qualified
Do not operate this machine unless the operator’s
manual has been read carefully, and you have been
qualified by supervised training and instruction.
Operator should be familiar with the job site and
surroundings before operating. Try all controls and
machine functions with the machine in an open area
before starting to work.
Know and observe all safety rules that may apply to
every work situation and work site.
TX03679,00016D0 –19–15DEC06–1/1
Wear Protective Equipment
TS206 –UN–23AUG88
Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
AM40430,0000084 –19–29MAR05–1/1
Avoid Unauthorized Machine Modifications
John Deere recommends using only genuine John
Deere replacement parts to ensure machine
performance. Never substitute genuine John Deere
parts with alternate parts not intended for the
application as these can create hazardous situations or
hazardous performance. Non-John Deere Parts, or any
damage or failures resulting from their use are not
covered by any John Deere warranty.
Modifications of this machine, or addition of
unapproved products or attachments, may affect
machine stability or reliability, and may create a hazard
for the operator or others near the machine. The
installer of any modification which may affect this
machine is responsible for establishing that the
modification does not adversely affect the machine or
its performance. This applies to all aspects of the
machine, including electronic controls.
Always contact an authorized dealer before making
machine modifications that change the intended use,
weight or balance of the machine, or that alter
machine controls, performance or reliability.
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Safety Information
00
0001
4
TX03679,0001734 –19–04DEC06–1/1
Inspect Machine
T6607AQ –UN–18OCT88
Inspect machine carefully each day by walking around it
before starting.
Keep all guards and shields in good condition and
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
TX03679,00016D2 –19–12FEB07–1/1
Stay Clear of Moving Parts
T133592 –UN–12SEP01
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.
DX,FLUID –19–03MAR93–1/1
Avoid High-Pressure Fluids
X9811 –UN–23AUG88
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
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Safety Information
00
0001
5
OUT4001,0000028 –19–11SEP06–1/1
Avoid High-Pressure Oil
T133509 –UN–17MAR06
T133840 –UN–20SEP00
This machine uses a high-pressure hydraulic system.
Escaping oil under pressure can penetrate the skin
causing serious injury.
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
TX03679,00016D4 –19–12FEB07–1/1
Beware of Exhaust Fumes
T133546 –UN–24AUG00
Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring
outside air into the area.
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Safety Information
00
0001
6
TX03679,00016F5 –19–04DEC06–1/1
Prevent Fires
T133552 –UN–14SEP00T133553 –UN–07SEP00T133554 –UN–07SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a
multi-purpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
TX03679,000174A –19–04DEC06–1/1
Prevent Battery Explosions
TS204 –UN–23AUG88
Battery gas can explode. Keep sparks, lighted matches,
and open flame away from the top of battery.
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
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Safety Information
00
0001
7
TX03679,00016D7 –19–03JAN07–1/1
Handle Chemical Products Safely
T133580 –UN–25AUG00
Exposure to hazardous chemicals can cause serious
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
TX03679,0001733 –19–12FEB07–1/1
Dispose of Waste Properly
T133567 –UN–25AUG00
Improper disposal of waste can threaten the environment.
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants can damage the atmosphere.
Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your
local environmental or recycling center or your authorized
dealer for more information.
TX03679,000174B –19–12FEB07–1/1
Prepare for Emergencies
TS291 –UN–23AUG88
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
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Safety Information
00
0001
8
TX03679,00016F2 –19–12FEB07–1/1
Use Steps and Handholds Correctly
T133468 –UN–30AUG00
Prevent falls by facing the machine when you get on and
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
TX03679,0001799 –19–03JAN07–1/1
Start Only From Operator’s Seat
T133715 –UN–07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,00016DD –19–19MAR07–1/1
Use and Maintain Seat Belt
T133716 –19–14SEP00
Use seat belt when operating machine. Remember to
fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced
every three years, regardless of appearance.
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Safety Information
00
0001
9
VD76477,0001206 –19–15DEC06–1/1
Prevent Unintended Machine Movement
P
1
TX1014609 –UN–19DEC06
Park Brake Switch
1—ON Position
Always set the park lock brake switch to the ON
position (1) before leaving the operator’s seat for any
reason.
Be careful not to accidentally actuate steering, travel or
other controls. Engage park brake and lower work
equipment to the ground during work interruptions. Stop
the engine before allowing anyone to approach the
machine. Follow proper parking procedures before leaving
the operator’s station.
VD76477,0001201 –19–02NOV06–1/1
Prevent Unintended Machine Movement—If
Equipped With Pilot Controls
TX1014474 –UN–12DEC06
Be careful not to accidentally actuate control levers when
co-workers are present. Always lock hydraulics on
backhoe during work interruptions. Lock hydraulics before
allowing anyone to approach machine.
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Safety Information
00
0001
10
TX03768,0000BAA –19–03JAN07–1/1
Avoid Work Site Hazards
T147554 –UN–01NOV01T147555 –UN–13DEC01
Avoid contact with gas lines, buried cables and water
lines. Call utility line location services to identify all
underground utilities before you dig.
Prepare work site properly. Avoid operating near
structures or objects that could fall onto the machine.
Clear away debris that could move unexpectedly if run
over.
Avoid boom or attachment contact with overhead
obstacles or overhead electrical lines. Never move any
part of machine or load closer than 3 m (10 ft) plus twice
the line insulator length to overhead wires.
Keep bystanders clear at all times. Use barricades or a
signal person to keep vehicles and pedestrians away. Use
a signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to
support machine. Be especially alert working near
embankments or excavations.
Avoid working under over-hanging embankments or
stockpiles that could collapse on machine.
Reduce machine speed when operating with tool on or
near ground when obstacles may be hidden (e.g., during
snow removal or clearing mud, dirt, etc.). At high speeds
hitting obstacles (rocks, uneven concrete or manholes)
can cause a sudden stop. Always wear your seat belt.
TX03768,0000BAF –19–07SEP06–1/1
Keep Riders Off Machine
T148715 –UN–06DEC01
Only allow the operator on the machine. Keep riders off.
Riders on machine are subject to injury such as being
struck by foreign objects and being thrown off of the
machine. Riders also obstruct the operator’s view resulting
in the machine being operated in an unsafe manner.
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