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 English - John Deere 35G Compact Excavator Technical Manual - Operation and Test.pdf
tm12892 French - Excavatrice 35G
tm12893 Spanish - Excavadora 35G

PRODUCT DETAILS:
Total Pages: 805 pages
File Format: PDF (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

TABLE OF CONTENTS
Section 9000: General Information....15
  Group 01: Safety....15
    Recognize Safety Information....18
    Follow Safety Instructions....19
    Operate Only If Qualified....20
    Wear Protective Equipment....21
    Avoid Unauthorized Machine Modifications....22
    Control Pattern Selector—If Equipped....23
    Add Cab Guarding for Special Uses....24
    Inspect Machine....25
    Stay Clear of Moving Parts....26
    Avoid High-Pressure Fluids....27
    Avoid High-Pressure Oils....28
    Work In Ventilated Area....29
    Prevent Fires....30
    Prevent Battery Explosions....31
    Handle Chemical Products Safely....32
    Decommissioning — Proper Recycling and Disposal of Fluids and Components....33
    Prepare for Emergencies....34
    Clean Debris from Machine....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
    Avoid Work Site Hazards....40
    Keep Riders Off Machine....42
    Avoid Backover Accidents....43
    Inspect and Maintain ROPS....44
    Avoid Machine Tip Over....45
    Use Special Care When Lifting Objects....47
    Add and Operate Attachments Safely....48
    Park and Prepare for Service Safely....49
    Service Cooling System Safely....50
    Remove Paint Before Welding or Heating....51
    Make Welding Repairs Safely....52
    Drive Metal Pins Safely....53
Section 9001: Diagnostics....54
  Group 10: Engine Control Unit (ECU) Diagnostic Trouble Codes....58
    Engine Control Unit (ECU) Diagnostic Trouble Codes....58
    000029.08 - Spare Accelerator Sensor Error (Pulse Communication) (P1227) (0001D-08)....54
    000091.02 - Accelerator Sensor Intermittent Failure (P0124) (0005B-02)....54
    000091.03 - Acceleration Sensor Error (High Voltage) (P0123) (0005B-03)....54
    000091.04 - Acceleration Sensor Error (Low Voltage) (P0122) (0005B-04)....54
    000100.01 - Oil Pressure Descend Error (P1198) (00064-01)....54
    000100.04 - Oil Pressure Switch Error (P1192) (00064-04)....54
    000110.00 - Cooling Water Temperature Rise Alarm (Overheat) (P0217) (0006E-00)....54
    000110.02 - Cooling Water Temperature Sensor Intermittent Failure (P0119) (0006E-02)....54
    000110.03 - Cooling Water Temperature Sensor Error (High Voltage) (P0118) (0006E-03)....54
    000110.04 - Cooling Water Temperature Sensor Error (Low Voltage) (P0117) (0006E-04)....54
    000158.00 - Power Supply Voltage Error (High Voltage) (P0563) (0009E-00)....54
    000158.01 - Power Supply Voltage Error (Low Voltage) (P0562) (0009E-01)....54
    000167.01 - Charge Alarm (P1568) (000A7-01)....54
    000167.04 - Charge Switch Error (P1562) (000A7-04)....54
    000190.00 - Overspeed Error (P0219) (000BE-00)....54
    000628.02 - ECU Internal Flash ROM Error (Checksum B) (P1605) (00274-02)....54
    000628.02 - ECU Internal Flash ROM Error (Checksum C) (P1606) (00274-02)....54
    000628.12 - ECU Internal Flash ROM Error (Checksum A) (P0605) (00274-0C)....54
    000630.02 - ECU Internal EEPROM Error (Checksum) (P1601) (00276-02)....54
    000630.12 - ECU Internal EEPROM Error (Read/Write Error) (P0601) (00276-0C)....54
    000638.02 - Engine Error (P1214) (0027E-02)....54
    000638.03 - Rack Actuator Error (High Current) (P1213) (0027E-03)....54
    000638.04 - Rack Actuator Error (Low Current) (P1212) (0027E-04)....54
    000638.07 - Rack Actuator Mechanical Failure (P1211) (0027E-07)....54
    000639.12 - CAN Communication Error (U0001) (0027F-0C)....54
    001078.04 - Speed Sensor Error (P0340) (00436-04)....54
    001079.02 - Sensor 5 V Intermittent Failure (P1644) (00437-02)....54
    001079.03 - Sensor 5 V Error (High Voltage) (P0643) (00437-03)....54
    001079.04 - Sensor 5 V Error (Low Voltage) (P0642) (00437-04)....54
    001136.01 - ECU Temperature Rise Alarm (P0634) (00470-00)....54
    001136.02 - ECU Temperature Sensor Intermittent Failure (P1664) (00470-02)....55
    001136.03 - ECU Temperature Sensor Error (High Voltage) (P0669) (00470-03)....55
    001136.04 - ECU Temperature Sensor Error (Low Voltage) (P0668) (00470-04)....55
    001210.03 - Rack Position Sensor Error (High Voltage) (P1203) (004BA-03)....55
    001210.04 - Rack Position Sensor Error (Low Voltage) (P1202) (004BA-04)....55
    001485.04 - Main Relay Error (P0686) (005CD-04)....55
    522241.02 - Rack Actuator Relay Intermittent Failure (P1224) (7F801-02)....55
    522241.03 - Rack Actuator Relay Error B (P1223) (7F801-03)....55
    522241.04 - Rack Actuator Relay Error A (P1222) (7F801-04)....55
    522242.02 - CSD Solenoid Valve Intermittent Failure (P1244) (7F802-02)....55
    522242.03 - CSD Solenoid Valve Error B (P1243) (7F802-03)....55
    522242.04 - CSD Solenoid Valve Error A (P1242) (7F802-04)....55
    522243.02 - Start Assist Relay Intermittent Failure (P1234) (7F803-02)....55
    522243.03 - Start Assist Relay Error B (P1233) (7F803-03)....55
    522243.04 - Start Assist Relay Error A (P1232) (7F803-04)....55
    522251.03 - EGR Valve Error B (Step Motor A-Phase) (P1403) (7F80B-03)....55
    522251.04 - EGR Valve Error A (Step Motor A-Phase) (P1402) (7F80B-04)....55
    522252.03 - EGR Valve Error B (Step Motor B-Phase) (P1413) (7F80C-03)....55
    522252.04 - EGR Valve Error A (Step Motor B-Phase) (P1412) (7F80C-04)....55
    522253.03 - EGR Valve Error B (Step Motor C-Phase) (P1423) (7F80D-03)....55
    522253.04 - EGR Valve Error A (Step Motor C-Phase) (P1422) (7F80D-04)....55
    522254.03 - EGR Valve Error B (Step Motor D-Phase) (P1433) (7F80E-03)....55
    522254.04 - EGR Valve Error A (Step Motor D-Phase) (P1432) (7F80E-04)....55
    522314.00 - Abnormal Water Temperature (P1217) (7F84A-00)....55
    522323.00 - Air Cleaner Clogging Alarm (P1101) (7F853-00)....55
    522329.00 - Oil/Water Separator Alarm (P1151) (7F859-00)....55
    522402.04 - Spare Speed Sensor Error (P1340) (7F8A2-04)....55
    522727.12 - ECU Internal Sub CPU Error A (P1610) (7F9E7-0C)....55
    522727.12 - ECU Internal Sub CPU Error B (P1611) (7F9E7-0C)....55
    522727.12 - ECU Internal Sub CPU Error C (P1612) (7F9E7-0C)....55
    522728.12 - ECU Internal Map Format Error (P1620) (7F9E8-0C)....55
  Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes....121
    Monitor Controller (DSZ) Diagnostic Trouble Codes....121
    E:1100 - Engine Trouble Alarm....56
    W:1100 - Engine Warning....56
    W:1102 - Exhaust Filter Regeneration Request....56
    W:1103 - Exhaust Filter Regeneration Inhibited Alarm....56
    W:1104 - Intermediate Gas Temperature Sensor Error....56
    W:1105 - Exhaust Filter Differential Pressure Sensor Error....56
    W:1106 - Inlet Port Gas Temperature Sensor Error....56
    W:1107 - Engine Injection Pressure Sensor Error....56
    W:1108 - Exhaust Filter Gas Inlet Air Pressure Sensor Error....56
    W:1109 - Engine Inlet Air Piping Abnormal Temperature....56
    W:1110 - Air Heat Relay Error....56
    W:1111 - Exhaust Filter Manual Regeneration Inhibited Alarm....56
    W:1206 - Air Filter Restriction Alarm....56
    W:1207 - Coolant Temperature Sensor Error....56
    W:1208 - Engine Speed Sensor Error....56
    W:1209 - Atmospheric Pressure Sensor Error....56
    W:1210 - Water Separator Alarm....56
    W:1211 - Ambient Air Temperature Sensor Error....56
    W:1303 - Combustion Temperature Sensor Error....56
    W:1304 - Engine Control Dial Error (CAN Signal)....56
    W:1310 - CAN Communication Error....56
    W:2201 - Overheat Alarm....56
    W:2202 - Engine Oil Pressure Alarm....56
    W:2304 - Fuel Sensor Error....56
    W:2306 - Boom Bottom Pressure Sensor Error....56
    W:2307 - Engine Control Dial Error (Analog Signal)....56
    W:2310 - EEPROM Error....56
Section 9005: Operational Checkout Procedure....169
  Group 10: Operational Checkout Procedure....169
    Operational Checkout....217
Section 9010: Engine....264
  Group 05: Theory of Operation....264
    Yanmar Engine....280
    Engine Fuel System Component Location....267
    Engine Cooling System Component Location....269
    Cold Weather Starting Aid....271
    Engine Speed Control System Operation....272
  Group 15: Diagnostic Information....264
    Yanmar Engine....280
  Group 20: Adjustments....264
    Engine Valve Lash (Clearance) Check and Adjustment....278
  Group 25: Tests....264
    Yanmar Engine....280
Section 9015: Electrical System....281
  Group 05: System Information....281
    Electrical Diagram Information....292
  Group 10: System Diagrams....281
    Explanation of Wire Markings....301
    Fuse and Relay Specifications....302
    System Functional Schematic, Wiring Diagrams, and Component Locations Master Legend....305
    System Functional Schematic....308
    Floor Harness (W1) Component Location....313
    Floor Harness (W1) Wiring Diagram....315
    Engine Harness (W2) Component Location....319
    Engine Harness (W2) Wiring Diagram....322
    Air Conditioner Harness (W3) Component Location....326
    Air Conditioner Harness (W3) Wiring Diagram....329
    Console Harness (W4) Component Location....330
    Console Harness (W4) Wiring Diagram....331
    Cab Harness (W5) Component Location....332
    Cab Harness (W5) Wiring Diagram....333
    Auto-Shutdown Harness (W6) Component Location....334
    Auto-Shutdown Harness (W6) Wiring Diagram....335
    Auxiliary Function Lever Harness (W7) Component Location....336
    Auxiliary Function Lever Harness (W7) Wiring Diagram....337
    Air Conditioner Compressor Harness (W8) Component Location....338
    Air Conditioner Compressor Harness (W8) Wiring Diagram....339
    Boom Work Light Harness (W9) Component Location....340
    Boom Work Light Harness (W9) Wiring Diagram....341
    Canopy Work Light Harness (W13) Component Location....342
    Canopy Work Light Harness (W13) Wiring Diagram....343
    Angle Blade Floor Harness (W14) Component Location....344
    Angle Blade Floor Harness (W14) Wiring Diagram....345
    Angle Blade Solenoid Harness (W15) Component Location....346
    Angle Blade Solenoid Harness (W15) Wiring Diagram....347
    Windshield Wiper Extension Harness (W16) Component Location....348
    Windshield Wiper Extension Harness (W16) Wiring Diagram....349
    Windshield Wiper Harness (W17) Component Location....350
    Windshield Wiper Harness (W17) Wiring Diagram....351
  Group 15: Sub-System Diagnostics....282
    Controller Area Network (CAN) Theory of Operation....355
    Starting and Charging Circuit Theory of Operation....358
    Auto-Shutdown Circuit Theory of Operation....361
    Engine Control Unit (ECU) Circuit Theory of Operation....363
    Monitor Controller (DSZ) Circuit Theory of Operation....368
    Pilot Shutoff Circuit Theory of Operation....372
    Travel Speed Control and Alarm Circuit Theory of Operation....374
    Windshield Wiper and Washer Circuit Theory of Operation....377
    Lighting Circuit Theory of Operation....379
    Heating and Air Conditioning Control Circuit Theory of Operation....381
    Auxiliary Function Control Lever Circuit Theory of Operation....385
  Group 16: Monitor Operation....282
    Service Menu....390
    Monitoring....393
    Setting....396
    Trouble Code Record....398
  Group 20: References....282
    Reading Diagnostic Trouble Codes With Monitor Display....402
    Service ADVISOR™ Diagnostic Application....404
    Service ADVISOR™ Connection Procedure....405
    Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application....407
    Fuse Test....410
    Relay Test....413
    Pressure Sensor Test....416
    Solenoid Test....418
    Temperature Sensor Test....419
    Alternator Test....420
    Electrical Component Checks....424
    Battery Remove and Install....429
    Monitor Controller (DSZ) Remove and Install....431
    Monitor Controller (DSZ) Replacement Calibration....434
    Engine Control Unit (ECU) Remove and Install....439
    Engine Control Unit (ECU) Replacement Calibration....441
    Fuel Pump Replacement Calibration....445
    Yanmar Display Calibration Values Test....447
    Air Conditioner Controller (ACF) Remove and Install....448
    Key Switch Remove and Install....450
    Engine Speed Dial Remove and Install....454
    Travel Alarm Remove and Install....455
    Disconnect Tab Retainer Connectors....456
    Disconnecting Spring Wire Clip Connectors....457
    Replace DEUTSCH™ Connectors....458
    Replace DEUTSCH™ Rectangular or Triangular Connectors....460
    Install DEUTSCH™ Contact....462
    Replace WEATHER PACK™ Connector....464
    Install WEATHER PACK™ Contact....466
    Replace (Pull Type) Metri-Pack™ Connectors....468
    Replace (Push Type) Metri-Pack™ Connectors....470
    Replace CINCH™ Connectors....471
    Install CINCH™ Contact....473
    Repair 32 and 48 Way CINCH™ Connectors....475
    Remove Connector Body from Blade Terminals....479
Section 9020: Power Train....480
  Group 05: Theory of Operation....480
    Track Adjuster and Recoil Spring Operation....482
    Travel Gear Case Operation....483
  Group 15: Diagnostic Information....480
    Noisy or Loose Track Chain....480
    Tight Track Chain....480
    Frequent Track Chain Sag Adjustment Required....480
    Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers....480
    Bent Track Shoes (Steel Track Only)....480
Section 9025: Hydraulic System....504
  Group 05: Theory of Operation....504
    Hydraulic System Operation....509
    Pilot System Operation....510
    Pilot Pump and Filter Operation....511
    Solenoid Valve Manifold Operation....512
    Pilot Shutoff Solenoid Valve Operation....514
    Travel Speed Solenoid Valve Operation....519
    Pilot Pressure Regulating Valve Operation....521
    Pilot Control Valve Operation....542
    Control Lever Pattern Selector Operation....525
    Travel Pilot Control Valve Operation....542
    Pilot Operation of Control Valve Operation....542
    Hydraulic Pump 1 and 2 Operation....533
    Hydraulic Pump Regulator Operation....535
    Hydraulic Pump 3 Operation....537
    Air Conditioner Torque Control Solenoid Valve Operation—If Equipped....539
    Control Valve Operation....542
    Control Valve Check Valves Operation....559
    Main Relief Valve Operation....563
    Circuit Relief and Anticavitation Valve Operation....565
    Swing Boom Make-Up Valve Operation....570
    Flow Combiner Valve Operation....572
    Auxiliary Function Control Valve Operation....575
    Boom Reduced Leakage Valve Operation....578
    Arm Regenerative Valve Operation....581
    Swing Reduction Gear Case Operation....584
    Swing Motor Operation....586
    Swing Motor Crossover Relief Valve Operation....588
    Swing Motor Crossover Relief Valve Cushion Valve Operation....591
    Swing Motor Make-Up Check Valve Operation....592
    Swing Motor Park Brake Release Circuit Operation....593
    Center Joint Operation....596
    Travel Motor and Park Brake Valve Operation....597
    Travel Motor Speed Circuit Operation....603
    Blade Circuit Operation....606
    Angle Blade Circuit Operation—If Equipped....608
    Angle Blade Solenoid Valve Operation—If Equipped....610
    Auxiliary Selector Valve Operation....611
    Hydraulic Cylinder Operation....613
    Return Filter Operation....614
  Group 15: Diagnostic Information....505
    All Hydraulic Functions Slow....505
    Hydraulic Oil Overheats....505
    No Hydraulic Functions....505
    Poor Combined Operation....505
    All Functions Cannot Be Operated....505
    Function Does Not Stop When Control Lever Released....505
    Some Functions Cannot Be Operated, All Others Are Normal....505
    Functions Move in Opposite Direction....505
    Arm and Boom Functions Do Not Operate or Do Not Operate as Expected....505
    All Dig Functions Slow or No Power....505
    Some Dig Functions Slow (Not All)....505
    Load Drifts Down When Control Lever is in Neutral Position....505
    Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle....505
    Arm In Speed Slow....505
    Swing Speed Slow in Both Directions....505
    Swing Speed Slow or Does Not Operate in One Direction....505
    Upperstructure Drift With Swing Valve in Neutral....505
    Swing Function Does Not Operate....505
    Travel Park Brakes Do Not Apply....505
    Track Will Not Move in One Direction....505
    Track Will Not Move in Either Direction....505
    Machine Mistracks at All Speeds in Both Directions....505
    Machine Mistracks in High Speed Only, or Mistracks One Direction in High Speed and the Other Direction in Low Speed....505
    Slow Travel Speed or Low Power....506
    Travel Speed Does Not Change to Slow Speed....506
    Combined Travel and Dig Functions Slow or No Power....506
    Travel is “Jerky”....506
    Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline....506
    Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs....506
    Swing Boom Does Not Move or Moves Slowly....506
    Blade Does Not Move or Moves Slowly....506
    Pump 1, Pump 2, Pump 3, and Pilot Pump Line Identification....682
    Control Valve Line Identification....683
    Pilot Control Lever Pattern Selector Valve Line Connection....685
    Swing Motor Line Identification....686
    Travel System Component Location....687
    Travel Hydraulic System Line Connection....688
    Blade System Component Location....689
    Blade Hydraulic System Line Connection....690
    Hydraulic System Schematic....692
    Hydraulic System Component Location....700
    Hydraulic System Pilot Line Connection....703
    Hydraulic System Main Line Connection....705
    Angle Blade Component Location—If Equipped....706
    Angle Blade Hydraulic System Line Connection—If Equipped....707
  Group 25: Tests....506
    JT05800 Digital Thermometer Installation....710
    JT02156A Digital Pressure and Temperature Analyzer Installation....711
    General Hydraulic Oil Cleanup Procedure....712
    Hydraulic Component Failure Cleanup Procedure....715
    Hydraulic Oil Tank Pressure Release Procedure....718
    Hydraulic System Warm-Up Procedure....720
    Pilot Pressure Regulating Valve Test and Adjustment....722
    Control Valve Spool Pilot Actuating Pressure Test....725
    Hydraulic Pump 1, 2, and 3 Main Relief Valve Test and Adjustment....728
    Circuit Relief and Anticavitation Valve Test and Adjustment....732
    Swing Motor Crossover Relief Valve Test and Adjustment....737
    Hydraulic Pump Flow Test....740
    Swing Motor Leakage Test....745
    Travel Motor Leakage Test....748
    Air Conditioner Torque Control Solenoid Valve Test....750
    Cylinder Drift Test—Boom, Arm, Bucket, and Blade....753
Section 9031: Heating and Air Conditioning....757
  Group 05: Theory of Operation....757
    Air Conditioning System Cycle of Operation....760
  Group 15: Diagnostic Information....757
    Air Conditioning System Does Not Operate....757
    No Air Flow From Heater and Air Conditioner Vents....757
    Air Conditioning Does Not Cool Interior of Cab....757
    Air Conditioning Runs Constantly, Too Cold....757
    Interior Windows Continue to Fog Using Air Conditioner....757
    Heater System Does Not Operate....757
    Heater Does Not Warm Interior of Cab....757
    Interior Windows Continue to Fog Using Heater....757
    Heater and Air Conditioner Component Location....787
  Group 25: Tests....757
    Refrigerant Cautions and Proper Handling....792
    Heater and Air Conditioner Operational Checks....793
    Refrigerant Leak Test....796
    Air Conditioner Compressor Clutch Test....797
    Refrigerant Hoses and Tubing Inspection....798
    Air Conditioner Compressor Belt Check....799
    R134a Air Conditioning System Test....800
    Operating Pressure Diagnostic Chart....803

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