John Deere 35G Compact Excavator Operation and Test Service Manual (TM12891) PDF - MJODTM12891.zip

A full service, diagnostics, and testing guide featuring electrical schematics for the John Deere 35G Compact Excavator, packed with the technical data needed to service, troubleshoot, and overhaul the machine the way expert technicians do.

The John Deere 35G Compact Excavator Operation and Test workshop guide covers:

* 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

PRODUCT DETAILS:

Total Pages: 805 pages

File Format: PDF (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