John Deere 135G Excavator Diagnostic Operation and Test Manual

John Deere 135G Excavator Diagnostic Operation and Test Manual

John Deere 135G Excavator Diagnostic Operation and Test Manual

TM12666

John Deere Repair Manual

John Deere 135G Excavator: Diagnostic and Test Manual (Often part of the larger “Technical Manual” set, which includes Operation & Maintenance).
Primary Function: To provide technicians with system theory, diagnostic procedures, troubleshooting guides, testing specifications, and adjustment procedures for all major machine systems.

John Deere 135G Excavator Diagnostic Operation and Test Manual

Detailed Contents Breakdown

Section 1: General Information

  • Machine Identification (Serial Number Locations)

  • Manual Use and Safety Messages

  • General Specifications (Weight, Dimensions, Engine Model, Capacities)

  • Fluid Recommendations and Viscosity Charts

  • Maintenance Interval Schedule (Fuel, Oil, Filter, Grease, Inspection Checkpoints)

  • Break-in Procedures

Section 2: Machine Systems

  • Theory of Operation: Detailed explanations of how each system functions.

  • Hydraulic System: Main pump (variable displacement piston pump), control valves, pressure compensator, pilot system, swing drive, travel motors, and hydraulic schematics.

  • Power Train: Final drives, swing mechanism, and travel brake operation.

  • Electronic Control System (If Equipped): Overview of the John Deere Control System (JDCS) or equivalent, including controller functions and sensor locations.

Section 3: Diagnostics

  • Diagnostic Trouble Code (DTC) List: Complete table of all possible codes (e.g., engine CAN bus codes, hydraulic sensor codes).

  • Troubleshooting Procedures: Step-by-step guides for symptoms without active codes (e.g., “Weak Excavator Force,” “Slow Travel,” “Engine Does Not Start,” “Swing Drift”).

  • Electrical Schematic Diagrams: Full-color, system-specific schematics with connector pin-outs.

Section 4: Testing and Adjusting

  • This is the Core Technical Section. Each sub-section includes:

    • Specifications: Performance standards (e.g., pump flow rates, relief valve pressures, engine high/low idle RPM).

    • Required Tools: Special service tools (e.g., pressure gauges, flow meters, JDdiagnostic adapter).

    • Test Procedures: How to connect tools, activate systems, and take measurements.

    • Adjustment Procedures: Steps to bring systems into specification.

  • Sub-Section Chapters:

    • Engine (John Deere 4045 or equivalent): Performance checks, cylinder contribution, injector tests.

    • Hydraulic System: Main pump output flow and pressure, pump servo pressure, pilot pressure, slew brake release pressure, swing relief pressure.

    • Control Valves: Individual valve section pressures (e.g., arm, boom, bucket, travel).

    • Cylinders: Drift check procedures (to diagnose internal leakage).

    • Electrical System: Sensor and switch testing (pressure sensors, angle sensors, control levers).

    • Power Train: Travel motor performance, brake holding force, swing motor torque.

Section 5: Schematics and Diagrams

  • Complete Hydraulic Schematic: With component call-outs and pressure test port locations.

  • Complete Electrical Schematic: Including power distribution, controller wiring, and ground locations.

  • Lubrication Diagram: Grease fitting locations and specifications.

  • Component Location Views: Major hydraulic and electrical component positions on the machine.

Section 6: Appendices and Reference

  • Torque Specifications: For engine, hydraulic fittings, and major structural bolts.

  • O-ring and Seal Kit Lists.

  • Cross-reference to Part Numbers for key service components.

  • Glossary of Terms.

John Deere 135G Excavator Diagnostic Operation and Test Manual