Part of the John Deere Repair Manuals.
Pinning down why a John Deere 400G crawler bulldozer won't run right is the job these 272 pages of factory Operation and Test data (TM-1411) are written for, and this John Deere 400G technical manual PDF hands you all of it. Electrical faults get traced on wiring diagrams that follow each circuit through switches and connectors, while hydraulic schematics map oil flow from the pump through the control valve to the cylinders. After General Information (torque values, fuels and lubricants) and the operational checkout, the engine, electrical, power train and hydraulic chapters run from theory of operation through system checks, diagnostics and tests, ending with miscellaneous components. Check that the air restriction indicator lights at 6.2 kPa (25 in. water), and set track sag to 22-29 mm (7/8-1-1/8 in.). Searchable, bookmarked text finds the right test fast.
What's Inside This John Deere 400G Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-32 | Safety Precautions, General Specifications, Torque Values, Fuels and Lubricants |
| Operational Checkout Procedure | 33-50 | Operational Checkout Record |
| Engine Operation and Test | 51-98 | Theory of Operation, System Operational Checks, Diagnostic Information, Adjustments, Tests, Cooling System, Radiator Cap, Thermostat, Fuel Injection Pump, Compression Pressure, Engine Oil Pressure |
| Electrical System Operation and Test | 99-166 | Theory of Operation, System Operational Checks, Diagnostic Information, Tests, Starting Circuit, Charging Circuit, Starting Motor, Ground Locations, Work Light Circuit |
| Power Train Operation and Test | 167-226 | Theory of Operation, System Operational Checks, Diagnostic Information, Adjustments, Tests, Power Train Block Diagram, Track Sag, Transmission Oil Filter Inspection, Steering Valve Operation, Transmission System Pressure |
| Hydraulic System Operation and Test | 227-252 | Theory of Operation, System Operational Checks, Diagnostic Information, Tests, Dozer Blade Lift Valve, Dozer System Relief Valve, Cylinder Leakage, Dozer Cylinder Drift, Hydraulic Oil Filter Inspection |
| Miscellaneous Components | 253-272 | Theory of Operation, Diagnostic Information, Adjustments, Tests |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Battery Reserve capacity | 180 minutes | p. 14 |
| O-ring boss fitting torque (3/8-24 UNF) | 8 Nm (6 lb-ft) | p. 20 |
| O-ring boss fitting torque (7/16-20 UNF) | 12 Nm (9 lb-ft) | p. 20 |
| Outside diameter of a new bushing | 44.5 mm (1.75 in.) | p. 199 |
| Air restriction indicator vacuum trip point | 635 mm (25 in.) water | p. 55 |
| Oil filter bypass valve differential opening pressure | 370 kPa (3.7 bar) (54 psi) | p. 57 |
| Fan belt deflection | 3/4-in. with 20 lb push | p. 67 |
| Volts | 12 volts | p. 103 |
| Minimum recommended bushing outside diameter (normal loading) | 39.6 mm (1.56 in.) | p. 199 |
| Hydraulic warm-up temperature | 40°C (100°F) | p. 237 |
| System Relief Valve Pressure | 151510 + 1380 - 0 kPa (2250 + 200 - 0 psi) | p. 248 |
| Hydraulic Pump Flow (New) | 5.37 L/min (14.2 gpm) | p. 249 |
John Deere 400G Common Problems This Manual Covers
John Deere 400G dozer diesel engine turns over but is hard to start or will not start
Open the fuel shut-off valve and confirm fuel quantity, then remove the tank cap and listen for air entering to rule out a plugged vent, per page 72. Drain water from the fuel tank trap and change the filter if it shows water. Do not depend on fuel filters to remove water or use de-icers (page 25). Check the air filter restriction indicator and clean the filters.
Manual Section: Engine Malfunctions p. 72Diesel engine overheats while dozing and the coolant temperature gauge reads high
Check coolant level and refill, but do not remove the radiator cap unless the engine is cool (page 65). Clean and straighten plugged or bent radiator and oil cooler fins. Measure fan belt deflection against 3/4 in. with a 20 lb push per page 67, and replace oil-soaked belts. Test the thermostat for sticking closed and test the radiator cap per the page 76 chart.
Manual Section: Engine Malfunctions p. 76Starting motor will not turn or starter solenoid chatters when the key switch is turned
Remove the negative (-) battery cable first and replace it last. Wear eye protection and remove rings and watch bands (page 101). Clean and tighten connections at the batteries, starter motor and frame ground. Check battery state of charge. A replacement must meet 625 amps cold cranking at -18°C (0°F) per page 103. Then check the key switch, start relay and starter solenoid. Never short across starter terminals (page 9).
Manual Section: Electrical System Malfunctions p. 134Diesel engine has little power and stays sluggish even with the throttle at fast idle
Inspect the fuel tank cap vent and replace the cap if plugged, and replace the fuel filter per page 75. Adjust fast idle to 2250 ± 25 rpm following page 82. Check the air restriction indicator, which trips at 635 mm (25 in.) water per page 55, and replace air cleaner elements if necessary. Run the fuel pump test next.
Manual Section: Engine Malfunctions p. 75Engine oil pressure drops low and the engine low pressure monitor indicator light comes on
Check oil level and fill as needed. A complete refill with filter takes 8.5 qt (8.0 L) per page 15. Verify the correct grade of oil and check for fuel dilution, running the fuel pump test as the page 77 chart directs. Then inspect the oil pressure regulating valve and clean a plugged or loose oil pump intake screen.
Manual Section: Engine Malfunctions p. 77Main hydraulic system functions operate slowly and feel weak with low power under load
Verify hydraulic oil temperature reaches 40°C (100°F) per page 237 before testing. Relieve pressure before disconnecting lines, tighten all connections before applying pressure, and search for leaks with cardboard, never your hand (page 248). Test system relief valve pressure against 2250 psi (+200, -0) on page 248. Then measure pump flow against 14.2 gpm new or 11.2 gpm used on page 249.
Manual Section: Hydraulic System Operation and Test p. 248Frequently Asked Questions
How do I adjust the John Deere 400G H-L-R shift linkage?
To check the H-L-R shift linkage, follow the procedure on page 189. If adjustment is required, refer to TM-1412, Group 0350. The detent must be felt in each position and the lever must align with the gear number. p. 189
How do I adjust the track sag on a John Deere 400G?
The track sag should be 22-29 mm (7/8-1-1/8 in.). To adjust, allow the unit to roll to a stop in the forward direction and measure the sag between the carrier roller and the front idler at the lowest point. p. 208
What are the replacement specifications for the engine oil filter on the John Deere 400G?
The engine oil capacity, including the filter, is 8.5 quarts (8.0 L). The engine uses a pressure lubrication system with a full-flow filter. p. 14
What is the correct torque for track shoe cap screws on a John Deere 400G crawler dozer?
Track shoe cap screws should be checked periodically for tightness and tightened to 110 lb-ft (149 N-m) of torque. Replacement hardware must be lubricated before tightening. p. 17
What is the procedure for checking the engine valve clearance on the John Deere 400G?
The intake valve clearance is 0.36 mm (0.014 in.) and the exhaust valve clearance is 0.46 mm (0.018 in.). Adjustments are made with the piston at TDC on the compression stroke, as detailed on page 85. p. 85
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