John Deere 35G Excavator Repair Guide Part 1: Engine Problems

Introduction: Scope, Audience, and Importance

This comprehensive guide is designed specifically for John Deere 35G owners and operators seeking to troubleshoot and repair their John Deere 35G engine. Maintaining the engine is crucial for ensuring optimal performance, minimizing costly downtime, and extending the life of your excavator. The John Deere 35G engine is the heart of your machine, directly influencing its power, productivity, and reliability on the job site. The John Deere 35G uses a Yanmar engine, renowned for its durability and efficiency. It delivers a net engine output of 17.4 kW (23.3 hp), making it a robust choice for a wide range of construction and landscaping tasks. By understanding the engine’s key features and following systematic troubleshooting steps, you can keep your equipment running smoothly and avoid unexpected breakdowns.

 

John Deere 35G Engine Overview

The John Deere 35G is powered by a Yanmar engine.

Net Engine Output: 17.4 kW (23.3 hp)

Emissions Rating: Meets current EPA Final Tier 4/EU Stage IV emissions standards

Engine Type: 3-cylinder, liquid-cooled diesel

Manufacturer: Yanmar

Importance: The engine’s performance is central to the excavator’s productivity, fuel efficiency, and longevity.

 

Introduction to Engine Repair

The John Deere 35G excavator stands out among major brand machines for its reliability and robust performance, but even the best equipment requires regular maintenance and occasional repair to keep running at peak efficiency. Engine repair is at the heart of maintaining your John Deere 35G, as the engine’s health directly influences the machine’s power, productivity, and overall lifespan. Whether you’re operating on a busy construction site or tackling landscaping projects, a well-maintained engine ensures your excavator delivers consistent performance and minimizes costly downtime.

 

Features like auto idle help improve fuel efficiency and reduce unnecessary engine wear by automatically lowering engine speed when the equipment is not in use. Monitoring for normal engine temperature and emissions is important to catch issues early. The operator plays a crucial role in performing regular maintenance and following best practices for engine care to ensure optimal performance and longevity.

When approaching engine repair, it’s essential to start with the basics:

• Check for adequate oil
• Inspect the air and fuel filters
• Verify fluid levels

 

These simple steps can often prevent more serious issues down the line. For the Deere 35G, using high-quality replacement parts from trusted brands is key. Look for components that offer a lifetime limited warranty to guarantee long-term reliability and peace of mind. By understanding your machine’s engine systems and following a systematic troubleshooting process, you can catch potential problems early, extend the life of your equipment, and maintain the high standards expected from a John Deere excavator. Remember, investing in proper maintenance and repair today means more power, better efficiency, and fewer headaches tomorrow.

 

Engine Cranks But Won't Start Or Hard To Start

Is your John Deere 35G engine refusing to start or giving you a hard time starting? Follow these expert troubleshooting steps to get your engine up and running smoothly.

1. Check the Fuel Tank

• Ensure the fuel tank is not empty. If low, fill it to the recommended level.

 

2. Verify the Fuel Type

• Confirm you are using the correct fuel type, especially when transitioning between winter and summer blends. If incorrect, drain and refill with the appropriate blend.

 

Bleeding the Air

1. Bleed Air from the Fuel System

• Ensure the fuel tank is full.
• Confirm the fuel shutoff valve is open.
• Turn the key switch to the ON position for 10–15 seconds to activate the electric fuel solenoid pump and bleed air.
• Wait 30 seconds before attempting to start the engine.
• Start the engine and inspect the fuel supply system for leaks. If the engine doesn't start, repeat the procedure.

 

Inspecting Fuel Filters

1. Check the Fuel Filter

• Replace a clogged filter or verify correct installation.
• Signs of a clogged filter include a darker appearance, stains or wet spots around connections, and a strong odor.

 

Inspecting Air Filters

1. Inspect the Air Filters

• Replace dirty air filters as needed.

 

Checking Fuel and Water Separator

1. Primary Fuel and Water Filter Separator

• Ensure correct installation and that the filter has been primed after installation.
• Change the O-ring every time you replace the fuel filter.
• To prime: Turn ignition on for 30 seconds without starting the engine; Turn ignition off and crank the engine for 15 seconds; If the engine still doesn't start, repeat the first step.

 

Battery and Electrical Checks

1. Electrical Connections and Battery

• Clean and tighten battery and starter connections.
• Charge the battery.
• If the issue persists, consider replacing the battery.

 

Checking Engine Oil

1. Engine Oil Viscosity

• Ensure the engine oil has the correct viscosity. If not, drain and refill with the appropriate oil.

If your engine still won't start after these steps, proceed to the next section for additional troubleshooting.

 

Engine Won't Crank

Follow these guidelines carefully to get your engine up and running smoothly again.

 

Battery and Electrical Checks

1. Clean Battery Terminals and Connections

• Use a battery terminal cleaner or a mixture of baking soda and water to remove any build-up.
• Ensure connections are tight and secure, and consider following a detailed John Deere 35G electrical system repair guide if you suspect deeper electrical issues.

 

2. Check for Loose Connections

• Inspect all engine system connections for looseness and tighten as needed.

 

Inspecting Fuses

1. Inspect the Fuses

Check the following fuses:

• Main relay 10 amp fuse (F4)
• Start 5 amp fuse (F6)
• Engine 5 amp fuse (F16)
• Pilot shut off 5 amp fuse (F17)
• Engine Control Unit 30 amp fuse (F63)

Access the fuse panel by locating the right control lever and removing the cover.

Replace any blown or damaged fuses with the same rating.

 

Checking Battery Level

1. Check Battery Level

• Use a multimeter to check battery voltage.
• If voltage is below the recommended level, charge or replace the battery.

If your engine still won't crank after these steps, continue to the next troubleshooting section.

 

Engine Knocks, Runs Irregularly, Or Stops

If your engine is knocking, running irregularly, or stopping, follow these steps:

Replace Clogged Air and Fuel Filters

• Replace both air and fuel filters if clogged.

Clean the Fuel Tank Inlet Screen

• Remove and clean the inlet screen to ensure proper fuel flow.

Reinstall Fuel Filter Properly

• If the fuel filter is not too dirty, reinstall it with the O-ring seal in place.

 

Bleeding Air

Bleed Air from the System

• Follow the air bleeding procedure as described in the previous section.

 

Checking Oil and Fuel Quality

Inspect Engine Oil Level

• Low oil can cause excessive friction and affect performance.

Check Fuel Quality

• Drain the fuel tank, change the primary fuel filter and water separator, bleed air, add fresh fuel, and clean the fuel tank inlet screen.
• Prime the system before starting the excavator.

 

If the engine continues to run irregularly or stops, proceed to the next troubleshooting section.

 

Engine Not Developing Full Power

If your John Deere 35G’s engine is not reaching its full power potential, take these steps:

 

Checking Idle RPM

1. Check the Idle RPM

• When the engine is warm, idle RPM should be between 1,300 and 1,350 RPM.
• Ensure the engine speed dial is in the high position.
• If the auto idle feature is not functioning, troubleshoot the auto idle system.

 

Hydraulic System Checks

1. Release Hydraulic Functions

• Release all hydraulic functions for 10 seconds and observe if the idle stabilizes; persistent issues may indicate problems best addressed with a dedicated John Deere 35G hydraulic system troubleshooting guide.

 

Inspecting Filters

1. Inspect Fuel and Air Filters

• Regularly inspect and replace filters as needed.
• Ensure any air trapped in the fuel system is bled properly.

 

Checking Fuel Type and Contamination

1. Fuel Type and Contamination

• Use the correct fuel type.
• If contamination is suspected, drain the tank, replace the primary fuel filter and water separator, bleed air, and refill with clean fuel.

 

Seeking Professional Help

1. Authorized Dealer Assistance

• If the problem persists, contact your authorized dealer for diagnosis and resolution of potential hydraulic issues, restricted exhaust system problems, or engine wear.

 

If your engine still lacks full power, consult your dealer or continue to the next troubleshooting section.

 

Engine Emits Excessive Black Exhaust Smoke

Under normal operating conditions, the exhaust from a John Deere 35G engine should be clear or light in color; excessive black smoke is not normal and indicates a problem.

 

Troubleshooting Black Smoke

Check Fuel Type

• Ensure you’re using the correct fuel. If not, drain and refill. Hard starting, stalling, or excessive smoke can also stem from a failing fuel shut-off solenoid and its symptoms.

 

Inspect Air Intake and Exhaust System

• Look for restrictions or dirt. If you find a cracked or damaged exhaust system, contact your authorized dealer.

 

Verify Thermostat Function

• If the thermostat is stuck open, the engine may run too cool, causing incomplete combustion and black or gray smoke.

 

If black smoke persists, seek assistance from a qualified technician.

 

Engine Oil and Cooling System Problems

Engine oil and cooling system issues can have a major impact on the performance and durability of your John Deere 35G excavator. Regularly checking oil levels and monitoring the condition of your hydraulic tank are essential steps in preventing engine damage and ensuring your machine operates at its best; following a step-by-step engine oil and oil filter change procedure on similar excavators can help you develop good service habits. The capacities of both the fuel tank and hydraulic system should be kept within recommended ranges to avoid overheating and maintain optimal system performance.

 

Troubleshooting Oil and Cooling System Issues

If you encounter problems with engine oil or the cooling system, it’s important to consult your operator’s manual or reach out to an authorized dealer for expert guidance. Issues like overheating may also point to failing components such as the engine oil cooler and its common symptoms. Using OEM motors and replacement parts—manufactured in the same factories as original equipment—ensures a guaranteed fit and reliable operation. When selecting parts, consider key specifications such as track length, track rollers, dig depth, dozer blade width, and undercarriage dimensions to ensure compatibility with your John Deere 35G. These factors not only affect installation but also influence the machine’s transport length, transport height, and overall operating weight, which are critical for both performance and safety on the job site.

 

Promptly addressing oil and cooling system issues helps minimize downtime and keeps your excavator ready for any challenge. Whether you’re replacing a travel motor, checking the hydraulic tank, or upgrading to high-quality OEM components, maintaining these systems is vital for the long-term efficiency and productivity of your equipment; using a properly sized engine stand for safe engine maintenance can also make complex repairs more manageable. Shop today for parts that deliver on performance and durability, and keep your Deere 35G running strong in every environment.

 

John Deere 35G Engine Key Specifications

• Engine Manufacturer: Yanmar
• Engine Type: 3-cylinder, liquid-cooled diesel
• Net Engine Output: 17.4 kW (23.3 hp)
• Emissions Rating: EPA Final Tier 4/EU Stage IV compliant