Complete Diagnostics, Operation and Test manual with electrical wiring diagrams for John Deere 35G Compact Excavator, with all the shop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 35G Compact Excavator workshop Operation and Test 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.

TM12891 - John Deere 35G Compact Excavator Technical Manual - Operation and Test.pdf
TM12891 - John Deere 35G Compact Excavator Technical Manual - Operation and Test.epub

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Total Pages: 805 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS     35G (PIN: 1FF035GX**K270001—)  
Foreword
   Technical Information Feedback Form
   General Information
      Safety
   Diagnostics
      Engine Control Unit (ECU) Diagnostic Trouble Codes
      Monitor Controller (DSZ) Diagnostic Trouble Codes
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      Monitor Operation
      References
   Power Train
      Theory of Operation
      Diagnostic Information
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Tests
   Heating and Air Conditioning
      Theory of Operation
      Diagnostic Information
      Tests

tm12891 - 35G Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Control Pattern Selector—If Equipped

Add Cab Guarding for Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Work In Ventilated Area

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Prepare for Emergencies

Clean Debris from Machine

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Inspect and Maintain ROPS

Avoid Machine Tip Over

Use Special Care When Lifting Objects

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9001: Diagnostics

Group 10: Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

000029.08 - Spare Accelerator Sensor Error (Pulse Communication) (P1227) (0001D-08)

000091.02 - Accelerator Sensor Intermittent Failure (P0124) (0005B-02)

000091.03 - Acceleration Sensor Error (High Voltage) (P0123) (0005B-03)

000091.04 - Acceleration Sensor Error (Low Voltage) (P0122) (0005B-04)

000100.01 - Oil Pressure Descend Error (P1198) (00064-01)

000100.04 - Oil Pressure Switch Error (P1192) (00064-04)

000110.00 - Cooling Water Temperature Rise Alarm (Overheat) (P0217) (0006E-00)

000110.02 - Cooling Water Temperature Sensor Intermittent Failure (P0119) (0006E-02)

000110.03 - Cooling Water Temperature Sensor Error (High Voltage) (P0118) (0006E-03)

000110.04 - Cooling Water Temperature Sensor Error (Low Voltage) (P0117) (0006E-04)

000158.00 - Power Supply Voltage Error (High Voltage) (P0563) (0009E-00)

000158.01 - Power Supply Voltage Error (Low Voltage) (P0562) (0009E-01)

000167.01 - Charge Alarm (P1568) (000A7-01)

000167.04 - Charge Switch Error (P1562) (000A7-04)

000190.00 - Overspeed Error (P0219) (000BE-00)

000628.02 - ECU Internal Flash ROM Error (Checksum B) (P1605) (00274-02)

000628.02 - ECU Internal Flash ROM Error (Checksum C) (P1606) (00274-02)

000628.12 - ECU Internal Flash ROM Error (Checksum A) (P0605) (00274-0C)

000630.02 - ECU Internal EEPROM Error (Checksum) (P1601) (00276-02)

000630.12 - ECU Internal EEPROM Error (Read/Write Error) (P0601) (00276-0C)

000638.02 - Engine Error (P1214) (0027E-02)

000638.03 - Rack Actuator Error (High Current) (P1213) (0027E-03)

000638.04 - Rack Actuator Error (Low Current) (P1212) (0027E-04)

000638.07 - Rack Actuator Mechanical Failure (P1211) (0027E-07)

000639.12 - CAN Communication Error (U0001) (0027F-0C)

001078.04 - Speed Sensor Error (P0340) (00436-04)

001079.02 - Sensor 5 V Intermittent Failure (P1644) (00437-02)

001079.03 - Sensor 5 V Error (High Voltage) (P0643) (00437-03)

001079.04 - Sensor 5 V Error (Low Voltage) (P0642) (00437-04)

001136.01 - ECU Temperature Rise Alarm (P0634) (00470-00)

001136.02 - ECU Temperature Sensor Intermittent Failure (P1664) (00470-02)

001136.03 - ECU Temperature Sensor Error (High Voltage) (P0669) (00470-03)

001136.04 - ECU Temperature Sensor Error (Low Voltage) (P0668) (00470-04)

001210.03 - Rack Position Sensor Error (High Voltage) (P1203) (004BA-03)

001210.04 - Rack Position Sensor Error (Low Voltage) (P1202) (004BA-04)

001485.04 - Main Relay Error (P0686) (005CD-04)

522241.02 - Rack Actuator Relay Intermittent Failure (P1224) (7F801-02)

522241.03 - Rack Actuator Relay Error B (P1223) (7F801-03)

522241.04 - Rack Actuator Relay Error A (P1222) (7F801-04)

522242.02 - CSD Solenoid Valve Intermittent Failure (P1244) (7F802-02)

522242.03 - CSD Solenoid Valve Error B (P1243) (7F802-03)

522242.04 - CSD Solenoid Valve Error A (P1242) (7F802-04)

522243.02 - Start Assist Relay Intermittent Failure (P1234) (7F803-02)

522243.03 - Start Assist Relay Error B (P1233) (7F803-03)

522243.04 - Start Assist Relay Error A (P1232) (7F803-04)

522251.03 - EGR Valve Error B (Step Motor A-Phase) (P1403) (7F80B-03)

522251.04 - EGR Valve Error A (Step Motor A-Phase) (P1402) (7F80B-04)

522252.03 - EGR Valve Error B (Step Motor B-Phase) (P1413) (7F80C-03)

522252.04 - EGR Valve Error A (Step Motor B-Phase) (P1412) (7F80C-04)

522253.03 - EGR Valve Error B (Step Motor C-Phase) (P1423) (7F80D-03)

522253.04 - EGR Valve Error A (Step Motor C-Phase) (P1422) (7F80D-04)

522254.03 - EGR Valve Error B (Step Motor D-Phase) (P1433) (7F80E-03)

522254.04 - EGR Valve Error A (Step Motor D-Phase) (P1432) (7F80E-04)

522314.00 - Abnormal Water Temperature (P1217) (7F84A-00)

522323.00 - Air Cleaner Clogging Alarm (P1101) (7F853-00)

522329.00 - Oil/Water Separator Alarm (P1151) (7F859-00)

522402.04 - Spare Speed Sensor Error (P1340) (7F8A2-04)

522727.12 - ECU Internal Sub CPU Error A (P1610) (7F9E7-0C)

522727.12 - ECU Internal Sub CPU Error B (P1611) (7F9E7-0C)

522727.12 - ECU Internal Sub CPU Error C (P1612) (7F9E7-0C)

522728.12 - ECU Internal Map Format Error (P1620) (7F9E8-0C)

Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

Monitor Controller (DSZ) Diagnostic Trouble Codes

E:1100 - Engine Trouble Alarm

W:1100 - Engine Warning

W:1102 - Exhaust Filter Regeneration Request

W:1103 - Exhaust Filter Regeneration Inhibited Alarm

W:1104 - Intermediate Gas Temperature Sensor Error

W:1105 - Exhaust Filter Differential Pressure Sensor Error

W:1106 - Inlet Port Gas Temperature Sensor Error

W:1107 - Engine Injection Pressure Sensor Error

W:1108 - Exhaust Filter Gas Inlet Air Pressure Sensor Error

W:1109 - Engine Inlet Air Piping Abnormal Temperature

W:1110 - Air Heat Relay Error

W:1111 - Exhaust Filter Manual Regeneration Inhibited Alarm

W:1206 - Air Filter Restriction Alarm

W:1207 - Coolant Temperature Sensor Error

W:1208 - Engine Speed Sensor Error

W:1209 - Atmospheric Pressure Sensor Error

W:1210 - Water Separator Alarm

W:1211 - Ambient Air Temperature Sensor Error

W:1303 - Combustion Temperature Sensor Error

W:1304 - Engine Control Dial Error (CAN Signal)

W:1310 - CAN Communication Error

W:2201 - Overheat Alarm

W:2202 - Engine Oil Pressure Alarm

W:2304 - Fuel Sensor Error

W:2306 - Boom Bottom Pressure Sensor Error

W:2307 - Engine Control Dial Error (Analog Signal)

W:2310 - EEPROM Error

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Yanmar Engine

Engine Fuel System Component Location

Engine Cooling System Component Location

Cold Weather Starting Aid

Engine Speed Control System Operation

Group 15: Diagnostic Information

Yanmar Engine

Group 20: Adjustments

Engine Valve Lash (Clearance) Check and Adjustment

Group 25: Tests

Yanmar Engine

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Explanation of Wire Markings

Fuse and Relay Specifications

System Functional Schematic, Wiring Diagrams, and Component Locations Master Legend

System Functional Schematic

Floor Harness (W1) Component Location

Floor Harness (W1) Wiring Diagram

Engine Harness (W2) Component Location

Engine Harness (W2) Wiring Diagram

Air Conditioner Harness (W3) Component Location

Air Conditioner Harness (W3) Wiring Diagram

Console Harness (W4) Component Location

Console Harness (W4) Wiring Diagram

Cab Harness (W5) Component Location

Cab Harness (W5) Wiring Diagram

Auto-Shutdown Harness (W6) Component Location

Auto-Shutdown Harness (W6) Wiring Diagram

Auxiliary Function Lever Harness (W7) Component Location

Auxiliary Function Lever Harness (W7) Wiring Diagram

Air Conditioner Compressor Harness (W8) Component Location

Air Conditioner Compressor Harness (W8) Wiring Diagram

Boom Work Light Harness (W9) Component Location

Boom Work Light Harness (W9) Wiring Diagram

Canopy Work Light Harness (W13) Component Location

Canopy Work Light Harness (W13) Wiring Diagram

Angle Blade Floor Harness (W14) Component Location

Angle Blade Floor Harness (W14) Wiring Diagram

Angle Blade Solenoid Harness (W15) Component Location

Angle Blade Solenoid Harness (W15) Wiring Diagram

Windshield Wiper Extension Harness (W16) Component Location

Windshield Wiper Extension Harness (W16) Wiring Diagram

Windshield Wiper Harness (W17) Component Location

Windshield Wiper Harness (W17) Wiring Diagram

Group 15: Sub-System Diagnostics

Controller Area Network (CAN) Theory of Operation

Starting and Charging Circuit Theory of Operation

Auto-Shutdown Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Monitor Controller (DSZ) Circuit Theory of Operation

Pilot Shutoff Circuit Theory of Operation

Travel Speed Control and Alarm Circuit Theory of Operation

Windshield Wiper and Washer Circuit Theory of Operation

Lighting Circuit Theory of Operation

Heating and Air Conditioning Control Circuit Theory of Operation

Auxiliary Function Control Lever Circuit Theory of Operation

Group 16: Monitor Operation

Service Menu

Monitoring

Setting

Trouble Code Record

Group 20: References

Reading Diagnostic Trouble Codes With Monitor Display

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

Fuse Test

Relay Test

Pressure Sensor Test

Solenoid Test

Temperature Sensor Test

Alternator Test

Electrical Component Checks

Battery Remove and Install

Monitor Controller (DSZ) Remove and Install

Monitor Controller (DSZ) Replacement Calibration

Engine Control Unit (ECU) Remove and Install

Engine Control Unit (ECU) Replacement Calibration

Fuel Pump Replacement Calibration

Yanmar Display Calibration Values Test

Air Conditioner Controller (ACF) Remove and Install

Key Switch Remove and Install

Engine Speed Dial Remove and Install

Travel Alarm Remove and Install

Disconnect Tab Retainer Connectors

Disconnecting Spring Wire Clip Connectors

Replace DEUTSCH™ Connectors

Replace DEUTSCH™ Rectangular or Triangular Connectors

Install DEUTSCH™ Contact

Replace WEATHER PACK™ Connector

Install WEATHER PACK™ Contact

Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

Replace CINCH™ Connectors

Install CINCH™ Contact

Repair 32 and 48 Way CINCH™ Connectors

Remove Connector Body from Blade Terminals

Section 9020: Power Train

Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation

Travel Gear Case Operation

Group 15: Diagnostic Information

Noisy or Loose Track Chain

Tight Track Chain

Frequent Track Chain Sag Adjustment Required

Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers

Bent Track Shoes (Steel Track Only)

“Popping” of Track

Cracked Track Link

Chipped Link Rails

Individual Undercarriage Component Wear

Measure Swing Bearing Wear

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Operation

Pilot System Operation

Pilot Pump and Filter Operation

Solenoid Valve Manifold Operation

Pilot Shutoff Solenoid Valve Operation

Travel Speed Solenoid Valve Operation

Pilot Pressure Regulating Valve Operation

Pilot Control Valve Operation

Control Lever Pattern Selector Operation

Travel Pilot Control Valve Operation

Pilot Operation of Control Valve Operation

Hydraulic Pump 1 and 2 Operation

Hydraulic Pump Regulator Operation

Hydraulic Pump 3 Operation

Air Conditioner Torque Control Solenoid Valve Operation—If Equipped

Control Valve Operation

Control Valve Check Valves Operation

Main Relief Valve Operation

Circuit Relief and Anticavitation Valve Operation

Swing Boom Make-Up Valve Operation

Flow Combiner Valve Operation

Auxiliary Function Control Valve Operation

Boom Reduced Leakage Valve Operation

Arm Regenerative Valve Operation

Swing Reduction Gear Case Operation

Swing Motor Operation

Swing Motor Crossover Relief Valve Operation

Swing Motor Crossover Relief Valve Cushion Valve Operation

Swing Motor Make-Up Check Valve Operation

Swing Motor Park Brake Release Circuit Operation

Center Joint Operation

Travel Motor and Park Brake Valve Operation

Travel Motor Speed Circuit Operation

Blade Circuit Operation

Angle Blade Circuit Operation—If Equipped

Angle Blade Solenoid Valve Operation—If Equipped

Auxiliary Selector Valve Operation

Hydraulic Cylinder Operation

Return Filter Operation

Group 15: Diagnostic Information

All Hydraulic Functions Slow

Hydraulic Oil Overheats

No Hydraulic Functions

Poor Combined Operation

All Functions Cannot Be Operated

Function Does Not Stop When Control Lever Released

Some Functions Cannot Be Operated, All Others Are Normal

Functions Move in Opposite Direction

Arm and Boom Functions Do Not Operate or Do Not Operate as Expected

All Dig Functions Slow or No Power

Some Dig Functions Slow (Not All)

Load Drifts Down When Control Lever is in Neutral Position

Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle

Arm In Speed Slow

Swing Speed Slow in Both Directions

Swing Speed Slow or Does Not Operate in One Direction

Upperstructure Drift With Swing Valve in Neutral

Swing Function Does Not Operate

Travel Park Brakes Do Not Apply

Track Will Not Move in One Direction

Track Will Not Move in Either Direction

Machine Mistracks at All Speeds in Both Directions

Machine Mistracks in High Speed Only, or Mistracks One Direction in High Speed and the Other Direction in Low Speed

Slow Travel Speed or Low Power

Travel Speed Does Not Change to Slow Speed

Combined Travel and Dig Functions Slow or No Power

Travel is “Jerky”

Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline

Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs

Swing Boom Does Not Move or Moves Slowly

Blade Does Not Move or Moves Slowly

Pump 1, Pump 2, Pump 3, and Pilot Pump Line Identification

Control Valve Line Identification

Pilot Control Lever Pattern Selector Valve Line Connection

Swing Motor Line Identification

Travel System Component Location

Travel Hydraulic System Line Connection

Blade System Component Location

Blade Hydraulic System Line Connection

Hydraulic System Schematic

Hydraulic System Component Location

Hydraulic System Pilot Line Connection

Hydraulic System Main Line Connection

Angle Blade Component Location—If Equipped

Angle Blade Hydraulic System Line Connection—If Equipped

Group 25: Tests

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure and Temperature Analyzer Installation

General Hydraulic Oil Cleanup Procedure

Hydraulic Component Failure Cleanup Procedure

Hydraulic Oil Tank Pressure Release Procedure

Hydraulic System Warm-Up Procedure

Pilot Pressure Regulating Valve Test and Adjustment

Control Valve Spool Pilot Actuating Pressure Test

Hydraulic Pump 1, 2, and 3 Main Relief Valve Test and Adjustment

Circuit Relief and Anticavitation Valve Test and Adjustment

Swing Motor Crossover Relief Valve Test and Adjustment

Hydraulic Pump Flow Test

Swing Motor Leakage Test

Travel Motor Leakage Test

Air Conditioner Torque Control Solenoid Valve Test

Cylinder Drift Test—Boom, Arm, Bucket, and Blade

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle of Operation

Group 15: Diagnostic Information

Air Conditioning System Does Not Operate

No Air Flow From Heater and Air Conditioner Vents

Air Conditioning Does Not Cool Interior of Cab

Air Conditioning Runs Constantly, Too Cold

Interior Windows Continue to Fog Using Air Conditioner

Heater System Does Not Operate

Heater Does Not Warm Interior of Cab

Interior Windows Continue to Fog Using Heater

Heater and Air Conditioner Component Location

Group 25: Tests

Refrigerant Cautions and Proper Handling

Heater and Air Conditioner Operational Checks

Refrigerant Leak Test

Air Conditioner Compressor Clutch Test

Refrigerant Hoses and Tubing Inspection

Air Conditioner Compressor Belt Check

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

John Deere 35G Compact Excavator Operation and Test Service Manual (TM12891)