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3520 and 3522 Sugar Cane

Harvester Repair Manual

TECHNICAL MANUAL
3520 and 3522 Sugar Cane
Harvester Repair
TM100419 02APR13 (ENGLISH)

For complete service information also see:

3520 and 3522 Sugar Cane Harvester


Diagnostic Technical Manual ............................. TM100519
PowerTech Plus 9.0 L Tier 3/Stage IIIA OEM
Diesel Engines — Base Engine.......................... CTM400
PowerTech Plus 9.0L Diesel Engines — Level
14 Electronic Fuel System With Denso HPCR .. CTM385
Alternators and Starting Motors ........................ CTM77
John Deere Starting Motor Repair ..................... CTM207
120 Series Hydraulic Cylinders .......................... CTM114319
John Deere Engine Repair.................................. CTM104

John Deere Thibodaux


PRINTED IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service work components requiring service instruction. At the
are identified in this manual and are recommended for use. beginning of each group are summary listings of all
Live with safety: Read the safety messages in the applicable essential tools, service equipment and tools,
introduction of this manual and the cautions presented other materials needed to do the job, service parts kits,
throughout the text of the manual. specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
This is the safety-alert symbol. When you see this machines. They are on-the-job guides containing only the
symbol on the machine or in this manual, be alert to the vital information needed for diagnosis, analysis, testing,
potential for personal injury. and repair.
Technical manuals are divided in two parts: repair and Fundamental service information is available from other
operation and tests. Repair sections tell how to repair sources covering basic theory of operation, fundamentals
the components. Operation and tests sections help you of troubleshooting, general maintenance, and basic type
identify the majority of routine failures quickly. of failures and their causes.
RW67285,0000B0A -19-22OCT01-1/1

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Contents
Section 10—General
Group 05—Safety Section 90—Operator's Station
Group 10—General Specifications Group 05—Air Conditioning System
Group 15—Fuels and Lubricants Group 10—System Components
Group 20—Tune-Up and Adjustments Group 15—Seats
Group 20—Cab
Section 20—Engine
Group 05—Component Removal and Installation Section 100—Topper System
Group 10—Cooling System Group 05—Topper
Group 20—Auxiliary Coolers
Section 110—Crop Divider System
Section 30—Fuel and Air Group 05—Crop Divider
Group 05—Diesel Fuel System
Group 10—Air Intake System Section 120—Knockdown Roller
Group 05—Knockdown Roller
Section 40—Electrical
Group 05—Batteries Section 130—Base Cutter System
Group 10—Electrical Harness and Connectors Group 05—Base Cutter Gear Case
Group 15—Wire Harness Routings
Group 20—Sensors and Switches
Group 30—Fuses and Relays Section 140—Feed Roller System
Group 40—Charging System Group 05—Buttlifter Roller (B1)
Group 45—Starting System Group 10—Bottom Feed Roller
Group 15—Top Feed Roller
Section 50—Power Train
Group 05—Pump Drive Gear Case Section 150—Chopper System
Group 05—Chopper
Section 55—Track
Group 05—Track Section 160—Cleaning System
Group 10—Final Drive Repair Group 05—Primary Extractor

Section 57—Wheel Section 170—Elevator System


Group 05—Wheel Group 05—Elevator Systems Installation

Section 60—Steering and Brakes Section 199—Dealer Fabricated Tools


Group 10—Steering Valve Group 05—Dealer Fabricated Tools
Group 15—Steering Arms and Pivots

Section 70—Hydraulic System


Group 05—Hydraulic Reservoir
Group 10—Hydraulic Pumps
Group 15—Hydraulic Valves
Group 20—Hydraulic Cylinders
Group 25—Hydraulic Motors
Group 30—Accumulators

Section 80—Miscellaneous
Group 05—Rails and Platform

Original Instructions. All information, illustrations and specifications in this


manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT © 2009, 2013
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ® Manual

TM100419 (02APR13) i 3520 and 3522 Sugar Cane Harvester Repair


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Contents

TM100419 (02APR13) ii 3520 and 3522 Sugar Cane Harvester Repair


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Section 10
General
Contents

Page
Page
Group 05—Safety
Recognize Safety Information ....................... 10-05-1 Avoid Hot Exhaust ....................................... 10-05-19
Understand Signal Words.............................. 10-05-1
Follow Safety Instructions.............................. 10-05-1 Group 10—General Specifications
Work in Clean Area ....................................... 10-05-2 Dimensions.................................................... 10-10-1
Service Machines Safely ............................... 10-05-2 Engine Specifications .................................... 10-10-2
Emergency Exit ............................................. 10-05-2 Capacities...................................................... 10-10-3
Work In Ventilated Area................................. 10-05-3 Critical Torque and Adhesive
Illuminate Work Area Safely .......................... 10-05-3 Specifications ............................................ 10-10-4
Replace Safety Signs .................................... 10-05-3 Identifying Zinc-Flake Coated
Use Proper Lifting Equipment........................ 10-05-4 Fasteners................................................... 10-10-4
Support Machine Properly ............................. 10-05-4 Unified Inch Bolt and Screw Torque
Avoid Heating Near Pressurized Values ........................................................ 10-10-5
Fluid Lines ................................................. 10-05-4 Metric Bolt and Screw Torque
Remove Paint Before Welding or Values ........................................................ 10-10-6
Heating ...................................................... 10-05-5 Face Seal Fittings Assembly
Precautions for Welding ................................ 10-05-5 and Installation—All Pressure
Live With Safety............................................. 10-05-6 Applications ............................................... 10-10-7
Construct Dealer-Made Tools Metric Face Seal and O-Ring
Safely......................................................... 10-05-6 Stud End Fitting Torque
Seat Safety Switch ........................................ 10-05-7 Chart—Standard Pressures ...................... 10-10-8
Tilting the Cab ............................................... 10-05-7 Metric Face Seal and O-Ring Stud
Protect Bystanders ....................................... 10-05-8 End Fitting Torque Chart—High
Use Steps and Handholds Pressure Applications................................ 10-10-9
Correctly .................................................... 10-05-8 SAE Face Seal and O-Ring
Wear Protective Clothing............................... 10-05-8 Stud End Fitting Torque
Handle Fuel Safely—Avoid Fires................... 10-05-9 Chart—Standard Pressures .................... 10-10-10
Service Accumulator Systems SAE Face Seal and O-Ring Stud
Safely......................................................... 10-05-9 End Fitting Torque Chart—High
Service Cooling System Safely ..................... 10-05-9 Pressure Applications.............................. 10-10-11
Prepare for Emergencies............................. 10-05-10 Four Bolt Flange Fittings Assembly
Use Safety Lights and Devices.................... 10-05-10 and Installation—All Pressure
Using Cylinder Safety Stops........................ 10-05-11 Applications ............................................. 10-10-12
Safe Transport of Harvester ........................ 10-05-11 SAE Four Bolt Flange Cap Screw
Avoid High-Pressure Fluids ......................... 10-05-12 Torque Values—Standard
Use Caution on Hillsides ............................. 10-05-12 Pressure Applications.............................. 10-10-13
Use Caution On Slopes When SAE Four Bolt Flange Cap Screw
Turning..................................................... 10-05-13 Torque Values—High Pressure
Stopping and Parking .................................. 10-05-13 Applications ............................................. 10-10-14
Service Tires Safely..................................... 10-05-14 Sealants and Adhesives
Avoid Electrical Power Lines ....................... 10-05-14 Cross-Reference Chart............................ 10-10-15
Keep Hands Away from Knives ................... 10-05-15 Harvester Specialty Tools and Part
Dispose of Waste Properly .......................... 10-05-15 Numbers .................................................. 10-10-16
Prevent Battery Explosions ......................... 10-05-15
Prevent Acid Burns...................................... 10-05-16 Group 15—Fuels and Lubricants
Fire Prevention ............................................ 10-05-17 Lubricate Machine Properly........................... 10-15-1
Stay Clear of Harvesting Units .................... 10-05-17 Diesel Engine Break-In Oil ............................ 10-15-1
Stay Clear of Rotating Drivelines................. 10-05-18 Diesel Engine Oil ........................................... 10-15-2
Keep Riders and Children Off Diesel Fuel..................................................... 10-15-3
Machine ................................................... 10-05-18 Lubricity of Diesel Fuel .................................. 10-15-3
Instructional Seat......................................... 10-05-18 Diesel Engine Coolant ................................... 10-15-4
Install All Guards ......................................... 10-05-19

Continued on next page

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Contents

Page

Heavy Duty Diesel Engine


Coolant ...................................................... 10-15-4
John Deere COOL-GARD™ II
Coolant Extender....................................... 10-15-5
Additional Information About
Diesel Engine Coolants and
John Deere COOL-GARD™ II
Coolant Extender....................................... 10-15-6
Operating in Warm Temperature
Climates..................................................... 10-15-7
Supplemental Coolant Additives.................... 10-15-7
Testing Diesel Engine Coolant....................... 10-15-8
Pump Drive, Base Cutter, and
Chopper Gear Case Oil ............................. 10-15-9
Hydraulic Oil .................................................. 10-15-9
Final Drive Gear Oil ..................................... 10-15-10
Grease......................................................... 10-15-10
Alternative and Synthetic
Lubricants ................................................ 10-15-10

Group 20—Tune-Up and Adjustments


Tune-Up and Adjustment............................... 10-20-1

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Group 05
Safety
Recognize Safety Information
This is a safety-alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe operating

T81389 —UN—07DEC88
practices.

DX,ALERT -19-29SEP98-1/1

Understand Signal Words


A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on

TS187 —19—30SEP88
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.

DX,SIGNAL -19-03MAR93-1/1

Follow Safety Instructions


Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are

TS201 —UN—23AUG88
available from your John Deere dealer.
There can be additional safety information contained on
parts and components sourced from suppliers that is not
reproduced in this operator's manual.
Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition.
If you do not understand any part of this manual and need
Unauthorized modifications to the machine may impair the
assistance, contact your John Deere dealer.
function and/or safety and affect machine life.
DX,READ -19-16JUN09-1/1

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Safety

Work in Clean Area


Before starting a job:
• Clean work area and machine.
• Make sure you have all necessary tools to do your job.
• Have the right parts on hand.

T6642EJ —UN—18OCT88
• Read all instructions thoroughly; do not attempt
shortcuts.

DX,CLEAN -19-04JUN90-1/1

Service Machines Safely


Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.

TS228 —UN—23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.

DX,LOOSE -19-04JUN90-1/1

Emergency Exit
The right-hand cab window may be used as an emergency
exit. Disengage the gas-filled spring on the sidewall of the
cab and open the window.

CQ294327 —UN—27MAR13

GB52027,0001149 -19-26MAR13-1/1

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Safety

Work In Ventilated Area


Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust
pipe extension.

TS220 —UN—23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.

DX,AIR -19-17FEB99-1/1

Illuminate Work Area Safely


Illuminate your work area adequately but safely. Use
a portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.

TS223 —UN—23AUG88
DX,LIGHT -19-04JUN90-1/1

Replace Safety Signs


Replace missing or damaged safety signs. Use this
operator’s manual for correct safety sign placement.
There can be additional safety information contained on
parts and components sourced from suppliers that is not

TS201 —UN—23AUG88
reproduced in this operator's manual.

DX,SIGNS -19-18AUG09-1/1

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PN=9
Safety

Use Proper Lifting Equipment


Lifting heavy components incorrectly can cause severe
injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.

TS226 —UN—23AUG88
DX,LIFT -19-04JUN90-1/1

Support Machine Properly


Always lower the attachment or implement to the ground
before you work on the machine. If the work requires
that the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.

TS229 —UN—23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
When implements or attachments are used with a
machine, always follow safety precautions listed in the
implement or attachment operator's manual.
DX,LOWER -19-24FEB00-1/1

Avoid Heating Near Pressurized Fluid Lines


Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders. Do not heat by welding, soldering,
or using a torch near pressurized fluid lines or other
flammable materials. Pressurized lines can accidentally

TS953 —UN—15MAY90
burst when heat goes beyond the immediate flame area.

DX,TORCH -19-10DEC04-1/1

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PN=10
Safety

Remove Paint Before Welding or Heating


Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:

TS220 —UN—23AUG88
• Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
before welding or heating.
Do not use a chlorinated solvent in areas where welding Dispose of paint and solvent properly.
will take place.
DX,PAINT -19-24JUL02-1/1

Precautions for Welding


Remove paint before welding or heating (see Safety
Section in this manual for more information on paint
removal and high-pressure lines).

CAUTION: Avoid potentially toxic fumes and dust.

TS953 —UN—15MAY90
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly. If you
sand or grind paint, avoid breathing the dust by
wearing an approved respirator. If you use solvent
or paint stripper, remove with soap and water
before welding. Remove solvent or paint stripper
containers and other flammable material from 3. Disconnect the positive (+) battery cable(s) or open
area before welding. Allow fumes to disperse at battery (+) switch if equipped.
least 15 minutes before welding or heating.
4. Clear or move any wiring harness sections away from
IMPORTANT: Welding on the engine is NOT the welding area.
ALLOWED. If welding must be performed on 5. Welding on engine components is not allowed.
the machine, follow these precautions.
6. Never connect the welder ground to any engine
IMPORTANT: High currents or electrostatic discharge component or engine driven components that may be
into electronic components from welding connected to the engine.
may cause permanent damage.
7. After welding, reverse steps 2—3.
1. Remove paint from the area to be welded and ground
cable clamp location.
2. Disconnect the negative (-) battery cable(s) or open
battery (-) switch if equipped.
DX,WELDING,PRECAUTIONS -19-06DEC10-1/1

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Safety

Live With Safety


Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.

TS231 —19—07OCT88
DX,LIVE -19-25SEP92-1/1

Construct Dealer-Made Tools Safely


Faulty or broken tools can result in serious injury. When
constructing tools, use proper, quality materials, and good
workmanship.

LX1016749 —UN—01JUL97
Do not weld tools unless you have the proper equipment
and experience to perform the job.

DX,SAFE,TOOLS -19-10OCT97-1/1

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Safety

Seat Safety Switch

CM023500020 —UN—07FEB05
The operator must be seated and reset switch activated to functions, the operator must return to seated position and
start harvesting functions. engage reset switch located on the armrest console.
If the operator leaves the seat for more than five seconds,
harvesting functions will stop. To restart harvesting
WM05597,00007DF -19-11FEB13-1/1

Tilting the Cab


The entire cab tilts forward, providing access to the engine
for maintenance and repair by a qualified technician.
The cab pivots at the front, raised by a single hydraulic
cylinder. Make sure there are no people near the machine.
Be sure that windows are closed, articles are removed
from the cab and the topper boom is completely lowered
T8130000499 —UN—21FEB13
to prevent damage. (See Service Section for tilting the
cab procedure).

WM05597,00007E0 -19-21FEB13-1/1

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PN=13
Safety

Protect Bystanders
Be sure everyone is clear of the harvester before starting
the engine or moving the steering wheel.

CM989999005 —UN—06JAN00
T803324,000062F -19-13APR05-1/1

Use Steps and Handholds Correctly


Prevent falls by facing the machine when getting on and

T133468 —UN—30AUG00
off. Maintain 3-point contact with steps, handholds, and
handrails.
Use extra care when mud, snow, or moisture present
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.

DX,WW,MOUNT -19-12OCT11-1/1

Wear Protective Clothing


Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.

TS206 —UN—23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR -19-10SEP90-1/1

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PN=14
Safety

Handle Fuel Safely—Avoid Fires


Handle fuel with care: it is highly flammable. Do not refuel
the machine while smoking or when near open flame or
sparks.
Always stop engine before refueling machine. Fill fuel

TS202 —UN—23AUG88
tank outdoors.
Prevent fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up spilled fuel.
Use only an approved fuel container for transporting
flammable liquids.
Never fill fuel container in pickup truck with plastic bed
liner. Always place fuel container on ground before
refueling. Touch fuel container with fuel dispenser nozzle Do not store fuel container where there is an open flame,
before removing can lid. Keep fuel dispenser nozzle in spark, or pilot light such as within a water heater or other
contact with fuel container inlet when filling. appliance.
DX,FIRE1 -19-12OCT11-1/1

Service Accumulator Systems Safely


Escaping fluid or gas from systems with pressurized
accumulators that are used in air conditioning, hydraulic,
and air brake systems can cause serious injury. Extreme
heat can cause the accumulator to burst, and pressurized
lines can be accidentally cut. Do not weld or use a torch

TS281 —UN—23AUG88
near a pressurized accumulator or pressurized line.
Relieve pressure from the pressurized system before
removing accumulator.
Relieve pressure from the hydraulic system before
removing accumulator. Never attempt to relieve hydraulic
system or accumulator pressure by loosening a fitting.
Accumulators cannot be repaired.
DX,WW,ACCLA2 -19-22AUG03-1/1

Service Cooling System Safely


Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
TS281 —UN—23AUG88
to relieve pressure before removing completely.

DX,RCAP -19-04JUN90-1/1

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PN=15
Safety

Prepare for Emergencies


Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.

TS291 —UN—23AUG88
DX,FIRE2 -19-03MAR93-1/1

Use Safety Lights and Devices


Prevent collisions between other road users, slow moving
tractors with attachments or towed equipment, and
self-propelled machines on public roads. Frequently
check for traffic from the rear, especially in turns, and use
turn signal lights.
Use headlights, flashing warning lights, and turn signals
day and night. Follow local regulations for equipment
lighting and marking. Keep lighting and marking visible,
clean, and in good working order. Replace or repair
lighting and marking that has been damaged or lost. An
implement safety lighting kit is available from your John

TS951 —UN—12APR90
Deere dealer.

DX,FLASH -19-07JUL99-1/1

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PN=16
Safety

Using Cylinder Safety Stops


When working under the harvester, always raise the
machine all the way up. Raise the machine, lower the
safety stops on suspension height cylinders and slowly
lower the harvester until the suspension is completely
locked. If a hose bursts, the safety stops limit the course
of the cylinders and the harvester will remain raised.

CM989999016 —UN—06JAN00
OU64006,0000157 -19-26MAR13-1/1

Safe Transport of Harvester


Before driving harvester on public roads, raise the topper.
It should not, however, obstruct the operator's view.
Unless other conditions require, normal configuration
of the harvester for road transport would be with frame
raised to level, crop dividers raised, and topper and
elevator lowered to not exceed height of the cab.

CQ280276 —UN—27FEB08

WM05597,00007FD -19-19FEB13-1/1

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PN=17
Safety

Avoid High-Pressure Fluids


Inspect hydraulic hoses periodically – at least once
per year – for leakage, kinking, cuts, cracks, abrasion,
blisters, corrosion, exposed wire braid or any other signs
of wear or damage.

X9811 —UN—23AUG88
Replace worn or damaged hose assemblies immediately
with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
with this type of injury should reference a knowledgeable
Search for leaks with a piece of cardboard. Protect hands medical source. Such information is available in
and body from high-pressure fluids. English from Deere & Company Medical Department in
Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1
If an accident occurs, see a doctor immediately. Any fluid 309-748-5636.
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
DX,FLUID -19-12OCT11-1/1

Use Caution on Hillsides


Avoid holes, ditches, and obstructions that may cause the
harvester to tip over, especially on hillsides.
NEVER drive near the edge of a gully or steep
embankment because it may cave in.
The danger of an overturn increases greatly with narrow
tread, 2032 mm (80 in.) or less, and with high speed.
Keep hydraulic oil level at upper level when operating on
hillsides. Low oil level might result in loss of steering. If
this should happen, hold harvester with brakes, shift to
NEUTRAL, apply parking brake, stop engine, and add

CM989999019 —UN—06JAN00
hydraulic oil to proper level.
Before operating on extremely steep slopes, fill hydraulic
system overfull in sight glass, from 4 to 8 L (1 to 2 gal.).
This is particularly important when using large hydraulic
cylinders, due to the volume of oil used to extend them.

WM05597,00007FE -19-19FEB13-1/1

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PN=18
Safety

Use Caution On Slopes When Turning


Ballast of machine is greatly affected by position of
elevator.
When operating on slopes, elevator MUST be centered

T8130000097 —UN—10JAN13
behind machine before turning.
The danger of an overturn increases greatly when elevator
is swung to left or right during a turn.

JR07957,000023F -19-10JAN13-1/1

Stopping and Parking


Your ability to stop your harvester and park it safely is just
as important as being able to get it underway safely.
Harvester rollover, collisions, runaway tractors, and
people being crushed under machines can happen when
operators ignore safety.
To avoid these accidents, take some precautions:
• Signal before stopping, turning, or slowing down on
highways.
• Pull over to right-hand shoulder of highway before
stopping, if possible.

CM989999020 —UN—06JAN00
• Slow down before braking.
• Pump brakes when stopping on slippery surfaces like
ice, snow, mud, or loose gravel.
• Shift to park or set parking brake.
• Turn off all electrical switches and remove key.

AG,T803324,55 -19-14JUL99-1/1

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PN=19
Safety

Service Tires Safely


Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount a tire unless you have the proper
equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld
or heat a wheel and tire assembly. The heat can cause
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles, damaged
rims or missing lug bolts and nuts.

TS211 —UN—23AUG88
DX,RIM -19-24AUG90-1/1

Avoid Electrical Power Lines


Put the topper and elevator in transport position before
driving on public roads.
Secure radio aerial in its transport position before driving
on public roads, it may come into contact with low-hanging
electrical cables. This would result in the operator
suffering a severe electrical shock.
Maintain minimum distance of 3 m (10 ft.) plus twice the
length of power line insulators.

CM989999024 —UN—06JAN00

JR07957,000027F -19-18FEB13-1/1

TM100419 (02APR13) 10-05-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=20
Safety

Keep Hands Away from Knives


Never attempt to clear obstructions in cutting areas unless
engine is shut off and key removed. Everyone must be
clear of the harvester before starting the engine.
Cutting/Shearing areas: topper, side knives, vine knives,
base cutter blades, cooling fans, extractors, and elevator
slats.

CM989999025 —UN—06JAN00
WM05597,0000800 -19-19FEB13-1/1

Dispose of Waste Properly


Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.

TS1133 —UN—26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
Inquire on the proper way to recycle or dispose of waste
recover and recycle used air conditioning refrigerants.
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN -19-03MAR93-1/1

Prevent Battery Explosions


Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
TS204 —UN—23AUG88

Do not charge a frozen battery; it may explode. Warm


battery to 16°C (60°F).

DX,SPARKS -19-03MAR93-1/1

TM100419 (02APR13) 10-05-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=21
Safety

Prevent Acid Burns


Sulfuric acid in battery electrolyte is poisonous. It is strong
enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not

TS203 —UN—23AUG88
exceed 2 L (2 quarts).
3. Get medical attention immediately.

DX,POISON -19-21APR93-1/1

TM100419 (02APR13) 10-05-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=22
Safety

Fire Prevention
1. Machines should be cleaned of debris at least daily,
particularly around engine, exhaust, and steering
components. The build up of crop debris in the engine
compartment, on the engine and near any moving
parts is a fire hazard.
2. Machines should be inspected at least daily for
potential fire hazards in electrical, exhaust, steering,
fuel, hydraulic, and brake systems. Repairs should be
made immediately.
3. Service personnel should be instructed on what to do
when a fire starts, how to use the fire extinguisher,
and must follow such instructions. Operators should

CM989999028 —UN—10NOV00
be required to demonstrate an ability to use fire
suppression equipment.
4. Hydraulic leaks, accumulation of grease, fuel, and oil
(including spillage) should be eliminated immediately.
5. The radiator and the engine cooling system should
be cleaned and serviced daily to maintain moderate
engine temperatures.
6. Any portable extinguisher or fire suppression system
carried on the machine that has been previously
used should be recharged or replaced before the
machine resumes operation. A partially discharged 8. Smoking, naked flames, etc., should not be permitted
extinguisher will have reduced capability and may not around any machine during fueling operations and/or
work a second time. when the fuel system is open to the atmosphere.
7. Prior to welding or brazing on any part of the machine, 9. Do not weld where hydraulic hoses or electrical wiring
the part and the surrounding area should be cleaned can be damaged. Depressurize hydraulic hoses
and a fire extinguisher should be made readily and move or protect. Move or protect electrical
available. wiring/harnesses.
WM05597,0000802 -19-19FEB13-1/1

Stay Clear of Harvesting Units


Topper, scrolls, side knives, knockdown rollers, and base
cutter cannot be completely shielded due to their function.
Stay clear of these moving elements during operation.
Always disengage main clutch, shut OFF engine, set

ES118704 —UN—21MAR95
parking brake, and remove key before servicing or
unclogging machine.
Stay clear of harvester during its harvesting operation to
avoid flying debris.

WM05597,0000801 -19-19FEB13-1/1

TM100419 (02APR13) 10-05-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=23
Safety

Stay Clear of Rotating Drivelines


Entanglement in rotating driveline can cause serious
injury or death.
Keep all shields in place at all times. Make sure rotating
shields turn freely.

TS1644 —UN—22AUG95
Wear close-fitting clothing. Stop the engine and be sure
that all rotating parts and drivelines are stopped before
making adjustments, connections, or performing any type
of service on engine or machine driven equipment.

DX,ROTATING -19-18AUG09-1/1

Keep Riders and Children Off Machine


Only allow the operator on the machine. Keep riders off
the machine except for periods of training or short periods
of observation.
Riders are subject to injury such as being thrown off the

TS253 —UN—23AUG88
machine. Riders also obstruct the operator's view resulting
in the machine being operated in an unsafe manner.
Children should never be allowed on the machine or in the
harvester cab when the engine is running.
The instructional seat should only be used for instruction
or short periods of machine observation, and not for the
accommodation of children.
KR43067,0000BB4 -19-25SEP12-1/1

Instructional Seat
The instructional seat, if so equipped, has been provided
only for training operators or diagnosing machine
problems.

RXA0103436 —UN—15JUN09

DX,SEAT,NA -19-19AUG09-1/1

TM100419 (02APR13) 10-05-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=24
Safety

Install All Guards


Rotating cooling system fans, belts, pulleys, and drives
can cause serious injury.
Keep all guards in place at all times during engine
operation.

TS677 —UN—21SEP89
Wear close-fitting clothes. Stop the engine and be sure
fans, belts, pulleys, and drives are stopped before making
adjustments, connections, or cleaning near fans and their
drive components.

DX,GUARDS -19-18AUG09-1/1

Avoid Hot Exhaust


Servicing machine or attachments with engine running
can result in serious personal injury. Avoid exposure and
skin contact with hot exhaust gases and components.
Exhaust parts and streams become very hot during

RG17488 —UN—21AUG09
operation. Exhaust gases and components reach
temperatures hot enough to burn people, ignite, or melt
common materials.

DX,EXHAUST -19-20AUG09-1/1

TM100419 (02APR13) 10-05-19 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=25
Safety

TM100419 (02APR13) 10-05-20 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=26
Group 10
General Specifications
Dimensions

CQ285205 —UN—02FEB10
High Capacity Elevator Direct Drive 5 ft Primary Extractor (Track)
Harvester Dimensions
Reference 3520 Track 3520 Wheel
A 5 900 mm (232 in.) 5 900 mm (232 in.)
B 3 550 mm (134 in.) 3 550 mm (134 in.)
C 3 860 mm (152 in.) 3 880 mm (153 in.)
D 4 030 mm (159 in.) 4 060 mm (160 in.)
E 1 320 mm (52 in.) 1 360 mm (54 in.)
F 5 150 mm (203 in.) 5 180 mm (204 in.)
G 13 600 mm (535 in.) 13 600 mm (535in.)
H 15 000 mm (591 in.) 15 000 mm (591 in.)
I 2 360 mm (93 in.) 2 440 mm (96 in.)
J 1 500 mm (59 in.) 1 520 mm (59 in.)

PW66162,000098F -19-13FEB13-1/1

TM100419 (02APR13) 10-10-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=27
General Specifications

Engine Specifications
Engine Specifications
Type John Deere 6090H, 9.0 L
Quantity of Cylinders 6
Model 6090HT803 Tier III
6090HT804 Non EGR Tier II
Power 337 HP to 2100 RPM
375 HP to 2100 RPM
Air Intake Turbocharger and air-to-air aftercooled
Oil Capacity Maximum Load 29.5 L (7.8 U.S. gal)
Coolant capacity 69.6 Liters (18.4 U.S. gal)
Bore 118.4 mm (4.66 in.)
Stroke 136 mm (5.4 in.)
Displacement 9.0 L (548 cu. in.)
Compression Ratio 16.0:1
Engine Firing Order 1-5-3-6-2-4
Tension (Electrical System) 12 Volt Maintenance-Free Battery (2 used)
Valves Per Cylinder 2 Intake
2 Exhaust
Battery 1 100 CCA
190 Minutes
Thermostat Start To Open Temperature 82° C
(180° F)
Thermostat Fully Open Temperature 94° C
(202° F)
Recommended Radiator Pressure Cap 100 kPa
(1 bar)
(15 psi)
Oil Pressure At Rated Speed With Oil 290 kPa
Warmed to 105°C (220°F) (2.9 bar)
(42 psi)
Oil Pressure At Low Idle (minimum) 138 kPa
(1.4 bar)
(20 psi)
Length 1 208 mm
(47.6 in.)
Width 630 mm
(24.8 in.)
Height 1 113 mm
(43.8 in.)
Weight (dry) 901 kg
(1 986 lb.)

PW66162,00009E5 -19-02APR13-1/1

TM100419 (02APR13) 10-10-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=28
General Specifications

Capacities
Approximate capacity
Component 3520 3522
Fuel Tank—Diesel 568 L (150 gal.) 568 L (150 gal.)
Hydraulic Oil Tank—SAE 10W30 super high 397 L (105 gal.) World 397 L (105 gal.) World
performance, heavy-duty diesel engine oil
Radiator Coolant—50% Clean Water and 50% 69.6 L (16.5 gal.) 69.6 L (16.5 gal.)
Ethylene Glycol
Final Drive of Track— 85W/140 oil or 4.2 L (1.1 gal.) 4.2 L (1.1 gal.)
80W/140 Synthetic oil
Final Drive of Wheel—85W/140 oil or 4.2 L (1.1 gal.) 4.2 L (1.1 gal.)
80W/140 Synthetic oil
Chopper Gear Case— 85W/140 oil 11.01 L (2.9 gal.) 11.01 L (2.9 gal.)
Base Cutter Gear Case— 85W/140 oil Dry 8.97 L (2.37 gal.) Dry 13.5 L (3.5 gal.)
Pump Drive Gear Case— 85W/140 oil 7.1 L (1.87 gal.) 7.1 L (1.87 gal.)
John Deere 6090 Engine—SAE 15W40 oil 29.5 L (7.8 gal.) 29.5 L (7.8 gal.)
Air Conditioner R-134a refrigerant 3.4 kg (7.5 lb.) 3.4 kg (7.5 lb.)
R-134a compressor oil 118 mL (4 oz.) 118 mL (4 oz.)
Approximate Weight of Harvester 19 050 kg (42 000 lb.) 19 780 kg (43 600 lb.)

PW66162,00007E7 -19-13FEB13-1/1

TM100419 (02APR13) 10-10-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=29
General Specifications

Critical Torque and Adhesive Specifications


Location Torque Adhesive
Feed Roller Motor Mounting Bolts and Nuts 110 N·m (80 lb.-ft.) Araldite
Top Feed Roller Pin Mountine Studs 35 N·m (24 lb.-ft.) Araldite
Bottom Feed Roller Mounting Studs 80 N·m (60 lb.-ft.) Araldite
Base Cutter Mounting Bolts 250 N·m (180 lb.-ft.) Araldite
Base Cutter Disk Mounting Bolts 110 N·m (80 lb.-ft.)
Chopper Gear Case Access Cover Cap Screws 25 N·m (20 lb.-ft.)
Chopper Case Cover Cap Screws 110 N·m (80 lb.-ft.) Loctite 242
Chopper—Lower Gear Mounting Cap Screws 300 N·m (225 lb.-ft.)
Chopper Flywheel Nut 373 N·m (275 lb.-ft.)
Final Drive Mounting Bolts 475 N·m (390 lb.-ft.) Loctite 271
Final Drive Motors 373 N·m (275 lb.-ft.) Loctite 271
Rear Wheel Bolts 380 N·m (280 lb.-ft.) Anti-Seize
Front Wheel Bolts 230 N·m (170 lb.-ft.) Anti-Seize
Track-Guides 237 N·m (175 lb.-ft.) Loctite 271
Track-Top Idler Roller 122 N·m (90 lb.-ft.) Loctite 271
Track-Rear Axle Inner Nut 815 N·m (600 lb.-ft.)
Track-Rear Axle Outer Nut (Bolts) 50 N·m (35 lb.-ft.) Loctite 242
Track-Rear Axle Mounting Bolts 380 N·m (280 lb.-ft.) Araldite
Track-Shoe 407 N·m (300 lb.-ft.) Loctite 271
Track-Rollers 339 N·m (250 lb.-ft.) Loctite 271
Track-Sprockets 271 N·m (200 lb.-ft.) L&S Loctite 271
529 N·m (390 lb.-ft.) BNA Loctite 271
Track-Segments Sprockets 271 N·m (200 lb.-ft.) Loctite 271
Engine Mounting Bolt 380 N·m (280 lb.-ft.)
Scroll Bottom Bearing Flange 110 N·m (80 lb.-ft.) Araldite
Scroll Motor Mounting Bolts 110 N·m (80 lb.-ft.) Araldite
Scroll Motor Mount Assembly Bolts 110 N·m (80 lb.-ft.) Loctite 271
All Motor Spline Adapter Hubs 35 N·m (25 lb.-ft.) Araldite
All Spline Hubs (Grade 8) 110 N·m (80 lb.-ft.) Araldite
Primary and Secondary Extractor Assemblies 110 N·m (80 lb.-ft.) Loctite 271
Primary Extractor (Motor In Can) 552 N·m (400 lb.-ft.) Dry
Top Nut of Swing Table Pin 460 N·m (300 lb.-ft.) Loctite 271
Bottom Nut of Swing Table Pin 815 N·m (600 lb.-ft.)

PW66162,0000919 -19-12FEB13-1/1

Identifying Zinc-Flake Coated Fasteners


Standard cap screws (A) have a reflective silver color.
Zinc plated cap screws (B) have a reflective gold color.
RXA0073812 —UN—03MAR04

Zinc-Flake Coated cap screws (C) have a dull silver color.

A—Standard Cap Screws C—Zinc-Flake Cap Screw (20


B—Zinc-plated Cap Screw mm and larger)

OURX985,0000024 -19-03NOV05-1/1

TM100419 (02APR13) 10-10-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=30
General Specifications

Unified Inch Bolt and Screw Torque Values


TS1671 —UN—01MAY03

Bolt or Screw SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N·m lb.-ft. N·m lb.-ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N·m lb.-ft. N·m lb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N·m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt Replace fasteners with the same or higher grade. If higher
or screw. DO NOT use these values if a different torque value or tightening grade fasteners are used, tighten these to the strength of the
procedure is given for a specific application. For plastic insert or crimped steel original. Make sure fastener threads are clean and that you
type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the properly start thread engagement. When possible, lubricate
tightening instructions for the specific application. Shear bolts are designed to fail plain or zinc plated fasteners other than lock nuts, wheel bolts
under predetermined loads. Always replace shear bolts with identical grade. or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6
in. (152 mm) long, and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ1 -19-12JAN11-1/1

TM100419 (02APR13) 10-10-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=31
General Specifications

Metric Bolt and Screw Torque Values


TS1670 —UN—01MAY03

4.8 8.8 9.8 10.9 12.9 12.9

4.8 8.8 9.8 10.9 12.9 12.9

Bolt or Screw Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N·m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength of Shear bolts are designed to fail under predetermined loads. Always
the bolt or screw. DO NOT use these values if a different torque value or replace shear bolts with identical property class. Replace fasteners with
tightening procedure is given for a specific application. For stainless steel the same or higher property class. If higher property class fasteners are
fasteners or for nuts on U-bolts, see the tightening instructions for the used, tighten these to the strength of the original. Make sure fastener
specific application. Tighten plastic insert or crimped steel type lock nuts threads are clean and that you properly start thread engagement. When
by turning the nut to the dry torque shown in the chart, unless different possible, lubricate plain or zinc plated fasteners other than lock nuts,
instructions are given for the specific application. wheel bolts or wheel nuts, unless different instructions are given for the
specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ2 -19-12JAN11-1/1

TM100419 (02APR13) 10-10-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=32
General Specifications

Face Seal Fittings Assembly and Installation—All Pressure Applications


Face Seal O-Ring to Stud End Installation 4. Remove thimble.
1. Inspect the fitting surfaces. They must be free of dirt Face Seal Straight Stud End O-Ring Installation
and/or defects.
1. Install a thimble over the fitting threads to protect the
2. Inspect the O-ring. It must be free of damage and/or
O-ring from nicks.
defects.
2. Slide the O-ring over the thimble into the turned down
3. Lubricate O-rings and install into groove using
section of the fitting.
petroleum jelly to hold in place.
3. Remove thimble.
4. Push O-ring into groove with petroleum jelly so O-ring
is not displaced during assembly. Fitting Installation
5. Index angle fittings and tighten by hand pressing joint 1. Install fitting by hand until snug.
together to insure O-ring remains in place.
2. Position adjustable fittings by unscrewing the fitting no
6. Tighten fitting or nut to torque value shown on the more than one turn.
chart per dash size stamped on the fitting. DO NOT
allow hoses to twist when tightening fittings. 3. Apply assembly torque per table.
Face Seal Adjustable Stud End O-Ring Installation Assembly Torque
1. Back off lock nut (jam nut) and washer to full exposed 1. Use one wrench to hold the connector body and one
turned down section of the fitting. wrench to tighten nut.
2. Install a thimble over the fitting threads to protect the 2. For a hydraulic hose, it may be necessary to use three
O-ring from nicks. wrenches to prevent twist; one on the connector body,
one on the nut, and one on the body of the hose fitting.
3. Slide the O-ring over the thimble into the turned down
section of the fitting.
RW67285,00013B5 -19-16OCT02-1/1

TM100419 (02APR13) 10-10-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=33
General Specifications

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures
N79757 —UN—13FEB08

I B E
G C F
G
F
A D

A—Stud Straight and Tube Nut C—90° Swivel Elbow and Tube E—Port Plug I— Lock Nut
B—Bulkhead Union and Nut F— Stud End
Bulkhead Lock Nut D—90° Adjustable Stud Elbow G—Tube Nut
H—Swivel Nut

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressure-Below 27.6 MPA (4,000 PSI)
Nominal Tube OD O-Ring Face Seal/ Bulkhead Jam Nut O-Ring Straight, Adjustable, and External Port Plug Stud EndsA
Hose ID Tube Swivel Nut TorqueA
Met- Inch Tube OD Thread Swivel Tube Nut Jam Jam Nut Thread Straight Adj Steel Aluminum
ric Size Nut Hex Swivel Nut Nut Torque Size Hex Lock or or
Tube Size Torque Hex SizeB Nut Gray Iron Brass
OD Size Hex Torque TorqueC
Size
mm Da- in. mm in. mm N·m lb-ft mm N·m lb-ft mm mm mm N·m lb-ft N·m lb-ft
sh
Siz-
e
4 -2 0.12 3.18 — — — — — — — M8 X 1 12 12 8 6 5 4
5
5 -3 0.18 4.76 — — — — — — — M10 X 1 14 14 15 11 10 7
8
6 -4 0.25 6.35 9/16-18 17 16 12 22 32 24 M12 X 1.5 17 17 25 18 17 12
0
8 -5 0.31 7.92 — — — — — — — M14 X 1.5 19 19 40 30 27 20
2
10 -6 0.37 9.53 11/16-16 22 24 18 27 42 31 M16 X 1.5 22 22 45 33 30 22
5
12 -8 0.50 12.70 13/16-16 24 50 37 30 93 69 M18 X 1.5 24 24 50 37 33 25
0
16 -10 0.62 15.88 1-14 30 69 51 36 118 87 M22 X 1.5 27 27 69 51 46 34
5
20 -12 0.75 19.05 1-3/16-1 36 102 75 41 175 129 M27 X 2 32 32 100 74 67 49
0 2
22 -14 0.87 22.23 1-3/16-1 36 102 75 41 175 129 M30 X 2 36 36 130 96 87 64
5 2
25 -16 1.00 25.40 1-7/16-1 41 142 105 46 247 182 M33 X 2 41 41 160 118 107 79
0 2
28 — — — — — — — — — — M38 x 2 46 46 176 130 117 87
32 -20 1.25 31.75 1-11/1 50 190 140 50 328 242 M42 X 2 50 50 210 155 140 103
0 6-12
38 -24 1.50 38.10 2-12 60 217 160 60 374 276 M48 X 2 55 55 260 192 173 128
0
50 -32 2.00 50.80 — — — — — — — M60 X 2 65 65 315 232 210 155
0
A
Tolerance is +15%, minus 20% of mean tightening torque unless otherwise specified.
B
The straight hex wrench sizes listed apply to connectors only and may not be the same as the corresponding plug of the same thread size.
C
These torques were established using steel plated connectors in aluminum and brass.

OUO1073,00022E1 -19-29AUG08-1/1

TM100419 (02APR13) 10-10-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=34
General Specifications

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications
N79757 —UN—13FEB08

I B E
G C F
G
F
A D

A—Stud Straight and Tube Nut C—90° Swivel Elbow and Tube E—Port Plug I— Lock Nut
B—Bulkhead Union and Nut F— Stud End
Bulkhead Lock Nut D—90° Adjustable Stud Elbow G—Tube Nut
H—Swivel Nut

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure-Above 27.6 MPA (4,000
PSI), Working Pressure-41.3 MPA (6,000 PSI)
Nominal Tube OD O-Ring Face Seal/ Bulkhead Jam Nut O-Ring Straight, Adjustable, and External
Hose ID Tube Swivel Nut TorqueA Port Plug Stud EndsA
Met- Inch Tube OD Thread Size Swivel Tube Jam Jam Nut Thread Size Straight Adj Steel
ric Nut Hex Nut/Swivel Nut Hex Torque Hex SizeB Lock Nut or
Tube Size Nut Torque Size Hex Size Gray Iron
OD Torque
mm Da- in. mm in. mm N·m lb-ft mm N·m lb-ft mm. mm mm N· lb-ft
sh m
Siz-
e
4 -2 0.125 3.18 — — — — — — — M8 X 1 12 12 8 6
5 -3 0.188 4.76 — — — — — — — M10 X 1 14 14 15 11
6 -4 0.250 6.35 9/16-18 17 24 18 22 32 24 M12 X 1.5 17 17 35 26
8 -5 0.312 7.92 — — — — — — — M14 X 1.5 19 19 45 33
10 -6 0.375 9.53 11/16-16 22 37 27 27 42 31 M16 X 1.5 22 22 55 41
12 -8 0.500 12.70 13/16-16 24 63 46 30 93 69 M18 X 1.5 24 24 70 52
16 -10 0.625 15.88 1-14 30 103 76 36 118 87 M22 X 1.5 27 27 100 74
20 -12 0.750 19.05 1-3/16-12 36 152 112 41 175 129 M27 X 2 32 32 170 125
22 -14 0.875 22.23 1-3/16-12 36 152 112 41 175 129 M30 X 2 36 36 215 159
25 -16 1.000 25.40 1-7/16-12 41 214 158 46 247 182 M33 X 2 41 41 260 192
28 — — — — — — — — — — M38 x 2 46 46 320 236
32 -20 1.250 31.75 1-11/16-12 — 286 211 50 328 242 M42 X 2 50 50 360 266
38 -24 1.500 38.10 2-12 — 326 240 60 374 276 M48 X 2 55 55 420 310
A
Tolerance is +15%, minus 20% of mean tightening torque unless otherwise specified.
B
The straight hex wrench sizes listed apply to connectors only and may not be the same as the corresponding plug of the same thread size.

OUO1073,00022E2 -19-29JAN08-1/1

TM100419 (02APR13) 10-10-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=35
General Specifications

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures
N79757 —UN—13FEB08

I B E
G C F
G
F
A D

A—Stud Straight and Tube Nut C—90° Swivel Elbow and Tube E—Port Plug I— Lock Nut
B—Bulkhead Union and Nut F— Stud End
Bulkhead Lock Nut D—90° Adjustable Stud Elbow G—Tube Nut
H—Swivel Nut

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressure-Below 27.6 MPA (4,000 PSI)
Nominal Tube OD O-Ring Face Seal/ Bulkhead Jam O-Ring Straight, Adjustable, and External Port Plug Stud EndsA
Hose ID Tube Swivel Nut Nut TorqueA
Metric Inch Tube OD Thread Swivel Tube Nut Jam Jam Thread Straight Adj Steel Aluminum
Tube Size Nut Hex Swivel Nut Nut Size Hex Lock or or
OD Size Nut Hex Torque SizeB Nut Gray Iron Brass
Torque Size Hex Torque TorqueC
Size
mm Da- in. mm in. in. N· lb-ft N· l- in. in. in. N·m lb-ft N·m lb-ft
sh m m b-f-
Size t
5 -3 0.188 4.78 — — — — — — — 3/8-24 5/8 9/16 12 9 8 6
6 -4 0.250 6.35 9/16-18 11/16 16 12 13/16 32 24 7/16-20 5/8 5/8 16 12 11 8
8 -5 0.312 7.92 — — — — — — — 1/2-20 3/4 11/16 24 18 16 12
10 -6 0.375 9.53 11/16-16 13/16 24 18 1 42 31 9/16-18 3/4 3/4 37 27 25 18
12 -8 0.500 12.70 13/16-16 15/16 50 37 1-1/8 93 69 3/4-16 7/8 15/16 50 37 33 25
16 -10 0.625 15.88 1-14 1-1/8 69 51 1-5/1 11 87 7/8-14 1-1/16 1-1/16 69 51 46 34
6 8
20 -12 0.750 19.05 1-3/16-12 1-3/8 10 75 1-1/2 17 12 1-1/16-12 1-1/4 1-3/8 102 75 68 50
2 5 9
22 -14 0.875 22.23 1-3/16-12 — 10 75 — 17 12 1-3/16-12 1-3/8 1-1/2 122 90 81 60
2 5 9
25 -16 1.000 25.40 1-7/16-12 1-5/8 14 105 1-3/4 24 18 1-5/16-12 1-1/2 1-5/8 142 105 95 70
2 7 2
32 -20 1.25 31.75 1-11/16-1 1-7/8 19 140 2 32 24 1-5/8-12 1-3/4 1-7/8 190 140 127 93
2 0 8 2
38 -24 1.50 38.10 2-12 2-1/4 21 160 2-3/8 37 27 1-7/8-12 2-1/8 2-1/8 217 160 145 107
7 4 6
50.8 -32 2.000 50.80 — — — — — — — 2-1/2-12 2-3/4 2-3/4 311 229 207 153
A
Tolerance is +15%, minus 20% of mean tightening torque unless otherwise specified.
B
The straight hex wrench sizes listed apply to connectors only and may not be the same as the corresponding plug of the same thread size.
C
These torques were established using steel plated connectors in aluminum and brass.

OUO1073,00022DE -19-29AUG08-1/1

TM100419 (02APR13) 10-10-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=36
General Specifications

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications
N79757 —UN—13FEB08

I B E
G C F
G
F
A D

A—Stud Straight and Tube Nut C—90° Swivel Elbow and Tube E—Port Plug I— Lock Nut
B—Bulkhead Union and Nut F— Stud End
Bulkhead Lock Nut D—90° Adjustable Stud Elbow G—Tube Nut
H—Swivel Nut

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure - Above 27.6 MPA (4,000
PSI), Working Pressure-41.3 MPA (6,000 PSI)
Nominal Tube OD O-Ring Face Seal/ Bulkhead Jam Nut O-Ring Straight, Adjustable, and External
Hose ID Tube Swivel Nut TorqueA Port Plug Stud EndsA
Met- Inch Tube OD Thread Size Swivel Tube Jam Jam Nut Thread Straight Adj Steel
ric Nut Hex Nut/Swivel Nut Hex Torque Size Hex SizeB Lock or
Tube Size Nut Torque Size Nut Gray Iron
OD Hex Torque
Size
mm D- in. mm in. in. N·m lb-ft N·m lb-ft in. in. in. N·m lb-ft
ash
Siz-
e
5 -3 0.188 4.78 — — — — — — — 3/8-24 5/8 9/16 18 13
6 -4 0.250 6.35 9/16-18 11/16 24 18 13/16 32 24 7/16-20 5/8 5/8 24 18
8 -5 0.312 7.92 — — — — — — — 1/2-20 3/4 11/16 30 22
10 -6 0.375 9.53 11/16-16 13/16 37 27 1 42 31 9/16-18 3/4 3/4 37 27
12 -8 0.500 12.70 13/16-16 15/16 63 46 1-1/8 93 69 3/4-16 7/8 15/16 75 55
16 -10 0.625 15.88 1-14 1-1/8 103 76 1-5/16 118 87 7/8-14 1-1/16 1-1/16 103 76
20 -12 0.750 19.05 1-3/16-12 1-3/8 152 112 1-1/2 175 129 1-1/16-12 1-1/4 1-3/8 177 131
22 -14 0.875 22.23 1-3/16-12 — 152 112 — 175 129 1-3/16-12 1-3/8 1-1/2 231 170
25 -16 1.000 25.40 1-7/16-12 1-5/8 214 158 1-3/4 247 182 1-5/16-12 1-1/2 1-5/8 270 199
32 -20 1.25 31.75 1-11/16-12 1-7/8 286 211 2 328 242 1-5/8-12 1-3/4 1-7/8 286 211
38 -24 1.50 38.10 2-12 2-1/4 326 240 2-3/8 374 276 1-7/8-12 2-1/8 2-1/8 326 240
A
Tolerance is +15%, minus 20% of mean tightening torque unless otherwise specified.
B
The straight hex wrench sizes listed apply to connectors only and may not be the same as the corresponding plug of the same thread size.

OUO1073,00022E0 -19-18JAN08-1/1

TM100419 (02APR13) 10-10-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=37
General Specifications

Four Bolt Flange Fittings Assembly and


Installation—All Pressure Applications
1. Clean sealing surfaces (A) and inspect. Scratches
cause leaks. Roughness causes seal wear and
unlevelness causes seal extrusion; therefore, if
defects cannot be polished out, replace component.
2. Install the correct o-ring (and backup washer if
required) into groove using petroleum jelly to hold it
in place.
3. Split flange (B): Loosely assemble split flange halves.
Make sure split is centrally located and perpendicular

CM992600061 —UN—12JAN00
to port. Hand-tighten bolts to hold parts in place. Do
not pinch o-ring (C).
4. One piece flange (D): Place hydraulic line in center of
flange and install four bolts. Flange must be centrally
located on port. Hand-tighten bolts to hold flange in
place. Do not pinch o-rings.
5. After components are properly positioned and bolts
are hand tightened, tighten one bolt, then tighten the
diagonally opposite bolt. Tighten the two remaining
bolts. Tighten all bolts as specified in the chart below.
6. Do Not use air wrenches. Do Not Tighten one bolt
fully before tightening the others. Do Not over tighten.
PW66162,00007EB -19-23OCT12-1/1

TM100419 (02APR13) 10-10-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=38
General Specifications

SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications

H70423 —UN—30NOV01
SAE Four Bolt Flange Cap Screw Torque Values—27,600 KPA (4,000 PSI) Pressure Applications
Torque
Newton Meters Foot Pounds
Nominal Flange Size Screw Sizea,b Min Max Min Max
1/2 5/16-18 UNC 20 31 15 23
3/4 3/8-16 UNC 28 54 21 40
1 3/8-16 UNC 37 54 27 40
1-1/4 7/16-14 UNC 47 85 35 63
1-1/2 1/2-13 UNC 62 131 46 97
2 1/2-13 UNC 73 131 54 97
2-1/2 1/2-13 UNC 107 131 79 97
3 5/8-11 UNC 187 264 138 195
3-1/2 5/8-11 UNC 158 264 117 195
4 5/8-11 UNC 158 264 117 195
5 5/8-11 UNC 158 264 117 195
a
JDM A17D, SAE Grade 5 or better cap screws with plated hardware.
b
1.5.1.2 Lock washers are permissible but not recommended.
OUO6435,0001549 -19-20NOV01-1/1

TM100419 (02APR13) 10-10-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=39
General Specifications

SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications

H70423 —UN—30NOV01
SAE Four Bolt Flange Cap Screw Torque Values—41,400 KPA (6,000 PSI) Pressure Applications
Torque
Newton Meters Foot Pounds
Nominal Flange Size Screw Sizea,b Min Max Min Max
1/2 5/16-18 UNC 20 31 15 23
3/4 3/8-16 UNC 34 54 25 40
1 7/16-14 UNC 57 85 42 63
1-1/4 1/2-13 UNC 85 131 63 63
1-1/2 5/8-11 UNC 159 264 117 195
2 3/4-10 UNC 271 468 200 345
a
JDM A17D, SAE Grade 5 or better cap screws with plated hardware.
b
1.5.1.2 Lock washers are permissible but not recommended.
OUO6435,000154C -19-29NOV01-1/1

TM100419 (02APR13) 10-10-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=40
General Specifications

Sealants and Adhesives Cross-Reference Chart


U.S. Part Number Canadian Part Color Size Description LOCTITE®
Number Number

Bonding

PM37513 PM38606 BLACK and 4 gm Epoxy Adhesive 445


WHITE
PM37391 PM38615 CLEAR 2 gm Gel Super Glue 454

Gasketing

PM38655 PM38625 PURPLE 50 mL Flexible Form-in-Place Gasket 515


PM37559 PM38600 BROWN 4 oz General Purpose Gasket Dressing —
PM38657 PM38628 BLUE 50 mL High-Flex Form-in-Place Gasket 17430
PM37553 — BURGUNDY 16 oz High Tack Gasket Dressing —
PM37465 PM38616 METALLIC 80 mL Ultra Blue RTV Silicone 587
BLUE
H154379 — Green — Sealant —

Priming

PM37509 PM38611 GREEN 4.5 oz Cure Primer 7649

Retaining

PM38651 PM38612 SILVER 50 mL QUICK METAL® Press Fit 660


PM37485 — GREEN 36 mL Maximum Strength 680
PM38652 PM38626 GREEN 36 mL High-Temperature 620

Thread Locking and Sealing

PM37477 PM38622 BLUE 36 mL Medium Strength 242


PM37418 PM38621 BLUE 6 mL Medium Strength 242
PM38654 PM38623 RED 36 mL High Strength 271
PM37421 PM38623 RED 6 mL High Strength 271
PM38656 PM38627 RED 36 mL High Strength 277
PM37398 PM38613 WHITE 6 mL Pipe Sealant with TEFLON® 592
PM37397 PM38613 WHITE 50 mL Pipe Sealant with TEFLON 592

LOCTITE is a trademark of Loctite Corp.


QUICK METAL is a trademark of Loctite Corp.
TEFLON is a trademark of Du Pont Co.
OUO6046,000218E -19-06MAR06-1/1

TM100419 (02APR13) 10-10-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=41
General Specifications

Harvester Specialty Tools and Part Numbers


Ground Drive

Number Name Use


CB01439350 (U.S.) Torque Multiplier Tool

1190315364 (U.S.) Tool - Track Recoil Spring

0841329348 (U.S.) Tool - Shaft Bullet 1”

0290289270 (U.S.) Tool - Axle Nut

0841331949 (U.S.) Tool - Sprocket Wear Gauge

0841338384 (U.S.) Tool - Roller Lube Nozzle

0290244461 (U.S.) Tool - Bushing Installer

0290244683 (U.S.) Tool - Sleeve

0290244684 (U.S.) Tool - Seal Installer

Base Cutter

Number Name Use


1190290188 (U.S.) Tool - Base Cutter Leg-Timing

1190323529 (U.S.) Puller Kit - Base Cutter Bearing

1191374512 (U.S.) Leg & Seal Alignment Tool

CB01407093 (U.S.) Base Cutter Leg Bearing Race


Installer

CB01444383 (U.S.) Tool - Base Cutter Seal Adapter

CB11422828 (U.S.) Tool - Base Cutter Leg Blocking


Assembly

CB11444166 (U.S.) Base Cutter Stand

CB11444448 (U.S.) Tool - Base Cutter Leg Bearing


Installer

Chopper

Number Name Use


CB01444732 (U.S.) Tool - Flywheel Seal

CB01444779 (U.S.) Tool - Chopper Box Freeze Plug

CB21443671 (U.S.) Motor Lift Tool

CB11444588 (U.S.) Flywheel Lifter

Continued on next page PW66162,000099D -19-21FEB13-1/2

TM100419 (02APR13) 10-10-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=42
General Specifications

Feed Rollers

Number Name Use


0290244355 (U.S.) Tool - Wiper Roll Bearing

0290244341 (U.S.) Tool - Front End Alignment

0841306323 (U.S.) Tool - Seal Installer

CB01444277 (U.S.) CRS - Tool - Freezer Plug - Feed Roller

Elevator

Number Name Use


0290227533 (U.S.) Tool - Swing Table Bearing

CB01445982 (U.S.) Tool - Swing Table Upper Bushing


Installer

CB01445983 (U.S.) Tool - Swing Table Lower Bushing


Installer

1190289732 (U.S.) Balancer - Extractor Fan Secondary

Base Cutter Cylinder

Number Name Use


CB11446203 (U.S.) Base Cutter Cylinder Trunnion
Seal Installer

CB11446242 (U.S.) Front Wheel Hub Cap Installer

CB11446249 (U.S.) Base Cutter Cylinder Trunnion


Cap Installer

PW66162,000099D -19-21FEB13-2/2

TM100419 (02APR13) 10-10-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=43
General Specifications

TM100419 (02APR13) 10-10-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=44
Group 15
Fuels and Lubricants
Lubricate Machine Properly Use only lubricants specified in this section.
IMPORTANT: Correct selection and proper use of Lubricate at the intervals listed in the
lubricating oils and grease is very important in machine's Operator's Manual.
keeping upkeep cost low, while providing long
machine life with satisfactory service.
NX1531,1015,A -19-13MAR97-1/1

Diesel Engine Break-In Oil


New engines are filled at the factory with either John • API Service Classification CC
Deere Break-In™ or John Deere Break-In Plus™ • ACEA Oil Sequence E2
Engine Oil. During the break-in period, add John Deere • ACEA Oil Sequence E1
Break-In™ or Break-In Plus ™ Engine Oil, respectively,
as needed to maintain the specified oil level. IMPORTANT: Do not use Plus-50™ II, Plus-50 or
engine oils meeting any of the following for the
Operate the engine under various conditions, particularly initial break-in of a new or rebuilt engine:
heavy loads with minimal idling, to help seat engine API CJ-4 ACEA E9
components properly.
API CI-4 PLUS ACEA E7
If John Deere Break-In Engine Oil is used during the initial API CI-4 ACEA E6
operation of a new or rebuilt engine, change the oil and API CH-4 ACEA E5
filter at a maximum of 250 hours.
API CG-4 ACEA E4
If John Deere Break-In Plus Engine Oil is used, change API CF-4 ACEA E3
the oil and filter at a minimum of 100 hours and a API CF-2
maximum equal to the interval specified for John Deere API CF
Plus-50™ II or Plus-50 oil.
After engine overhaul, fill the engine with either John These oils will not allow the engine to
Deere Break-In™ or Break-In Plus™ Engine Oil. break in properly.

If John Deere Break-In or Break-In Plus Engine Oil is John Deere Break-In Plus™ Engine Oil can be used for
not available, use an SAE 10W-30 viscosity grade diesel all John Deere diesel engines at all emission certification
engine oil meeting one of the following and change the oil levels.
and filter at a maximum of 100 hours of operation:
After the break-in period, use John Deere Plus-50™
• API Service Classification CE II, John Deere Plus-50, or other diesel engine oil as
• API Service Classification CD recommended in this manual.
Break-In is a trademark of Deere & Company.
Break-In Plus is a trademark of Deere & Company
Plus-50 is a trademark of Deere & Company.
DX,ENOIL4 -19-20APR11-1/1

TM100419 (02APR13) 10-15-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=45
Fuels and Lubricants

Diesel Engine Oil 50 o C 122o F


Use oil viscosity based on the expected air temperature
range during the period between oil changes. 40 o C 104o F

John Deere Plus-50™ II oil is preferred. 30 o C 86 o F

SAE 15W-40
John Deere Plus-50™ is also recommended.

SAE 10W-40
20 o C 68 o F

SAE 10W-30
Other oils may be used if they meet one or more of the

SAE 0W-40
SAE 5W-30
following: 10 o C 50 o F

• John Deere Torq-Gard™ 0o C 32 o F


• API Service Category CJ-4
• API Service Category CI-4 PLUS -10 o C 14 o F
• API Service Category CI-4
• ACEA Oil Sequence E9 -20 o C -4 o F
• ACEA Oil Sequence E7

TS1691 —UN—18JUL07
• ACEA Oil Sequence E6 -30 o C -22 o F
• ACEA Oil Sequence E5
• ACEA Oil Sequence E4
-40 o C -40 o F
Multi-viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply Oil Viscosities for Air Temperature Ranges
with all existing emissions regulations for the area in
which the engine operates.
DO NOT use diesel fuel with sulfur content greater than
10 000 mg/kg (10 000 ppm).
Plus-50 is a trademark of Deere & Company
Torq-Gard is a trademark of Deere & Company
DX,ENOIL11 -19-11APR11-1/1

TM100419 (02APR13) 10-15-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=46
Fuels and Lubricants

Diesel Fuel
Consult your local fuel distributor for properties of the
Sulfur Content for Tier 3 and Stage III A Engines
diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low • Use of diesel fuel with sulfur content less than 1000
temperature requirements of the geographical area in mg/kg (1000 ppm) is RECOMMENDED
which they are marketed. • Use of diesel fuel with sulfur content 1000–5000 mg/kg
(1000–5000 ppm) REDUCES oil and filter change
Diesel fuels specified to EN 590 or ASTM D975 are intervals.
recommended. Renewable diesel fuel produced by
hydrotreating animal fats and vegetable oils is basically • BEFORE using diesel fuel with sulfur content greater
identical to petroleum diesel fuel. Renewable diesel that than 5000 mg/kg (5000 ppm), contact your John Deere
meets EN 590 or ASTM D975 is acceptable for use at all dealer
percentage mixture levels. Sulfur Content for Tier 2 and Stage II Engines
Required Fuel Properties • Use of diesel fuel with sulfur content less than 500
In all cases, the fuel shall meet the following properties: mg/kg (500 ppm) is RECOMMENDED.
• Use of diesel fuel with sulfur content 500–5000 mg/kg
Cetane number of 43 minimum. Cetane number greater (500–5000 ppm) REDUCES the oil and filter change
than 47 is preferred, especially for temperatures below interval
–20°C (–4°F) or elevations above 1500 m (5000 ft.). • BEFORE using diesel fuel with sulfur content greater
than 5000 mg/kg (5000 ppm), contact your John Deere
Cold Filter Plugging Point (CFPP) should be at least 5°C dealer
(9°F) below the expected lowest temperature or Cloud
Point below the expected lowest ambient temperature. Sulfur Content for Other Engines
Fuel lubricity should pass a maximum scar diameter of • Use of diesel fuel with sulfur content less than 5000
0.45 mm as measured by ASTM D6079 or ISO 12156-1. mg/kg (5000 ppm) is recommended.
Diesel fuel quality and sulfur content must comply with • Use of diesel fuel with sulfur content greater than 5000
mg/kg (5000 ppm) REDUCES the oil and filter change
all existing emissions regulations for the area in which
intervals.
the engine operates. DO NOT use diesel fuel with sulfur
content greater than 10 000 mg/kg (10 000 ppm). IMPORTANT: Do not mix used diesel engine oil or any
other type of lubricating oil with diesel fuel.
Sulfur content for Interim Tier 4 and Stage III B engines
• Use ONLY ultra low sulfur diesel (ULSD) fuel with a IMPORTANT: Improper fuel additive usage may
maximum of 15 mg/kg (15 ppm) sulfur content. cause damage on fuel injection equipment
of diesel engines.
DX,FUEL1 -19-11APR11-1/1

Lubricity of Diesel Fuel


Most diesel fuels manufactured in the United States, If fuel of low or unknown lubricity is used, add John Deere
Canada, and the European Union have adequate lubricity Fuel-Protect Diesel Fuel Conditioner (or equivalent) at
to ensure proper operation and durability of fuel injection the specified concentration.
system components. However, diesel fuels manufactured
in some areas of the world may lack the necessary lubricity. Lubricity of Biodiesel Fuel
IMPORTANT: Make sure the diesel fuel used Fuel lubricity can improve significantly with biodiesel
in your machine demonstrates good blends up to B20 (20% biodiesel). Further increase in
lubricity characteristics. lubricity is limited for biodiesel blends greater than B20.

Fuel lubricity should pass a maximum scar diameter of


0.45 mm as measured by ASTM D6079 or ISO 12156-1.
DX,FUEL5 -19-14APR11-1/1

TM100419 (02APR13) 10-15-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=47
Fuels and Lubricants

Diesel Engine Coolant


The engine cooling system is filled to provide year-round A 50% mixture of propylene glycol engine coolant in water
protection against corrosion and cylinder liner pitting, and provides freeze protection to -33°C (-27°F).
winter freeze protection to -37°C (-34°F).
If protection at lower temperatures is required, consult
John Deere COOL-GARD is preferred for service. your John Deere dealer for recommendations.
If John Deere COOL-GARD is not available, use a low Water quality
silicate ethylene glycol or propylene glycol base coolant
concentrate in a 50% mixture of concentrate with quality Water quality is important to the performance of the
water. cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol and
The coolant concentrate shall be of a quality that provides propylene glycol base engine coolant concentrate.
cavitation protection to cast iron and aluminum parts in
the cooling system. John Deere COOL-GARD meets this IMPORTANT: Do not use cooling system sealing
requirement. additives or antifreeze that contains
sealing additives.
Freeze protection
A 50% mixture of ethylene glycol engine coolant in water IMPORTANT: Do not mix ethylene glycol and
provides freeze protection to -37°C (-34°F). propylene glycol base coolants.
DX,COOL8 -19-16NOV01-1/1

Heavy Duty Diesel Engine Coolant


The engine cooling system is filled to provide year-round
protection against corrosion and cylinder liner pitting, and
• Is formulated with a quality nitrite-free additive package.
winter freeze protection to -37°C (-34°F). If protection at
• Provides cylinder liner cavitation protection according to
either the John Deere Cavitation Test Method or a fleet
lower temperatures is required, consult your John Deere study run at or above 60% load capacity
dealer for recommendations.
• Protects the cooling system metals (cast iron, aluminum
The following engine coolants are preferred: alloys, and copper alloys such as brass) from corrosion

• John Deere COOL-GARD™ II Premix The additive package must be part of one of the following
• John Deere COOL-GARD II PG Premix coolant mixtures:

Use John Deere COOL-GARD II PG Premix when a • ethylene glycol or propylene glycol base prediluted
non-toxic coolant formulation is required. (40—60%) heavy duty coolant
• ethylene glycol or propylene glycol base heavy
Additional Recommended Coolants duty coolant concentrate in a 40—60% mixture of
concentrate with quality water
The following engine coolant is also recommended:
Water Quality
• John Deere COOL-GARD II Concentrate in a 40–60%
mixture of concentrate with quality water. Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
John Deere COOL-GARD II Premix, COOL-GARD II PG
water is recommended for mixing with ethylene glycol and
Premix, and COOL-GARD II Concentrate coolants do not
propylene glycol base engine coolant concentrate.
require use of supplemental coolant additives.
IMPORTANT: Do not use cooling system sealing
Other Coolants additives or antifreeze that contains
John Deere COOL-GARD II and COOL-GARD II PG sealing additives.
coolants might not be available in the geographical area Do not mix ethylene glycol and propylene
where service is performed. glycol base coolants.
If these coolants are unavailable, use a coolant Do not use coolants that contain nitrites.
concentrate or prediluted coolant intended for use with
heavy duty diesel engines and with a minimum of the
following chemical and physical properties:
COOL-GARD is a trademark of Deere & Company
DX,COOL3 -19-14APR11-1/1

TM100419 (02APR13) 10-15-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=48
Fuels and Lubricants

John Deere COOL-GARD™ II Coolant Extender


Some coolant additives will gradually deplete during IMPORTANT: Do not add a supplemental coolant
engine operation. For John Deere COOL-GARD™ II additive when the cooling system is drained
Premix, COOL-GARD II PG Premix, and COOL-GARD II and refilled with any of the following:
Concentrate, replenish coolant additives between drain
intervals by adding John Deere COOL-GARD II Coolant • John Deere COOL-GARD II
Extender. • John Deere COOL-GARD II PG
John Deere COOL-GARD II Coolant Extender should not The use of non-recommended supplemental coolant
be added unless indicated by coolant testing. additives may result in additive drop-out, gelation of the
John Deere COOL-GARD II Coolant Extender is a coolant, or corrosion of cooling system components.
chemically matched additive system for use with all Add the recommended concentration of John Deere
John Deere COOL-GARD II coolants. John Deere COOL-GARD II Coolant Extender. DO NOT add more
COOL-GARD II Coolant Extender is not intended for use than the recommended amount.
with nitrite-containing coolants.
COOL-GARD is a trademark of Deere & Company
DX,COOL16 -19-20APR11-1/1

TM100419 (02APR13) 10-15-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=49
Fuels and Lubricants

Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™
II Coolant Extender
Engine coolants are a combination of three chemical
Avoid Automotive-type Coolants
components: ethylene glycol (EG) or propylene glycol
(PG) antifreeze, inhibiting coolant additives, and quality Never use automotive-type coolants (such as those
water. meeting ASTM D3306). These coolants do not contain the
correct additives to protect heavy-duty diesel engines. Do
Coolant Specifications
not treat an automotive engine coolant with supplemental
John Deere COOL-GARD™ II Premix either EG or coolant additives because the high concentration of
PG, are fully formulated coolants that contain all three additives can result in additive fallout.
components in their correct concentrations. DO NOT
Water Quality
add an initial charge of John Deere COOL-GARD II
Coolant Extender to COOL-GARD II Premix. DO NOT Water quality is important to the performance of the
add any other supplemental coolant additive or water to cooling system. Distilled, deionized, or demineralized
COOL-GARD II Premix. water is recommended for mixing with ethylene glycol
John Deere COOL-GARD II Concentrate contains both and propylene glycol base engine coolant concentrate.All
ethylene glycol and inhibiting coolant additives. Mix this water used in the cooling system should meet the
product with quality water, but DO NOT add an initial following minimum specifications for quality:
charge of John Deere COOL-GARD II Coolant Extender Chlorides <40 mg/L
or any other supplemental coolant additive. Sulfates <100 mg/L

Replenish Coolant Additives Total dissolved solids <340 mg/L


Total hardness <170 mg/L
Some coolant additives will gradually deplete during pH 5.5 to 9.0
engine operation. Periodic replenishment of inhibitors
is required, even when John Deere COOL-GARD II Freeze Protection
Premix or COOL-GARD II Concentrate is used. Follow
the recommendations in this manual for the use of John The relative concentrations of glycol and water in the
Deere COOL-GARD II Coolant Extender. engine coolant determine its freeze protection limit.
Why use John Deere COOL-GARD II Coolant Ethylene Glycol Freeze Protection Limit
Extender? 40% -24°C (-12°F)
50% -37°C (-34°F)
Operating without proper coolant additives will result in
60% -52°C (-62°F)
increased corrosion, cylinder liner erosion and pitting, and
other damage to the engine and cooling system. A simple Propylene Glycol Freeze Protection Limit
mixture of ethylene glycol or propylene glycol and water 40% -21°C (-6°F)
will not give adequate protection. 50% -33°C (-27°F)
60% -49°C (-56°F)
John Deere COOL-GARD II Coolant Extender is a
chemically matched additive system designed to fortify the
proprietary additives used in John Deere COOL-GARD II DO NOT use a coolant-water mixture greater than 60%
Premix and COOL-GARD II Concentrate and to provide ethylene glycol or 60% propylene glycol.
optimum protection for up to six years or 6000 hours of
operation.
COOL-GARD is a trademark of Deere & Company
DX,COOL17 -19-20APR11-1/1

TM100419 (02APR13) 10-15-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=50
Fuels and Lubricants

Operating in Warm Temperature Climates


John Deere engines are designed to operate using glycol IMPORTANT: Water may be used as coolant in
base engine coolants. emergency situations only.
Always use a recommended glycol base engine coolant, Foaming, hot surface aluminum and iron
even when operating in geographical areas where freeze corrosion, scaling, and cavitation will occur
protection is not required. when water is used as the coolant, even when
John Deere COOL-GARD™ II Premix is available in a coolant conditioners are added.
concentration of 50% ethylene glycol. However, there Drain cooling system and refill with
are situations in warm temperature climates where a recommended glycol base engine coolant
coolant with lower glycol concentration (approximately as soon as possible.
20% ethylene glycol) has been approved. In these cases,
the low glycol formulation has been modified to provide
the same level of corrosion inhibitor as John Deere
COOL-GARD II Premix (50/50).

COOL-GARD is a trademark of Deere & Company


DX,COOL6 -19-03NOV08-1/1

Supplemental Coolant Additives


Some coolant additives will gradually deplete during
engine operation. For nitrite-containing coolants,
• John Deere COOL-GARD II
replenish coolant additives between drain intervals by
• John Deere COOL-GARD II PG
adding a supplemental coolant additive as determined If other coolants are used, consult the coolant supplier
necessary by coolant testing. and follow the manufacturer's recommendation for use of
John Deere Liquid Coolant Conditioner is recommended supplemental coolant additives.
as a supplemental coolant additive for nitrite-containing The use of non-recommended supplemental coolant
coolants. additives may result in additive drop-out and gelation of
John Deere Liquid Coolant Conditioner is not designed the coolant.
for use with John Deere COOL-GARD™ II Premix, Add the manufacturer's recommended concentration of
COOL-GARD II PG Premix, or COOL-GARD II supplemental coolant additive. DO NOT add more than
Concentrate. the recommended amount.
IMPORTANT: Do not add a supplemental coolant
additive when the cooling system is drained
and refilled with any of the following:
COOL-GARD is a trademark of Deere & Company
DX,COOL4 -19-14APR11-1/1

TM100419 (02APR13) 10-15-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=51
Fuels and Lubricants

Testing Diesel Engine Coolant


Maintaining adequate concentrations of glycol and
inhibiting additives in the coolant is critical to protect the Add only the recommended concentration of John Deere
engine and cooling system against freezing, corrosion, COOL-GARD II Coolant Extender. DO NOT add more
and cylinder liner erosion and pitting. than the recommended amount.

Test the coolant solution at intervals of 12 months or less When Using Nitrite-Containing Coolants
and whenever excessive coolant is lost through leaks or Compare the test strip results to the supplemental coolant
overheating. additive (SCA) chart to determine the amount of inhibiting
Coolant Test Strips additives in your coolant and whether more John Deere
Liquid Coolant Conditioner should be added.
Coolant test strips are available from your John Deere
dealer. These test strips provide a simple, effective Add only the recommended concentration of John Deere
method to check the freeze point and additive levels of Liquid Coolant Conditioner. DO NOT add more than the
your engine coolant. recommended amount.

When Using John Deere COOL-GARD II Coolant Analysis

John Deere COOL-GARD II Premix™ , COOL-GARD For a more thorough evaluation of your coolant, perform a
II PG Premix and COOL-GARD II Concentrate are coolant analysis. The coolant analysis can provide critical
maintenance free coolants for up to six years or 6000 data such as freezing point, antifreeze level, pH, alkalinity,
hours of operation, provided that the cooling system is nitrite content (cavitation control additive), molybdate
topped off using only John Deere COOL-GARD II Premix content (rust inhibitor additive), silicate content, corrosion
or COOL-GARD II PG premix. Test the coolant condition metals, and visual assessment.
annually with coolant test strips designed for use with Contact your John Deere dealer for more information on
John Deere COOL-GARD II coolants. If the test strip coolant analysis.
chart indicates that additive is required, add John Deere
COOL-GARD II Coolant Extender as directed.
COOL-GARD is a trademark of Deere & Company
DX,COOL9 -19-11APR11-1/1

TM100419 (02APR13) 10-15-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=52
Fuels and Lubricants

Pump Drive, Base Cutter, and Chopper Gear


Case Oil
Depending upon the expected air temperature range
during the drain interval, use oil viscosity shown on the
adjoining temperature chart.
John Deere 85W/140 EP (Extreme Pressure) API GL-5
gear oil is recommended. If other oils are used, they must
meet performance requirements of:
• API Service Classification GL-5
• Military Specification MIL-L-2105C

TS1416 —UN—31JAN94
PW66162,00007FC -19-21FEB13-1/1

Hydraulic Oil
The standard hydraulic oil is SAE 10W30, super high
performance. ISO 68 hydraulic oil is optionally available. 50ºC 122ºF
Other oils may be used if they meet one of the following 40ºC 104ºF
specifications: API Service CF-4/SH, MIL-L-2140C,
MIL-L-2140CD, OR MIL-L-2140B. 86ºF
30ºC
SAE 10W30

SAE 15W40

20ºC 68ºF

10ºC 50ºF

0ºC 32ºF
CQ284935 —UN—23DEC11

-10ºC 14ºF

-20ºC -4ºF

-23ºC -10ºF

PW66162,0000467 -19-21FEB13-1/1

TM100419 (02APR13) 10-15-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=53
Fuels and Lubricants

Final Drive Gear Oil


Recommended oil is a synthetic oil with EP (Extreme
Pressure) features complying with MILL- 2105C and API
GL5 with a viscosity grade of 80W- 140.
PW66162,00007FD -19-23OCT12-1/1

Grease
Use grease based on NLGI consistency numbers and the
expected air temperature range during the service interval.
John Deere SD Polyurea Grease is preferred.
The following greases are also recommended:
• John Deere HD Lithium Complex Grease
• John Deere HD Water Resistant Grease
• John DeereGREASE-GARD™
Other greases may be used if they meet the following:
• NLGI Performance Classification GC-LB
IMPORTANT: Some types of grease thickeners are not

TS1673 —UN—31OCT03
compatible with others. Consult your grease
supplier before mixing different types of grease.

Greases for Air Temperature Ranges

GREASE-GARD is a trademark of Deere & Company


DX,GREA1 -19-14APR11-1/1

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require The temperature limits and service intervals shown in
lubricant recommendations different from those printed in this manual apply to both conventional and synthetic
this manual. lubricants.
Some John Deere brand coolants and lubricants may not
Re-refined base stock products may be used if the
be available in your location.
finished lubricant meets the performance requirements.
Consult your John Deere dealer to obtain information and
recommendations.
Synthetic lubricants may be used if they meet the
performance requirements as shown in this manual.
DX,ALTER -19-11APR11-1/1

TM100419 (02APR13) 10-15-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=54
Group 20
Tune-Up and Adjustments
Tune-Up and Adjustment
General Information
• Clean radiator core, air conditioning condenser,
Before tuning up harvester engine, determine whether a hydraulic cooler, and charge air cooler.
tune-up will restore operating efficiency. When there is • Check radiator cap.
doubt, the following preliminary tests will help determine if • Inspect all hoses.
the engine can be tuned up. If the condition is satisfactory, Cylinder Head and Valves:
proceed with the tune-up. Choose from the following
procedures only those necessary to restore the harvester. • Set valve clearance.
Preliminary Engine Testing Fuel System:

Test for engine compression (minimum readings at • Check fuel tank for water and drain off, if necessary.
cranking speed). It is very important that all cylinder • Check fuel tank and lines for leaks or restrictions.
pressures be approximately alike. There should be less • Check electric fuel pump pressure.
than 172 kPa (1.72 bar) (25 psi) difference between • Bleed fuel system.
cylinder pressures. • Check injection pump timing.
• Replace fuel filter.
Engine Tune-Up • Replace water separator.
Air Intake System: Electrical System
• Check system for leaks. • Clean and tighten battery cables and connections.
Exhaust System:
• Check alternator belt for wear and damage.
• Check alternator output.
• Check system for leaks. Check for restricted muffler • Check neutral safety start switch operation.
or exhaust pipe. • Check safety seat switch operation.
• Check starter draw.
Crankcase Vent: • Check battery voltage.
• Check for restrictions. • Inspect all wiring.
Cooling System:
PW66162,0000918 -19-18JAN13-1/1

TM100419 (02APR13) 10-20-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=55
Tune-Up and Adjustments

TM100419 (02APR13) 10-20-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=56
Section 20
Engine
Contents

Page

Group 05—Component Removal and Installation


Specifications ................................................ 20-05-1
John Deere Engine Repair—Use
CTM........................................................... 20-05-1
Inspect Belt Tensioner ................................... 20-05-2

Group 10—Cooling System


Specifications ................................................ 20-10-1
Special Tools ................................................. 20-10-1
Test Radiator Cap.......................................... 20-10-1
Test Surge Tank Cap ..................................... 20-10-2
Test Radiator and Surge Tank ....................... 20-10-2
Thermostat Repair—Use CTM ...................... 20-10-3
Engine Water Pump Repair—Use
CTM........................................................... 20-10-3

Group 20—Auxiliary Coolers


Remove and Install Air Conditioning
Condenser-Fuel Cooler ............................. 20-20-1

TM100419 (02APR13) 20-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 20-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Component Removal and Installation
Specifications
Item Measurement Specification

Belt Tensioner Mounting Cap Screw Torque 35 N·m


(26 lb.-ft.)
PW66162,000091F -19-18JAN13-1/1

John Deere Engine Repair—Use CTM


For complete repair information, the component technical
manual (CTM) is also required. Use the appropriate
component technical manual in conjunction with this
machine manual.

P15127 —UN—10JAN08
TP40492,000109E -19-13SEP12-1/1

TM100419 (02APR13) 20-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=59
Component Removal and Installation

Inspect Belt Tensioner


IMPORTANT: Inspect all belt tensioner and pulley
systems in this manner.

NOTE: Pulley and dust shield can be serviced separate


from spring tensioner. Spring tensioner is
serviced as an assembly.

1. With belt ON the drive, perform the following


checks: A

a. Check to see if tensioning arm (A) is against free


arm stops (B). Replace belt if this condition is seen.

RXA0073092 —UN—09JAN04
b. Check belt tracking mark on the pulley. Replace
belt tensioner if tracking mark is considerably wider
than belt.
2. With belt OFF the drive, perform the following
checks: B
B
NOTE: Do not pry between pulley and spring case.

a. Release tension on belt using a long-handle 1/2 in.


drive tool. Remove belt from alternator pulley.
b. Release tension on tension arm (A).
c. Rotate tension arm (A) slowly using a 1/2 in. drive C

RXA0074277 —UN—29MAR04
tool. Arm should rotate smoothly between arm
stops (B); if not, replace tensioner.
d. Replace tension mechanism if there is:
• Metal-to-metal contact is present between rotating
and stationary parts at location (C and D) on
tensioner.
• Cracks or broken spring case or broken stops.
3. Install belt tensioner with cap screw to engine front
cover at mounting holes. Tighten to specification. D
Specification
Belt Tensioner Mounting

RXA0073094 —UN—09JAN04
Cap Screw—Torque......................................................................35 N·m
(26 lb.-ft.)

A—Tension Arm C—Metal-to-Metal Contact


B—Free Arm Stops Between Arm and Spring
Case
D—Metal-to-Metal Contact
Between Arm and End Cap

PW66162,000091E -19-18JAN13-1/1

TM100419 (02APR13) 20-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=60
Group 10
Cooling System
Specifications
Item Measurement Specification

Radiator Cap Test Pressure 103.4 kPa


(1.03 bar)
(15 psi)
Surge Tank Cap Test Pressure 103.4 kPa
(1.03 bar)
(15 psi)
Radiator Test Pressure 124 kPa
(1.2 bar)
(18 psi)
Surge Tank Test Pressure 103 kPa
(1.3 bar)
(15 psi)
PW66162,000091D -19-18JAN13-1/1

Special Tools
For more information, or to order tools referenced in this
group, see the SERVICEGARD™ online tool catalog or
your John Deere dealer.
SERVICEGARD is a trademark of Deere & Company

PW66162,00009C9 -19-19MAR13-1/1

Test Radiator Cap


SPECIAL TOOLS NEEDED:
• Cooling System Pressure Pump
Used to pressure check cooling system components.
Tool Number—D05104ST
Install D05104ST Pressure Pump1.
Pressurize cap and relief should occur close to
specification.

R26406N —UN—29NOV88
Specification
Radiator Cap—Test
Pressure................................................................................... 103.4 kPa
(1.03 bar)
(15 psi)

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.

PW66162,000091A -19-18JAN13-1/1

TM100419 (02APR13) 20-10-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=61
Cooling System

Test Surge Tank Cap


SPECIAL TOOLS NEEDED:
• Cooling System Pressure Pump
Used to pressure check cooling system components.
Tool Number—D05104ST
• Surge Tank Pressure Test Adapter Kit
Adapter used with D05104ST cooling system pressure
pump.
Tool Number—JDG10539

R26406N —UN—29NOV88
1. Install D05104ST Pressure Pump1 and JDG10539-2
Adapter1 on surge tank cap.
2. Pressurize cap and relief should occur close to
specification.
Specification
Surge Tank Cap—Test
Pressure................................................................................... 103.4 kPa
(1.03 bar)
(15 psi)
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,000091B -19-18JAN13-1/1

Test Radiator and Surge Tank


SPECIAL TOOLS NEEDED:
• Cooling System Pressure Pump
Used to pressure check cooling system components.
Tool Number—D05104ST

RW4517 —UN—15NOV88
Surge Tank Pressure Test Adapter Kit
Adapter used with D05104ST cooling system pressure
pump.
Tool Number—JDG10539
Remove cap and visually check radiator or surge tank
for leaks or damage.
Attach D05104ST Pressure Pump1 in radiator neck.
Pressurize radiator according to specifications. Repair if
Surge Tank—Test
radiator does not maintain pressure to specification.
Pressure...................................................................................... 103 kPa
To test surge tank, use JDG10539 Surge Tank Pressure (1.3 bar)
Test Adapter Kit1. Pressurize tank to specifications using (15 psi)
JDG10539-1 Adapter1 along with coolant leak off hose
plug. Repair or replace as necessary.
Specification
Radiator—Test
Pressure...................................................................................... 124 kPa
(1.2 bar)
(18 psi)
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,000091C -19-18JAN13-1/1

TM100419 (02APR13) 20-10-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=62
Cooling System

Thermostat Repair—Use CTM


For complete repair information, the component technical
manual (CTM) is also required. Use the appropriate
component technical manual in conjunction with this
machine manual.

P15127 —UN—10JAN08
TP40492,000108F -19-11SEP12-1/1

Engine Water Pump Repair—Use CTM


For complete repair information, the component technical
manual (CTM) is also required. Use the appropriate
component technical manual in conjunction with this
machine manual.

P15127 —UN—10JAN08
TP40492,0000134 -19-17APR09-1/1

TM100419 (02APR13) 20-10-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=63
Cooling System

TM100419 (02APR13) 20-10-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=64
Group 20
Auxiliary Coolers
Remove and Install Air Conditioning
Condenser-Fuel Cooler
1. Recover refrigerant from system. (See Discharge
and Recover Air Conditioning System in Section 90,
Group 05.)
2. Disconnect latches and open cooling package door
until door rests on door stop.

CAUTION: Avoid personal injury. Fins on


condenser-fuel cooler are sharp. Use

T8130000256 —UN—23JAN13
protective clothing.

3. Tag and disconnect refrigerant hoses (D). Cap and


plug hoses and fittings.
NOTE: Use pinch pliers to clamp fuel hoses (B) before
disconnecting to prevent excessive fuel loss.
Cut tie bands as necessary.
Do not allow condenser to fall forward after cap
screws have been removed from brackets. A—Nut D—Refrigerant Hoses
B—Fuel Hoses (2 used) E—Latch
Lower bracket is not removable from C—Cap Screw (2 used) F— Nut
condenser-fuel cooler.

4. Loosen hose clamps and disconnect fuel hoses (B).


Cap and plug hoses and fittings. 9. Repair or replace as needed. (See Repair Condenser
in Section 90, Group 10.)
5. Remove nut (F) and cap screw from lower bracket.
10. Install in reverse order of removal using these special
6. Remove nut (A) and cap screw from upper bracket. instructions:
7. Pull latch (E) downward and remove air conditioning • If removed, install upper bracket.
condenser-fuel cooler. • Charge air conditioning. (See Charge Air
8. If necessary, remove cap screws (C) and upper Conditioning System in Section 90, Group 05.)
bracket from condenser-fuel cooler.
PW66162,0000937 -19-23JAN13-1/1

TM100419 (02APR13) 20-20-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=65
Auxiliary Coolers

TM100419 (02APR13) 20-20-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=66
Section 30
Fuel and Air
Contents

Page

Group 05—Diesel Fuel System


Other Material................................................ 30-05-1
John Deere Fuel System
Repair—Use CTM ..................................... 30-05-1
Remove and Install Fuel Filters ..................... 30-05-2
Bleed Fuel System—Use CTM...................... 30-05-3
Remove and Install Fuel Tank ....................... 30-05-4
Remove and Install Fuel Cooler .................... 30-05-9

Group 10—Air Intake System


Remove and Install Engine Air
Filters......................................................... 30-10-1
Clean and Inspect Primary Air
Filter........................................................... 30-10-1
Remove and Install Air Cleaner
Inlet Assembly ........................................... 30-10-2
Turbocharger Repair—Use CTM................... 30-10-2

TM100419 (02APR13) 30-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 30-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Diesel Fuel System
Other Material
Number Name Use
PM37397 (U.S.) Pipe Sealant Used to seal threads.
592 (LOCTITE®)

Loctite is a trademark of Henkel Corporation


PW66162,0000943 -19-31JAN13-1/1

John Deere Fuel System Repair—Use CTM


For complete repair information, the component technical
manual (CTM) is also required. Use the appropriate
component technical manual in conjunction with this
machine manual.

P15127 —UN—10JAN08
PW66162,00005E8 -19-01NOV12-1/1

TM100419 (02APR13) 30-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=69
Diesel Fuel System

Remove and Install Fuel Filters


CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury. Relieve
pressure before disconnecting fuel or other lines.
Tighten all connections before applying pressure.

X9811 —UN—23AUG88
Keep hands and body away from pinholes and
nozzles which eject fluids under high pressure.
Use a piece of cardboard or paper to search
for leaks. Do not use your hand.
If ANY fluid is injected into the skin, it must
be surgically removed within a few hours by
High Pressure Fluids
a doctor familiar with this type of injury or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other
knowledgeable medical source.

CAUTION: Due to High Pressure Common Rail


system design, fuel in filter is likely to be under
high pressure. To avoid possible personal harm,
open valves (B) and (J) on bottom of filters to
relieve pressure prior to removing each filter.
Avoid fire hazard from spilled fuel. Use
appropriate container and materials to catch and

RG14250 —UN—06JUN05
clean up fuel when replacing filter elements.

IMPORTANT: Avoid damaging fuel injection system.


Remove all dirt and contamination from filter
assemblies and surrounding area.
Both Primary and Final filters must be replaced
at the same time. Do NOT pre-fill filters with fuel.
A—Primary Filter Header G—Canister Lip
Remove and Install Primary and Final B—Primary Filter Drain Valve H—Header Lip
Fuel Filter Elements C—Water-In-Fuel Sensor I— Final Filter Header
Connector J— Drain Valve
1. Park machine on level surface, shut off engine, and D—Primary Filter Canister K—Final Filter
remove key. E—Primary Filter Element L— Filter Packing
F— Packing
2. Thoroughly clean primary filter header (A) and
surrounding area.
3. Connect a fuel drain line to primary filter drain valve 10. Place new primary filter element (E) in canister (D)
(B) on bottom of filter and drain all fuel from primary with tangs on bottom going into canister.
filter canister (D).
11. Screw canister (D) into filter header (A), turn clockwise.
4. Disconnect water-in-fuel sensor connector (C). Tighten until canister lip (G) snugly mates with header
lip (H).
5. Turn primary filter canister (D) counterclockwise and
remove. 12. Turn filter additional 3/4 turn after seal contact with
header.
6. Pull primary filter element (E) downward and remove
from primary filter header. 13. Connect water-in-fuel sensor connector (C).
7. Inspect primary filter header and primary filter canister 14. Thoroughly clean final filter header (I) and surrounding
sealing surfaces. Clean as required. area.
8. Place new packing (F) on primary filter canister. 15. Connect a fuel drain line to drain valve (J) on bottom
of filter and drain all fuel from the filter.
9. Place a thin film of fuel on primary filter packing (F).
16. Turn final filter (K) counterclockwise to remove.

Continued on next page PW66162,00009DD -19-02APR13-1/3

TM100419 (02APR13) 30-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=70
Diesel Fuel System

17. Inspect final filter header sealing surface and clean 21. Screw final filter clockwise into final filter header.
as required. Tighten until final filter snugly mates with final filter
header.
18. Install drain valve and tighten to specification.
Specification
22. Turn filter additional 3/4 turn after seal contact with
Final Fuel Filter Drain
header.
Valve—Torque........................................................................ 3.4—4 N·m NOTE: If necessary, turn key off and on again to repeat
(30—35 lb.-in.) priming procedure before starting engine.
19. Install new filter packing (L) on filter.
23. Turn ignition key to ON for 60 seconds to prime the
20. Apply a thin film of fuel on filter packing. fuel system before starting engine.
PW66162,00009DD -19-02APR13-2/3

Remove and Install 30 Micron Fuel Filter


1. Thoroughly clean filter assembly and surrounding area.
2. Turn handle (A) and remove cover (B).
3. Remove and discard filter element (C).
4. Install new filter element and verify that it is seated
inside housing.
5. Install cover and tighten handle.
NOTE: If necessary, turn key off and on again to repeat
priming procedure before starting engine.

T8120002634 —UN—07JAN13
6. Turn ignition key to ON for 60 seconds to prime the
fuel system before starting engine.
7. Operate machine for 3 minutes and check for leaks.

A—Handle C—Filter Element


B—Cover

PW66162,00009DD -19-02APR13-3/3

Bleed Fuel System—Use CTM


For complete repair information, the component technical
manual (CTM) is also required. Use the appropriate
component technical manual in conjunction with this
machine manual.
P15127 —UN—10JAN08

TP40492,0001091 -19-01NOV12-1/1

TM100419 (02APR13) 30-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=71
Diesel Fuel System

Remove and Install Fuel Tank


1. Park machine on level surface, shut off engine, and
remove key.
2. Disconnect batteries. (See Battery Disconnect Switch
in Section 40, Group 05.)
IMPORTANT: Avoid damaging fuel injection
system. Remove all dirt and contamination
around tank fittings.

3. Clean fuel tank (A) and surrounding area.

T8130000253 —UN—22JAN13
4. Close valve (E).
5. Disconnect and plug hose (D).
NOTE: Approximate capacity of fuel tank is 568
L (150 gal.).
Removing drain plug (C) allows for complete
drainage of fuel tank.

6. Connect a new hose to valve and place opposite end


of hose into an appropriate container.
7. Open valve and drain fuel. Close valve.

T8130000254 —UN—22JAN13
8. Loosen clamp (B).
9. Remove drain plug (C) and drain remaining fuel into
an appropriate container.
10. Install drain plug and tighten clamp.
11. Remove valve (E). Plug open tank fitting.

A—Fuel Tank D—Hose


B—Clamp E—Valve
C—Drain Plug

Continued on next page PW66162,00009DC -19-02APR13-1/8

TM100419 (02APR13) 30-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=72
Diesel Fuel System

12. Remove side cap screws (B), upper cap screws (A),
and front lower cooling package shield (C).
13. Disconnect fuel level sensor electrical connector (D).

A—Upper Cap Screw (2 used) C—Front Lower Cooling


B—Side Cap Screw (6 used) Package Shield
D—Fuel Level Sensor Electrical
Connector

T8130000261 —UN—29JAN13
T8130000262 —UN—29JAN13
PW66162,00009DC -19-02APR13-2/8

14. Remove left-hand ladder (B). (See Remove and Install


Left-Hand Ladder in Section 80, Group 05.)
15. Remove cap screws (A) and platform plate (C).

A—Cap Screw (5 used) C—Platform Plate


B—Left-Hand Ladder

T8130000263 —UN—29JAN13

Continued on next page PW66162,00009DC -19-02APR13-3/8

TM100419 (02APR13) 30-05-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=73
Diesel Fuel System

16. Disconnect electrical connectors (B) located behind air


cleaner shield (D) near alarm (A).
17. Remove nut (C) and cap screw.
18. Remove cap screws (H) and support (I).

T8130000264 —UN—29JAN13
19. Loosen locking nuts (G).
20. Remove cap screws (F) that retain P-clamps to air
cleaner shield.
21. Remove cap screws (E).
22. Remove nuts, cap screws (J), and air cleaner shield.

A—Alarm F— Cap Screw (2 used)


B—Electrical Connectors (2 G—Locking Nut (2 used)
used) H—Cap Screw (4 used)
C—Nut I— Support
D—Air Cleaner Shield J— Cap Screw (4 used)
E—Cap Screw (2 used)

T8130000265 —UN—29JAN13
Continued on next page PW66162,00009DC -19-02APR13-4/8

TM100419 (02APR13) 30-05-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=74
Diesel Fuel System

23. Loosen and remove cap screws as necessary to


position lift point cover (A) as shown.
24. Loosen clamps and remove railing (B).

T8130000269 —UN—30JAN13
CAUTION: Approximate weight of platform
is 29 kg (64 lb.).

25. Remove cap screws (D) and platform (C).


26. Remove cap screws (E).

A—Lift Point Cover D—Cap Screw (12 used)


B—Railing E—Cap Screws (2 used)
C—Platform

T8130000266 —UN—30JAN13
Continued on next page PW66162,00009DC -19-02APR13-5/8

TM100419 (02APR13) 30-05-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=75
Diesel Fuel System

27. Remove nuts, U-bolt (B), and clamp base from charge
air cooler tube (A).
28. Remove nuts (C) and inner carriage bolts.
29. Remove nuts (D) and cap screws.

T8130000267 —UN—30JAN13
30. Remove nuts (E) and outer carriage bolts.
NOTE: Cooling package lower rubber isolator
shown removed for clarity.
Catch clamp base (G) as upper platform
support is removed.

31. Disconnect vent hose from fitting (H). Cap opening


in fuel tank.
32. Remove nuts and U-bolt (F).
33. Pull upper platform support (I) outward and remove.

T8130000268 —UN—30JAN13
34. Disconnect fuel return hose (J). Cap and plug hose
and fitting.

A—Charge Air Cooler Tube F— U-Bolt


B—U-Bolt G—Clamp Base
C—Nut (2 used) H—Fitting
D—Nuts (2 used) I— Upper Platform Support
E—Nuts (2 used) J— Fuel Return Hose

T8130000270 —UN—30JAN13
T8130000456 —UN—30JAN13

Continued on next page PW66162,00009DC -19-02APR13-6/8

TM100419 (02APR13) 30-05-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=76
Diesel Fuel System

35. Tilt cab. (See Cab Tilt Procedure in Section 90, Group
20.)
36. Remove cap screws (A) and center platform (B).
37. Remove cap screws (D) and lower platform support

T8130000457 —UN—30JAN13
(C).

A—Cap Screw (6 used) C—Lower Platform Support


B—Center Platform D—Cap Screw (4 used)

PW66162,00009DC -19-02APR13-7/8

38. Remove locking nut and cap screw (A). Position fuel
tank strap (B) rearward.

CAUTION: Approximate weight of fuel tank


is 43 kg (95 lb.).

T8130000459 —UN—01FEB13
39. Support fuel tank with an appropriate lifting device.
NOTE: Position hoses and wire harnesses as
necessary to remove fuel tank.

40. Slide fuel tank outward away from frame and remove.
41. If necessary, remove fuel level sensor.
42. Repair or replace fuel tank as necessary.
A—Cap Screw B—Fuel Tank Strap
43. Install fuel tank in reverse order of removal using the
following special instructions:
• Apply PM37397 Pipe Sealant to fuel tank fittings.
• Be sure to route all hoses and harnesses free from • Turn key switch to the ON position for 60 seconds
pinch points and without twists or binds. before starting engine to prime fuel system.
• Clean and inspect fuel tank supports. Repair or • Operate machine for 3 minutes and check for leaks.
replace as necessary.
PW66162,00009DC -19-02APR13-8/8

Remove and Install Fuel Cooler Condenser-Fuel Cooler in Section 20, Group 20 for
removal and installation of air conditioning condenser-fuel
Fuel cooler is integrated into the air conditioning system cooler.)
condenser. (See Remove and Install Air Conditioning
PW66162,0000934 -19-22JAN13-1/1

TM100419 (02APR13) 30-05-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=77
Diesel Fuel System

TM100419 (02APR13) 30-05-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=78
Group 10
Air Intake System
Remove and Install Engine Air Filters
NOTE: Clean only primary filter when engine air filter
restriction warning light in cab comes on.
Primary and secondary air filters are located

T8130000460 —UN—31JAN13
inside housing behind end cap (A).

1. Unlatch clamps (B) and remove end cap (A).


IMPORTANT: If secondary filter is dirty or seal
is damaged, replace filter.

2. Remove and inspect primary and secondary filters.


(See Clean and Inspect Primary Air Filter in Section
30, Group 10.)
A—End Cap B—Clamps (3 used)
3. Remove any debris from inside housing.
4. Install in reverse order.
PW66162,000093F -19-28FEB13-1/1

Clean and Inspect Primary Air Filter


IMPORTANT: Do not attempt to clean secondary filter
(B). Replace secondary air filter every second
or third primary air filter change.

Cleaning Dusty Filter

E58856 —UN—02AUG10
Tap sides of primary air filter (A) gently by hand to loosen
dirt. Do not tap filter against a hard surface.
IMPORTANT: Use compressed air to clean primary
air filter; use only a special air cleaning gun.
Ordinary air nozzle severely damages air filter
due to concentrated air pressure.
A—Primary Air Filter B—Secondary Air Filter
When tapping filter does not remove dust, clean filter with
compressed air. Hold nozzle next to inner surface and
move up and down pleats.
Ensure gasket is in good condition.
IMPORTANT: Do not direct air against outside of
filter, this forces dirt through to inside. Replacing Air Filter
Repeat procedure to remove additional dirt. Replace primary air filter after one year of service, six
cleanings, or when air filter restriction warning light
Inspect air filter before reinstalling. remains on. Replace damaged filters immediately.
Inspecting
Hold a bright light inside filter and check for damage.
Discard filter when screen is damaged or when filter
shows slightest rupture or hole.
PW66162,0000940 -19-31JAN13-1/1

TM100419 (02APR13) 30-10-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=79
Air Intake System

Remove and Install Air Cleaner Inlet


Assembly
1. Turn off engine and remove key.
2. Loosen clamp (A) attached to elbow (B).
3. Completely loosen clamps (E) until clamp halves are
disconnected.
4. Lift air cleaner inlet assembly (D) upward and remove.
IMPORTANT: Do not allow moisture or debris to

T8130000461 —UN—31JAN13
enter opening in elbow. Cap opening until air
cleaner inlet assembly is installed.

5. Cap opening in elbow.


6. Remove screen (C) from assembly. Clean as needed.
7. Inspect all parts. Replace or repair as necessary.
8. Install in reverse order.

A—Clamp D—Air Cleaner Inlet Assembly


B—Elbow E—Clamp (2 used)
C—Screen

T8130000462 —UN—31JAN13
PW66162,0000941 -19-31JAN13-1/1

Turbocharger Repair—Use CTM


For complete repair information the component technical
manual (CTM) is also required. Use the appropriate
component manual in conjunction with this machine
manual.
P15127 —UN—10JAN08

Service ADVISOR™ Manuals Tab

OUO1073,0002292 -19-04JAN08-1/1

TM100419 (02APR13) 30-10-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=80
Section 40
Electrical
Contents

Page
Page
Group 05—Batteries
Specifications ................................................ 40-05-1 Remove and Install Hydraulic Oil
Servicing Battery ........................................... 40-05-1 Temperature Sensor .................................. 40-20-4
Checking Battery Fluid Level......................... 40-05-2 Remove and Install Hydraulic
Preventing Battery Damage .......................... 40-05-2 Reservoir Level Switch .............................. 40-20-5
Charging Battery............................................ 40-05-3 Remove and Install Crop Divider
Battery Disconnect Switch............................. 40-05-4 Position Sensor (If Equipped).................... 40-20-6
Remove and Install Batteries......................... 40-05-5 Remove and Install Air Filter
Restriction Switch ...................................... 40-20-7
Group 10—Electrical Harness and Connectors
Use Electrical Insulating Group 30—Fuses and Relays
Compound ................................................. 40-10-1 Replacing Fuses............................................ 40-30-1
Electrical System Visual Fuse and Relay Panel Location..................... 40-30-1
Inspection .................................................. 40-10-1 Fuse and Relay Identification ........................ 40-30-2
Basic Electrical Component
Handling / Precautions Group 40—Charging System
for Vehicles Equipped with Remove and Install Alternator ....................... 40-40-1
Computer Controlled Systems................... 40-10-1 John Deere Engine
Electrical Connector / Wiring Accessories—Alternator
Harness Handling and Repair ................... 40-10-2 Repair ........................................................ 40-40-1
Repair Procedure R-A ................................... 40-10-3
Repair Procedure R-B ................................... 40-10-6 Group 45—Starting System
Repair Procedure R-C ................................... 40-10-9 Remove and Install Starting
Repair Procedure R-D ................................. 40-10-12 Motor ......................................................... 40-45-1
Repair Procedure R-E ................................. 40-10-14 John Deere Starting Motor Repair.................. 40-45-1
Repair Procedure R-F ................................. 40-10-16
Repair Procedure R-G................................. 40-10-19
Repair Procedure R-I................................... 40-10-20
Repair Procedure R-J.................................. 40-10-22
Repair Procedure R-K ................................. 40-10-27
Repair Procedure R-M................................. 40-10-29
Repair Procedure R-N ................................. 40-10-31
Harness Repair — Splice
Connector ................................................ 40-10-34

Group 15—Wire Harness Routings


Cab Harness Routing .................................... 40-15-1
Armrest Harness Routing .............................. 40-15-3
Front Chassis Harness Routing..................... 40-15-4
Engine Harness Routing................................ 40-15-6
Battery Harness Routing ............................... 40-15-9
Rear Chassis Harness Routing ................... 40-15-10
Main Track Harness Routing ....................... 40-15-11
Elevator Harness Routing............................ 40-15-12

Group 20—Sensors and Switches


Other Material................................................ 40-20-1
Specifications ................................................ 40-20-1
Replace Engine Sensors and
Switches—Use CTM ................................. 40-20-1
Remove and Install Engine Access
Door Switch ............................................... 40-20-2
Remove and Install Fuel Level
Sensor ....................................................... 40-20-3

TM100419 (02APR13) 40-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 40-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Batteries
Specifications
Item Measurement Specification

Battery Cable Clamp Nut Torque 7 N·m


(62 lb.-in.)
PW66162,00008CC -19-04JAN13-1/1

Servicing Battery
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the state of California to cause cancer and
reproductive harm. Wash hands after handling.

TS204 —UN—23AUG88
CAUTION: Batteries produce explosive gas and
contain sulfuric acid which is strong enough
to eat holes in clothing and cause blindness.
Improper servicing of battery can result in
serious injury to you or others. DO NOT attempt
to service battery unless you have the proper
equipment and experience to perform the job.

Proper battery maintenance is vital to dependable service.


Keep water level even with bottom of cell filler neck and
never below the top of the cell plates. Do not add water
in freezing weather unless engine is run 2 to 3 hours to

N36877 —UN—07OCT88
mix electrolyte.
Keep battery clean by wiping with a damp cloth. Keep all
connections clean and tight. Remove any corrosion, and
wash terminals with solution of baking soda and water.
Coat with grease prior to attaching cable.
Keep battery fully charged, especially during cold weather.
IMPORTANT: BATTERY IS NEGATIVE GROUNDED.
Always connect starter cable to positive (+) polarity in battery or alternator may result in
terminal of battery and battery ground cable permanent damage to electrical system.
to negative (-) terminal of battery. Reversed
PW66162,00005D3 -19-29AUG12-1/1

TM100419 (02APR13) 40-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=83
Batteries

Checking Battery Fluid Level


WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the state of California to cause cancer and
reproductive harm. Wash hands after handling.

CAUTION: Sulfuric acid in battery electrolyte is


poisonous. It is strong enough to burn skin,
eat holes in clothing, and cause blindness if
splashed into eyes. Wear rubber gloves and
goggles when checking battery fluid level.

1. Park machine on level surface.


2. Shut off engine and remove key.
3. Clean top of battery with damp cloth.
4. Remove battery caps.
IMPORTANT: Fluid level cannot be accurately
checked with battery tilted.

TS203 —UN—23AUG88
5. Fill battery to a level that fluid covers plates in each
cell and below fill cap neck.
6. Install battery caps.

PW66162,00005D4 -19-29AUG12-1/1

Preventing Battery Damage


WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the state of California to cause cancer and
reproductive harm. Wash hands after handling.

TS204 —UN—23AUG88
CAUTION: Battery gas can explode. Keep sparks
and flames away from batteries. Use a flashlight
to check battery electrolyte level.
NEVER check battery charge by placing
a metal object across the posts. Use a
voltmeter or hydrometer.
Always remove ground (-) battery clamp
first and replace it last. DO NOT polarize the alternator.
Disconnect battery cables before using an electric welder
Be sure that alternator connections are correct before
on the machine.
cables are connected to battery.
Store batteries below 26 °C (80 °F) for maximum shelf life.
Carefully observe polarity when attaching booster battery.
Check voltage after storage, and recharge as needed as
DO NOT operate the engine with alternator or battery recommended by battery manufacturer.
disconnected.
DO NOT store batteries in discharged state, or stack
DO NOT short across battery or alternator terminals, batteries on top of each other.
or allow battery positive (+) cable or alternator wire to
become grounded.
PW66162,00005D5 -19-29AUG12-1/1

TM100419 (02APR13) 40-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=84
Batteries

Charging Battery
CAUTION: DO NOT charge a frozen battery.
WARNING: Battery posts, terminals, and related
Warm to 16 °C (60 °F) before charging.
accessories contain lead and lead compounds, chemicals
known to the state of California to cause cancer and DO NOT use battery charger as a booster if battery
reproductive harm. Wash hands after handling. has a 1.15 specific gravity reading or lower.
Keep battery fully charged, especially during cold weather.
NOTE: Attach a ground strap to negative “-” battery
post so ground connection can be made
CAUTION: Never charge a frozen battery. Thaw at away from the battery.
room temperature before connecting to battery
charger. Only charge batteries in a well ventilated If a unit has more than one battery, each battery
area. Disconnect both cables from battery must be charged separately.
terminals when charging batteries in machine.
IMPORTANT: DO NOT connect or disconnect live
Disconnect both battery cables and connect charger circuits. Turn off charger and connect ground
positive cable to “+” terminal and charger negative cable cable last, away from battery.
to “-” terminal. Stop or cut back charging rate if battery cable
Follow instructions provided with charger or reference feels hot, or is venting electrolyte. Battery
the charging chart below. Always charge batteries with a temperature must not exceed 52 °C (125 °F).
12-Volt charger.
Ventilate the area where batteries are being charged.
Battery Charging According to Battery Size/Charge/Output in Amperes
Typical Battery Group Size Group 31
Reserve Capacity 126—180 Minutes
Charger Output (Amperes) 2 10 15 30 40 60
Battery Voltage % State of Charging Time In Hours
(Specific Charge
Gravity)a
12.4—12.6V 75% 19 6 5 4 4 4
(1.225)
12.2—12.4V 50% 35 9 7 5 5 4
(1.190)
12.0—12.2V 25% 51 13 9 6 5 5
(1.155)
11.7—12.0V 0% 67 16 12 7 6 5
(1.120)
<10 Volts Initially set charge to BOOST to see appreciable charge. Then switch to medium setting for the remaining of charge.
a
Specific gravity MUST be between 1.265—1.285 to consider battery fully charged.
PW66162,00005D6 -19-29AUG12-1/1

TM100419 (02APR13) 40-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=85
Batteries

Battery Disconnect Switch


IMPORTANT: Avoid damage to electrical components
of machine. Battery disconnect switch must be
in OFF position prior to welding on machine.

T8120001101 —UN—30AUG12
NOTE: Battery disconnect switch (A) is located on right
side of machine inside pump service door.
Switch Position Harvester Status
Rotated Clockwise (when viewed Power ON
from face of switch)
Rotated Counterclockwise (when Power OFF
viewed from face of switch)

Rotate switch to OFF position before leaving machine A—Battery Disconnect Switch
unattended.
Rotate switch to OFF position and remove key when
performing maintenance or storing machine.
PW66162,000089F -19-09NOV12-1/1

TM100419 (02APR13) 40-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=86
Batteries

Remove and Install Batteries


CAUTION: BATTERIES ARE NEGATIVE
GROUNDED ONLY. Always remove grounded (-)
battery clamp first and replace it last. Always

T8120002612 —UN—04JAN13
connect battery ground cable to negative (-)
posts of battery. Connect starter cable to
positive (+) post of battery. Reversed polarity
in battery or alternator connections results in
permanent damage to electrical system.

IMPORTANT: Replacement batteries must have


same terminal locations.

NOTE: Procedure for rearward battery (F) shown.


Procedure for forward battery (E) is similar.
Cut tie bands as necessary.

T8120002613 —UN—04JAN13
1. Park machine on level surface. Shut off engine and
remove key.
2. Disconnect batteries. (See Battery Disconnect Switch
in Section 40, Group 05.)
3. Remove cap screws (A) and battery cover (B).
4. Loosen nut and disconnect (-) battery cable clamp (D).
5. Pull insulator (C) away from positive cable connector.
A—Cap Screws (2 used) E—Forward Battery
6. Loosen (+) battery cable nut and disconnect positive B—Battery Cover F— Rearward Battery
battery cable. C—Insulator G—Nut (2 used each battery)
D—(-) Battery Cable Clamp
7. Loosen nuts (G) from each end of battery retaining
bracket.
8. Tilt and remove rearward battery (F).
• Charge battery as necessary. (See Charging Battery
in Section 40, Group 05.)
9. Inspect, test, and replace battery as necessary. • Tighten battery cable clamp nuts to specification.
Specification
10. Install battery in reverse order of removal using the
Battery Cable Clamp
following special instructions:
Nut—Torque....................................................................................7 N·m
• Clean battery, battery posts, and cable clamps. (See (62 lb.-in.)
Servicing Battery in Section 40, Group 05.)
• Check battery fluid level and fill as necessary. (See
Checking Battery Fluid Level in Section 40, Group
05.)
PW66162,000083E -19-04JAN13-1/1

TM100419 (02APR13) 40-05-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=87
Batteries

TM100419 (02APR13) 40-05-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=88
Group 10
Electrical Harness and Connectors
Use Electrical Insulating Compound
Apply AT66865 Compound directly to the terminals
between the wire seal and connector body. This provides
a moisture barrier, especially in wet and humid conditions.
PW66162,00006C4 -19-23OCT12-1/1

Electrical System Visual Inspection


Visual inspection of the electrical system's wiring • Loose wires and/or open circuits
harnesses and components for the following items can • Poor/corroded connections
significantly reduce diagnostic time: • Battery condition (terminal corrosion, voltage, cold
• Mechanical damage to the wiring harness covering or cranking amperage capacity, electrolyte level)
harness itself • Alternator condition (dirty, belt tension)
• Disconnected or damaged connectors • Overheated or discolored components
• Bare wires and/or shorts to ground
PW66162,00006C5 -19-23OCT12-1/1

Basic Electrical Component Handling / Precautions for Vehicles Equipped with Computer
Controlled Systems

• Never disconnect the batteries while the key switch is Why: This can cause computer system errors from
on and the engine is running. interrupting a computer program while it is running and
Why: This can cause electrical voltage spikes that can electrical voltage spikes that are produced can damage
damage electronic components. electronic components.

• Do not connect jumper cables while the key switch is on. • Do not apply power or ground to any component as a
Why: This can cause electrical voltage spikes that can test unless specifically instructed to do so.
damage electronic components. Why: Connecting the wrong voltage to the wrong point
of an electronic system can cause electronic component
• Disconnect batteries prior to recharging (if possible) failures.
Why: Electrical loads in the machine can slow the
recharging process. Battery chargers can cause • When welding on the machine, make sure to connect
electrical voltage spikes that can damage electronic ground lead to the parts being welded. For maximum
components. protection disconnect all electronic controllers before
welding.
• Never jump start the machine with a voltage higher than Why: The high currents associated with welding can
the machine is designed to operate on damage wiring harnesses that are involved in the
Why: This can damage electronic components ground path. Welding can also cause electrical voltage
spikes that can damage electronic components.
• Do not connect or disconnect electrical connectors
while the key switch is on or the machine is running.
PW66162,00006C6 -19-23OCT12-1/1

TM100419 (02APR13) 40-10-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=89
Electrical Harness and Connectors

Electrical Connector / Wiring Harness Handling and Repair

• Electrical connectors must not be forcibly mated or action may not be readily visible, but may prevent
un-mated. new terminals from being properly retained and cause
Why: The connectors have been designed to be mated replacement of the connector body.
easily. If you have to use tools or excessive force you
may be doing something wrong. Prying on or forcing • When installing a new terminal on a wire make sure the
connectors may cause permanent damage to the proper crimping tools is used.
locking mechanism, contacts or both. Why: Each part of the electrical terminal is designed
for a specific purpose, failure to properly crimp the
• When working on connectors make sure you are terminal can result in future electrical or mechanical
working on the correct terminal! problems. Terminal crimping tools are available through
Why: Measuring diagnostic values at the wrong SERVICEGARD. It is important to make sure the
connector terminal can lead to unnecessary part insulation and wire crimps on each terminal are made
replacement. The male and female halves of an properly. Soldering terminals is not recommended. See
electrical connector are mirror images of each other repair procedures in the Connector Repair Procedures
and it is easy to confuse terminal locations. Look for the Group
terminal identifier info on the connector body.
• Soldering splices is not recommended.
• Use proper terminals for any connector repairs. Why: Any repairs to wires in the harness should not
Why: In some connectors different terminal materials allow moisture to come in contact with the actual copper
are used (to carry different currents). If improper conductor. Soldering a wire splice is not recommended
terminals or terminal materials are used future electrical because a portion of stranded wire will become solid
problems may occur from corrosion or current carrying and can cause it to break in the future, especially if it is
capacity. subject to movement. When repairing a broken wire in
a wiring harness, use "Heat-Shrinkable" butt splices.
• When removing terminals from a connector body it Be careful not to place a splice in any section of the
is very important to use the proper extraction tool harness subject to motion or flexing.
and procedure. Extraction tools are available through
SERVICEGARD.
Why: The connector body can be damaged if terminals
are just "jerked" out. The damage caused by this
PW66162,00006C7 -19-23OCT12-1/1

TM100419 (02APR13) 40-10-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=90
Electrical Harness and Connectors

Repair Procedure R-A


Remove Contact From Connector Body
1. Open secondary lock (C) by gently prying locking
tabs (A) off locking studs (B).

H74026 —UN—19FEB03
A—Locking Tab C—Secondary Lock
B—Locking Stud

H74027 —UN—19FEB03
Continued on next page PW66162,00006C8 -19-23OCT12-1/6

TM100419 (02APR13) 40-10-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=91
Electrical Harness and Connectors

2. Insert JDG364 WEATHER PACK™ Extractor1 (A) into


connector body socket from mating face (C) as shown
depressing locking tabs (B) and gently pull contact out
in the direction of arrow.

A—JDG364, WEATHER PACK C—Mating Face


Extractor D—Wire Entry

H74028 —UN—29APR03
B—Locking Tabs

H74011 —UN—19FEB03
C
B

H74029 —UN—29APR03
C D
B H74012 —UN—19FEB03

WEATHER PACK is a trademark of Packard Electric


1
Included in JT07195B Electrical Repair Kit
Continued on next page PW66162,00006C8 -19-23OCT12-2/6

TM100419 (02APR13) 40-10-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=92
Electrical Harness and Connectors

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Insert wire (A) through seal (B) and position as shown.

H74030 —UN—19FEB03
A—Wire B—Seal

1
Included in JDG155 Electrical Repair Tool Kit
PW66162,00006C8 -19-23OCT12-3/6

3. Place wire and seal (A) in contact (D) as shown and


crimp both wire crimp (C) and seal crimp (B) using
JDG783 Crimping Tool.

A—Wire and Seal C—Wire Crimp


B—Seal Crimp D—Contact

H74031 —UN—19FEB03
H74032 —UN—19FEB03
H74034 —UN—19FEB03

Continued on next page PW66162,00006C8 -19-23OCT12-4/6

TM100419 (02APR13) 40-10-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=93
Electrical Harness and Connectors

IMPORTANT: Make sure contact is fully seated


and locked.

4. Install contact in connector body in appropriate socket.


Slide contact in until locking tabs click into place.

H74033 —UN—19FEB03
PW66162,00006C8 -19-23OCT12-5/6

NOTE: If secondary lock is difficult to close, contact


may not be properly seated or locked.

5. Close secondary lock (C) until locking tabs (B)


securely lock over locking studs (A).

A—Locking Stud C—Secondary Lock

H74035 —UN—19FEB03
B—Locking Tab

PW66162,00006C8 -19-23OCT12-6/6

Repair Procedure R-B


Remove Contact from Connector Body
1. If applicable, remove screws (A) and clamps (C).

WZ290900997 —UN—01DEC09
• Unscrew rear connector assembly (D), and slide
grommet (B) and assembly away from connector.
2. Select correct size extractor tool for size of wire to be
removed:
• JDG361 Extractor Tool11 for 12—14 gauge wire
• JDG362 Extractor Tool1 for 16—18 gauge wire
• JDG363 Extractor Tool for 20 gauge wire
A—Screw (2 used) C—Clamp (2 used)
B—Grommet D—Rear Connector Assembly

1
Included in JDG359 DEUTSCH Electrical Repair Tool Kit
Continued on next page PW66162,00006C9 -19-23OCT12-1/4

TM100419 (02APR13) 40-10-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=94
Electrical Harness and Connectors

3. Start correct size extractor tool (A) over wire and slide
rearward along wire until tool tip snaps onto wire.
IMPORTANT: Do NOT twist tool when inserting
in connector.

4. Slide extractor tool along wire into connector body until

H75297 —UN—24FEB03
it is positioned over terminal contact and depressing
locking tabs (B).
5. Pull wire out of connector body using extractor tool.

A—Extractor Tool B—Locking Tabs

H75290 —UN—24FEB03
B

H75296 —UN—24FEB03
Continued on next page PW66162,00006C9 -19-23OCT12-2/4

TM100419 (02APR13) 40-10-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=95
Electrical Harness and Connectors

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Adjust selector (A) on JDG360 Crimper for correct
wire size.

H75295 —UN—24FEB03
3. Loosen lock nut (B) and turn adjusting screw (C) in
until it stops.
4. Insert contact (D) and turn adjusting screw (C) until
contact is flush with cover (E). Tighten lock nut (B).
5. Insert wire (F) into contact (D) and crimp until handle
touches stop.
6. Release handle and remove contact.
IMPORTANT: If all wire strands are not crimped into
contact, cut off wire at contact and repeat
contact installation procedures.

H75294 —UN—24FEB03
7. Inspect contact to be certain all wires are in crimped
barrel.

A—Selector D—Contact
B—Lock Nut E—Cover
C—Adjusting Screw F— Wire

H75293 —UN—24FEB03
H75292 —UN—24FEB03

1
Included in JDG155 Electrical Repair Tool Kit
Continued on next page PW66162,00006C9 -19-23OCT12-3/4

TM100419 (02APR13) 40-10-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=96
Electrical Harness and Connectors

8. Push contact straight into connector body until positive


stop is felt.
9. Pull on wire slightly to be certain contact is locked in
place.
10. If removed, install rear connector assembly in reverse

H75291 —UN—24FEB03
order of removal.

PW66162,00006C9 -19-23OCT12-4/4

Repair Procedure R-C


Remove Contact from Connector Body
1. Remove secondary lock from male contact body by
inserting hooked end of JDG1383 DEUTSCH Terminal
Tool1 in slot (A) and gently pulling lock (B) from contact

H74116 —UN—19FEB03
body, or from female contact body by inserting flat end
of tool between seal (C) and lock (D) and gently prying
lock from contact body.

A—Slot C—Seal
B—Lock D—Lock

H74117 —UN—19FEB03
1
Included in JDG359 DEUTSCH Electrical Repair Tool Kit
Continued on next page PW66162,00006CA -19-23OCT12-1/5

TM100419 (02APR13) 40-10-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=97
Electrical Harness and Connectors

2. Insert JDG1383 DEUTSCH Terminal Tool1 into


connector body socket from mating face (C) as shown,
lift locking tab (A) and gently pull contact out through
seal (B) in direction of arrow.

A—Locking Tab C—Mating Face


B—Seal

H74118 —UN—19FEB03
B

H74013 —UN—19FEB03
C

H74119 —UN—19FEB03
A

H74014 —UN—06NOV02

1
Included in JDG359 DEUTSCH Electrical Repair Tool Kit
Continued on next page PW66162,00006CA -19-23OCT12-2/5

TM100419 (02APR13) 40-10-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=98
Electrical Harness and Connectors

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Place wire (A) in contact (D) as shown and crimp
both the wire crimp (C) and insulation crimp (B) using
JDG144 Crimping Pliers1.

H74120 —UN—19FEB03
A—Wire C—Wire Crimp
B—Insulation Crimp D—Contact

H74122 —UN—19FEB03
H74121 —UN—19FEB03
1
Included in JDG155 Electrical Repair Tool Kit
PW66162,00006CA -19-23OCT12-3/5

IMPORTANT: Make sure contact is fully seated


and locked.

3. Insert contact in connector body in appropriate socket.


Slide contact in until locking tabs click into place.
H74123 —UN—19FEB03

Continued on next page PW66162,00006CA -19-23OCT12-4/5

TM100419 (02APR13) 40-10-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=99
Electrical Harness and Connectors

NOTE: If secondary lock is difficult to install, contact


may not be properly seated or locked.

4. Install secondary lock (A) and push down until firmly


seated.

A—Secondary Lock

H74124 —UN—19FEB03
H74125 —UN—19FEB03
PW66162,00006CA -19-23OCT12-5/5

Repair Procedure R-D


Remove Contact From Connector Body
1. Insert JDG777 Terminal Extraction Tool1 into
connector body socket from mating face (C) as shown
and depress locking tab (B).

H75319 —UN—26FEB03
2. Gently pull contact out in the direction of arrow.

A—JDG777, Terminal C—Mating Face


Extraction Tool
B—Locking Tab

H75303 —UN—27FEB03

C
B

1
Included in JT07195B Electrical Repair Kit
Continued on next page PW66162,00006CB -19-23OCT12-1/3

TM100419 (02APR13) 40-10-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=100
Electrical Harness and Connectors

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Place wire in contact as shown and crimp both wire
crimp (C) and insulation crimp (B) using JDG144
Crimping Pliers1.

H75320 —UN—26FEB03
A—Wire C—Wire Crimp
B—Insulation Crimp D—Contact

H75321 —UN—26FEB03
1
Included in JDG155 Electrical Repair Tool Kit
PW66162,00006CB -19-23OCT12-2/3

IMPORTANT: Make sure contact is fully seated


and locked.

3. Install contact in connector body in appropriate socket.


Slide contact in until locking tab clicks into place.

H75322 —UN—26FEB03
PW66162,00006CB -19-23OCT12-3/3

TM100419 (02APR13) 40-10-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=101
Electrical Harness and Connectors

Repair Procedure R-E


Remove Contact From Connector Body
1. Remove secondary lock (A) by gently prying locking
tabs (B) off locking studs (C).

H75324 —UN—26FEB03
A—Secondary Lock C—Locking Studs
B—Locking Tabs

PW66162,00006CC -19-23OCT12-1/6

2. Insert JDG777 Terminal Extraction Tool1 (A) into


connector body socket from mating face (C) as shown
and depress locking tab (B) and gently pull contact out
in the direction of arrow.

A—JDG777, Terminal C—Mating Face


Extraction Tool

H75325 —UN—26FEB03
B—Locking Tab

H75312 —UN—26FEB03
C

1
Included in JT07195B Electrical Repair Kit
PW66162,00006CC -19-23OCT12-2/6

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Insert wire (A) through seal (B) and position as shown.
H75326 —UN—26FEB03

A—Wire B—Seal

1
Included in JDG155 Electrical Repair Tool Kit
Continued on next page PW66162,00006CC -19-23OCT12-3/6

TM100419 (02APR13) 40-10-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=102
Electrical Harness and Connectors

3. Place wire and seal (A) in contact (D) and crimp both
the wire crimp (C) and seal crimp (B) using JDG144
Crimping Pliers1.

A—Seal C—Wire Crimp


B—Seal Crimp D—Contact

H75327 —UN—26FEB03
H75328 —UN—26FEB03
1
Included in JDG155 Electrical Repair Tool Kit
PW66162,00006CC -19-23OCT12-4/6

IMPORTANT: Make sure contact is fully seated


and locked.

4. Install contact in connector body in appropriate socket.


Slide contact in until locking tabs click into place.

H75329 —UN—26FEB03
Continued on next page PW66162,00006CC -19-23OCT12-5/6

TM100419 (02APR13) 40-10-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=103
Electrical Harness and Connectors

NOTE: If secondary lock is difficult to install, contact


may not be properly seated or locked.

5. Install secondary lock (A) by aligning with connector


body and wires and pushing down until locking tabs
(B) lock on locking studs (C).

H75324 —UN—26FEB03
A—Secondary Lock C—Locking Studs
B—Locking Tabs

PW66162,00006CC -19-23OCT12-6/6

Repair Procedure R-F


Remove Contact From Connector Body
1. Remove secondary lock (A) by gently prying locking
tabs (B) off locking studs (C).

H75333 —UN—26FEB03
A—Secondary Lock C—Locking Studs
B—Locking Tabs

PW66162,00006CD -19-23OCT12-1/6

2. Insert JDG777 Terminal Extraction Tool1 (A) into


connector body socket from mating face (C) as shown
and depress locking tab (B) and gently pull contact out
in the direction of arrow.

A—JDG777, Terminal C—Mating Face


Extraction Tool

H75334 —UN—27FEB03
B—Locking Tab

B
H75314 —UN—26FEB03

1
Included in JT07195B Electrical Repair Kit
Continued on next page PW66162,00006CD -19-23OCT12-2/6

TM100419 (02APR13) 40-10-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=104
Electrical Harness and Connectors

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Insert wire (A) through seal (B) and position as shown.

H75335 —UN—26FEB03
A—Wire B—Seal

1
Included in JDG155 Electrical Repair Tool Kit
PW66162,00006CD -19-23OCT12-3/6

3. Place wire and seal (A) in contact (D) as shown and


crimp both wire crimp (C) and seal crimp (B) using
JDG144 Crimping Pliers1.

A—Seal C—Wire Crimp


B—Seal Crimp D—Contact

1 H75336 —UN—26FEB03
H75337 —UN—26FEB03
Included in JDG155 Electrical Repair Tool Kit
Continued on next page PW66162,00006CD -19-23OCT12-4/6

TM100419 (02APR13) 40-10-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=105
Electrical Harness and Connectors

IMPORTANT: Make sure contact is fully seated


and locked.

4. Install contact in connector body in appropriate socket.


Slide contact in until locking tabs click into place.

H75338 —UN—26FEB03
PW66162,00006CD -19-23OCT12-5/6

NOTE: If secondary lock is difficult to install, contact


may not be properly seated or locked.

5. Install secondary lock (A) by aligning with connector


body and wires and pushing down until locking tabs
(B) lock on locking studs (C).

H75333 —UN—26FEB03
A—Secondary Lock C—Locking Studs
B—Locking Tabs

PW66162,00006CD -19-23OCT12-6/6

TM100419 (02APR13) 40-10-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=106
Electrical Harness and Connectors

Repair Procedure R-G


Remove Contact From Connector Body
1. Insert a “T” pin (A) or other similar device into
connector body socket from mating face (C) as shown
and depress locking tab (B).

H75465 —UN—05MAR03
2. Gently push contact out in the direction of arrow.

A—”T” Pin C—Mating Face


B—Locking Tab

H75429 —UN—06MAR03
B

PW66162,00006CE -19-23OCT12-1/3

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Place wire (A) in contact (D) as shown and crimp both
wire crimp (C) and insulation crimp (B) using JDG144

H75466 —UN—05MAR03
Crimping Pliers1.

A—Wire C—Wire Crimp


B—Insulation Crimp D—Contact

H75467 —UN—05MAR03

1
Included in JDG155 Electrical Repair Tool Kit
Continued on next page PW66162,00006CE -19-23OCT12-2/3

TM100419 (02APR13) 40-10-19 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=107
Electrical Harness and Connectors

IMPORTANT: Make sure contact is fully seated


and locked

NOTE: Terminal will seat only one way. If terminal does


not pull into the connector body socket, check to
make sure terminal is aligned correctly.

H75468 —UN—05MAR03
3. Check to make sure locking tab on new contact is in
the outward position, then pull on wire until contact
locks in connector body socket.

PW66162,00006CE -19-23OCT12-3/3

Repair Procedure R-I


Remove Contact From Connector Body
1. Insert JDG777 Terminal Extraction Tool1 (A) into
connector body socket from mating face (C) as shown
and depress locking tab (B).

H75460 —UN—05MAR03
2. Gently push contact out in the direction of arrow.

A—JDG777, Terminal C—Mating Face


Extraction Tool
B—Locking Tab

H75430 —UN—06MAR03
C
B

1
Included in JT07195B Electrical Repair Kit
Continued on next page PW66162,00006CF -19-23OCT12-1/3

TM100419 (02APR13) 40-10-20 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=108
Electrical Harness and Connectors

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1
2. Place wire in contact as shown and crimp both wire
crimp (C) and insulation crimp (B) using JDG144

H75461 —UN—05MAR03
Crimping Pliers1.

A—Wire C—Wire Crimp


B—Insulation Crimp D—Contact

H75462 —UN—05MAR03
1
Included in JDG155 Electrical Repair Tool Kit
PW66162,00006CF -19-23OCT12-2/3

IMPORTANT: Make sure contact is fully seated


and locked

NOTE: Terminal will seat only one way. If terminal does


not pull into the connector body socket, check to
make sure terminal is aligned correctly.

H75463 —UN—05MAR03
3. Check to make sure locking tab on new contact is in
the outward position, then pull on wire until contact
locks in connector body socket.

PW66162,00006CF -19-23OCT12-3/3

TM100419 (02APR13) 40-10-21 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=109
Electrical Harness and Connectors

Repair Procedure R-J


Remove Contact From Connector Body
1. Remove secondary lock (A) by gently prying locking
tabs (B) off locking studs (C).

H73987 —UN—19FEB03
A—Secondary Lock C—Locking Studs
B—Locking Tabs

Continued on next page PW66162,00006D0 -19-23OCT12-1/6

TM100419 (02APR13) 40-10-22 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=110
Electrical Harness and Connectors

2. Insert JDG777 Terminal Extraction Tool1 into


connector body socket from mating face (C) as shown
and depress locking tab (A) and gently pull contact out
in the direction of arrow.

A—Locking Tab C—Mating Face


B—Wire Entry

H73988 —UN—19FEB03
Placement of Extraction Tool Small Contact
B

H73972 —UN—01NOV02
C A

Cross Section View Small Contact

H73989 —UN—19FEB03
Placement of Extraction Tool Large Contact
A

H73971 —UN—01NOV02
B

Cross Section View Large Contact

1
Included in JT07195B Electrical Repair Kit
Continued on next page PW66162,00006D0 -19-23OCT12-2/6

TM100419 (02APR13) 40-10-23 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=111
Electrical Harness and Connectors

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Insert wire (A) through seal (B) and position as shown.

H73990 —UN—19FEB03
A—Wire B—Seal

Large Contact Seal

H73991 —UN—19FEB03
Small Contact Seal

1
Included in JDG155 Electrical Repair Tool Kit
Continued on next page PW66162,00006D0 -19-23OCT12-3/6

TM100419 (02APR13) 40-10-24 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=112
Electrical Harness and Connectors

3. Place wire and seal (A) in contact (D) as shown and


crimp both wire crimp (C) and seal crimp (B) using
JDG144 Crimping Pliers1.

A—Wire and Seal C—Wire Crimp


B—Seal Crimp D—Contact

H73992 —UN—19FEB03
Large Contact

H73994 —UN—19FEB03
H73993 —UN—19FEB03
Small Contact

H73995 —UN—19FEB03

1
Included in JDG155 Electrical Repair Tool Kit
Continued on next page PW66162,00006D0 -19-23OCT12-4/6

TM100419 (02APR13) 40-10-25 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=113
Electrical Harness and Connectors

IMPORTANT: Make sure contact is fully seated


and locked.

4. Install contact in connector body in appropriate socket.


Slide contact in until locking tabs click into place.

H73996 —UN—19FEB03
Large Contact

H73997 —UN—19FEB03
Small Contact
PW66162,00006D0 -19-23OCT12-5/6

NOTE: If secondary lock is difficult to install, contact


may not be properly seated or locked.

5. Install secondary lock (A) by aligning with connector


body and wires and pushing down until locking tabs
(B) lock on locking studs (C).

H73998 —UN—19FEB03
A—Secondary Lock C—Locking Studs
B—Locking Tabs

PW66162,00006D0 -19-23OCT12-6/6

TM100419 (02APR13) 40-10-26 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=114
Electrical Harness and Connectors

Repair Procedure R-K


Remove Contact from Connector Body
1. Insert JDG140 Terminal Extraction Tool1 (A) in
connector body over contact to depress locking tabs
(C).

H73956 —UN—19FEB03
2. While holding extraction tool firmly in place, depress
plunger (B) and push contact out of connector body.

A—JDG140, Contact Extraction C—Locking Tabs


1
Tool
B—Plunger

H73955 —UN—19FEB03
E

H73953 —UN—31OCT02
D C

1
Included in JT07195B Electrical Repair Kit
Continued on next page PW66162,00006D1 -19-23OCT12-1/3

TM100419 (02APR13) 40-10-27 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=115
Electrical Harness and Connectors

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Place wire (A) in contact (D) and crimp both wire
crimp (C) and insulation crimp (B) using JDG783

H73957 —UN—19FEB03
Crimping Tool.

A—Wire C—Wire Crimp


B—Insulation Crimp D—Contact

H73958 —UN—19FEB03
H73981 —UN—19FEB03
1
Included in JDG155 Electrical Repair Tool Kit
PW66162,00006D1 -19-23OCT12-2/3

IMPORTANT: Make sure contact is fully seated


and locked.

3. Install contact in connector body in appropriate socket.


Slide contact in until locking tabs click into place.
H73982 —UN—19FEB03

PW66162,00006D1 -19-23OCT12-3/3

TM100419 (02APR13) 40-10-28 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=116
Electrical Harness and Connectors

Repair Procedure R-M


Remove Contact From Connector Body
1. Unlock slide type secondary lock (A) by disengaging
teeth (B) and sliding lock in direction of arrow; or door
type secondary lock by opening door (C).

H73857 —UN—19FEB03
A—Slide Type Secondary Lock C—Door Type Secondary Lock
B—Teeth

H73858 —UN—19FEB03
PW66162,00006D2 -19-23OCT12-1/5

2. Insert JDG777 Terminal Extraction Tool1 into


connector body socket from mating face (D) as shown
and lift locking tab (A) and gently pull terminal out past
secondary lock (B) in direction of arrow.

A—Locking Tab C—Wire Entry


B—Secondary Lock D—Mating Face

H73879 —UN—19FEB03
H73765 —UN—01NOV02

1
Included in JT07195B Electrical Repair Kit
Continued on next page PW66162,00006D2 -19-23OCT12-2/5

TM100419 (02APR13) 40-10-29 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=117
Electrical Harness and Connectors

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Place wire (A) in contact (D) and crimp both wire
crimp (C) and insulation crimp (B) using JDG144
Crimping Pliers1.

H73921 —UN—19FEB03
A—Wire C—Wire Crimp
B—Insulation Crimp D—Contact

H73922 —UN—19FEB03
H73983 —UN—19FEB03
Properly Crimped Contact

1
Included in JDG155 Electrical Repair Tool Kit
PW66162,00006D2 -19-23OCT12-3/5

IMPORTANT: Make sure contact is fully seated


and locked.

3. Install contact in connector body in appropriate socket.


Slide contact in until the lock clicks into place.
H73978 —UN—19FEB03

Continued on next page PW66162,00006D2 -19-23OCT12-4/5

TM100419 (02APR13) 40-10-30 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=118
Electrical Harness and Connectors

NOTE: If secondary lock is difficult to engage, contact


may not be properly seated or locked.

4. Engage slide type secondary lock (A) by disengaging


teeth (B) and sliding in direction of arrow; or door type
secondary lock (C) by closing door until it locks in place.

H73977 —UN—19FEB03
H73858 —UN—19FEB03
PW66162,00006D2 -19-23OCT12-5/5

Repair Procedure R-N


Remove Contact From Connector Body
1. Open secondary lock doors (A) by gently prying
locking tabs (B) off locking studs (C).

H75453 —UN—05MAR03
A—Secondary Lock Door C—Locking Studs
B—Locking Tabs

H75454 —UN—05MAR03

Continued on next page PW66162,00006D3 -19-23OCT12-1/5

TM100419 (02APR13) 40-10-31 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=119
Electrical Harness and Connectors

2. Insert JDG777 Terminal Extraction Tool1 (A) into


connector body socket from mating face (C) as shown
and depress locking tab (B) and gently pull contact out
in the direction of arrow.

A—JDG777, Terminal C—Mating Face


Extraction Tool

H75455 —UN—05MAR03
B—Locking Tab

H75431 —UN—06MAR03
B

1
Included in JT07195B Electrical Repair Kit
PW66162,00006D3 -19-23OCT12-2/5

Install New Contact


1. Remove contact and strip wire using JDG145
Electrician's Pliers1.
2. Place wire in contact as shown and crimp both wire
crimp (C) and insulation crimp (B) using JDG144

H75456 —UN—05MAR03
Crimping Pliers1.

A—Wire C—Wire Crimp


B—Insulation Crimp D—Contact

H75457 —UN—05MAR03

1
Included in JDG155 Electrical Repair Tool Kit
Continued on next page PW66162,00006D3 -19-23OCT12-3/5

TM100419 (02APR13) 40-10-32 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=120
Electrical Harness and Connectors

IMPORTANT: Make sure contact is fully seated


and locked.

3. Install contact in connector body in appropriate socket.


Slide contact in until locking tab clicks into place.

H75458 —UN—05MAR03
PW66162,00006D3 -19-23OCT12-4/5

NOTE: If secondary lock door is difficult to close, contact


may not be properly seated or locked.

4. Close secondary lock door (A) until locking tabs (B)


are securely locked over locking studs (C).

H75454 —UN—05MAR03
A—Secondary Lock Door C—Locking Studs
B—Locking Tabs

PW66162,00006D3 -19-23OCT12-5/5

TM100419 (02APR13) 40-10-33 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=121
Electrical Harness and Connectors

Harness Repair — Splice Connector


1. Strip 7 mm (3/8”) of insulation from end of wires (A) to
be spliced.
2. Cut a length of shrink wrap material long enough to

CM073510484 —UN—21SEP07
cover splicing area. Slide shrink wrap (C) on wire
away from spliced area as shown.
3. Install connector (B) to ends of stripped wires and
crimp connector.
4. Solder both ends of the connector.
IMPORTANT: Be sure that shrink wrap seals and
covers spliced area completely.

5. Center shrink wrap over splice and use a heat gun or


hair dryer to heat shrink wrap.

CM073510485 —UN—21SEP07
A—Wires C—Shrink Wrap
B—Connector

PW66162,00006D4 -19-23OCT12-1/1

TM100419 (02APR13) 40-10-34 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=122
Group 15
Wire Harness Routings
Cab Harness Routing

47 48
45 3 5
29 46 4
30 43
1 31 42 44
41 49
32 40 58
39
6
38 57 59
36 37 50
56
35 7
33 34 54
53
55 8
20 51
19 9
21
10
22 52 11
18
12
17
15 14 13
16

T8130000169 —UN—06FEB13
23
28 24
27 25
26

Continued on next page CG01926,000031D -19-08FEB13-1/2

TM100419 (02APR13) 40-15-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=123
Wire Harness Routings

1— X242—Right Speaker 17— X249—Primary Display Unit 33— X248—Dome Lamp Switch 47— X265—Road Light Switch
2— X243—Left Speaker J1 34— X276—Wiper Timer N.C. 48— X264—Hazard Light Switch
3— X269—Left Wiper Motor 18— X250—Park Brake 35— X275—Wiper Timer N.O. 49— X270—Camera
4— X282—Left Horn 19— X254—Right Wiper Motor 36— X274—Wiper Timer 2 50— X281—Terminating Resistor
5— X283—Left Horn 20— X252—AUTEQ Alarm 37— X273—Wiper Timer 1 51— X271—Center Wiper Motor
6— X284—Left Outside Road 21— X253—AUTEQ Alarm 38— X272—Wiper Timer C 52— X255—AUTEQ Display
Lamp 22— X251—AutoTrac Display 39— X124—Cab Harness-to- 53— X397—Center Wiper Switch
7— X285—Left Field Lamp 23— X292—Universal AutoTrac Flasher Relay Harness 54— X398—Side Wiper Switch
8— X286—Left Inside Road Lamp 24— X293—Universal AutoTrac 40— X258—Secondary Extractor 55— X399—Wiper Diode
9— X288—GPS Receiver 25— X112—Cab Harness-to-Cab Switch 56— X262—High-Low Switch
10— X091—GPS Receiver-to- Load Center Harness 41— X257—Primary Extractor 57— X261—Transport Switch
Ground 26— X113—Cab Harness-to-Cab Switch 58— X260—Positrac Switch
11— X287—Beacon Light Load Center Harness 42— X256—Knockdown Roller 59— X120—Cab Harness-to-
12— X289—Right Inside Road 27— X070—Ground Tilt Switch Flasher Module Harness
Lamp 28— X060—Ground 43— X259—Reversing Cooling
13— X290—Right Field Lamp 29— X244—Panel Lamp Fan
14— X291—Right Outside Road 30— X245—Panel Lamp 44— X268—Beacon Light Switch
Lamp 31— X246—Dome Lamp 45— X267—Engine Work Light
15— X280—Right Horn 32— X247—Dome Lamp Switch
16— X279—Right Horn 46— X266—Field Light Switch
CG01926,000031D -19-08FEB13-2/2

TM100419 (02APR13) 40-15-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=124
Wire Harness Routings

Armrest Harness Routing

G
E F H
J
I
D
B
C

A
F

L
M
N
F O
P

T8130000170 —UN—06FEB13
X
V
W

A—X221—Neutral Switch H—X211—Left Crop Divider Tilt N—X202—Crop Divider Float U—X225—Resume Switch
B—X217—Throttle Switch Switch Switch V—X226—Hi-Low Switch
C—X216—Right Side Knife I— X212—Right Crop Divider Tilt O—X203—Secondary Hood W—X102—Armrest
On-Off Switch Switch Rotate Switch Harness-to-Steering Column
D—X215—Left Side Knife On-Off J— X209—Hydraulic Reset P—X220—Elevator Diode Harness
Switch Switch Q—X204—Ground Drive Position X—X100—Armrest
E—X214—Elevator K—X438—Secondary Display Sensor Harness-to-Cab Load Center
Forward-Reverse Switch Unit R—X223—Left Elevator Swing Harness
F— X213—Elevator Up-Down L— X200—Topper Left-Right Pedal
Switch Switch S—X222—Right Elevator Swing
G—X210—Basecutter M—X201—Primary Hood Rotate Pedal
Forward-Reverse Switch Switch T— X224—Elevator On-Off Switch
CG01926,000031E -19-05FEB13-1/1

TM100419 (02APR13) 40-15-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=125
Wire Harness Routings

Front Chassis Harness Routing


1 2 3

10
9

6 5 4

28
21 22 23
27 29
25 30
26 31 11

24

20
19
12
18
17
16
13

15

14

T8130000168 —UN—07FEB13

Continued on next page CG01926,000031C -19-05FEB13-1/2

TM100419 (02APR13) 40-15-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=126
Wire Harness Routings

1— X107—Cab Load Center 7— X030—Ground 16— X104—Cab Load Center 25— X237—CAN Diagnostic
Harness-to-Engine Harness 8— X090—Ground Harness-to-Automatic Base 26— X236—Propulsion Steering
31 #1 9— X080—Ground Cutter Harness Control J1
2— X110—Cab Load Center 10— X040—Ground 17— X233—Multi-function 27— X235—Propulsion Steering
Harness-to-Engine Harness 11— X108—Mainframe Control Lever Control J2
14 Harness-to-Cab Load Center 18— X232—Multi-function 28— X234—Propulsion Steering
3— X108—Cab Load Center Harness Control Lever Control J3
Harness-to-Mainframe 12— X115—Mainframe 19— X230—Operators Presence 29— X105—Cab Load Center
Harness Harness-to-Engine Harness Switch Harness-to-Auxiliary Power
4— X111—Cab Load Center 13— X103—Cab Load Center 20— X229—Crop Divider Diode Strip Harness
Harness-to-Engine Harness Harness-to-Air Conditioning 21— X099—Load Center 30— X112—Cab Load Center
Ground Plug Harness 22— X228—Light Switch Harness-to-Cab Harness
5— X109—Cab Load Center 14— X116—Mainframe 23— X227—Elevator Diode 31— X113—Cab Load Center
Harness-to-Engine Harness Harness-to-Main Track 24— X100—Cab Load Center Harness-to-Cab Harness
18 Harness Harness-to-Armrest
6— X106—Cab Load Center 15— X101—Cab Load Center Harness
Harness-to-Engine Harness Harness-to-Automatic Base
31 #2 Cutter Harness
CG01926,000031C -19-05FEB13-2/2

TM100419 (02APR13) 40-15-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=127
Wire Harness Routings

Engine Harness Routing


Engine: Front Right Side

2 3
4
1 5
13

28 6 12
11
7
8

18

9 17
10 15 14
16

27 19

20

23
22
26
25 24

21 30
29 31
32
33
46 34

45 35
36

44 37

43

42 T8130000166 —UN—06FEB13

41
38

40 39

Continued on next page CG01926,0000316 -19-08FEB13-1/3

TM100419 (02APR13) 40-15-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=128
Wire Harness Routings

1— X126—Engine Harness-to- 11— X361—Basecutter Up 22— X316—Left Ground Drive 35— X405—Right Crop Divider
Positive Terminal Battery Solenoid Pump Float Solenoid
Harness 12— X364—Basecutter Down 23— X317—Chopper Pump 36— X347—Right Height Sensor
2— X298—Transfer Pump Fuse Solenoid Solenoid 37— X299—Vehicle Control Unit
3— X437—ECU Fuse 13— X362—Door Switch 24— X318—Chopper Transducer 38— Row Sense
4— X320—Vehicle Control Unit 14— X363—Left Crop Divider 25— X313—Basecutter Pump 39— Row Sense
Fuse Float Solenoid Solenoid 40— X303—Unloading Solenoid
5— X321—Vehicle Control Unit 15— X346—Left Height Sensor 26— X314—Right Ground Drive 41— X302—Basecutter Pump
Fuse 16— X360—Knock-Down Roller Pump Solenoid
6— X353—Topper Right-Left Tilt Solenoid 27— X315—Primary Extractor 42— X304—Topper Up-Down
Solenoid 17— X358—Left Side Crop Pump 43— X305—Primary Hood Rotate
7— X354—Left Side Knife Divider Tilt Solenoid 28— X050—Ground 44— X306—Right Crop Divider
Solenoid 18— X357—Right Side Crop 29— X308—Starter Relay 45— X297—Left Crop Divider
8— X355—Right Side Knife Divider Tilt Solenoid 30— X310—Starter Relay 46— X307—Elevator Swing
Solenoid 19— X350—CAN Terminator 31— X311—Starter Relay
9— X356—Topper Collector 20— X351—Engine Control Unit 32— X309—Starter Relay
Solenoid J2 33— X301—Vehicle Control Unit
10— X130—Engine Harness-to- 21— X352—Basecutter Pressure 34— X300—Vehicle Control Unit
Engine Extension Harness Sensor
Continued on next page CG01926,0000316 -19-08FEB13-2/3

TM100419 (02APR13) 40-15-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=129
Wire Harness Routings

Engine: Rear Left Side

10

2 9 11
8
1
7
5 12
4 6
13 14
15
3 16 17
19
18

36 37
38
40 23 20
39 21
22

35

24
32

34 33

T8130000167 —UN—06FEB13
26 25
27
28
31
30 29

1— X390—Left Turn Signal 11— X115—Engine Harness-to- 21— X114—Cooling 33— X342—Front Washer Motor
2— X391—Right Turn Signal Mainframe Harness Harness-to-Engine Harness 34— X341—Side Washer Motor
3— X296—Steering Input Device 12— X294—Pressure Sensors 22— X470—Auxiliary Power 35— X338—Compressor
4— X295—Engine Work Light 13— X331—Park Break Solenoid 23— X340—Fuel Sensor 36— X348—Air Filter Restriction
5— X121—Turn Signal 14— X330—Positrac Solenoid 24— X322—Feed Roller Switch
Harness-to-Engine Harness 15— X328—Variable Speed Forward-Reverse Solenoid 37— X326—Hydraulic Oil Filter
6— X121—Engine Harness-to- Solenoid 25— X093—Engine Ground Restriction Pressure Sensor
Turn Signal Harness 16— X327—High-Low Solenoid 26— X336—Starter “S” Motor 38— X329—Brake Pressure
7— X109—Engine Harness 17— X344—Reverse Coil (Top) 27— X010—Engine Ground Sensor
18-to-Cab Harness Solenoid 28— X061—Engine Ground 39— X323—Hydraulic Oil
8— X106—Engine Harness 31 18— X343—Proportional Coil 29— X337—Starter Motor Temperature Sensor
#2-to-Cab Harness (Right) Solenoid Positive 40— X324—Hydraulic Oil Level
9— X110—Engine Harness 19— X119—Engine Harness-to- 30— X337—Starter Motor Switch
14-to-Cab Harness Rear Frame Harness Positive
10— X107—Engine Harness 31 20— X118—Engine Harness-to- 31— X337—Starter Motor
#1-to-Cab Harness Rear Frame Harness Positive
32— X339—Air Conditioning
High Pressure Switch
CG01926,0000316 -19-08FEB13-3/3

TM100419 (02APR13) 40-15-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=130
Wire Harness Routings

Battery Harness Routing

A
B
C
D

T8130000165 —UN—07FEB13
G

A—X456—Battery Negative D—X457—Battery Positive G—X359—Primary Tachometer


Terminal Terminal Sensor
B—X455—Battery Positive E—X459—Battery Disconnect H—X126—Positive Terminal
Terminal Switch Battery Harness-to-Engine
C—X458—Battery Negative F— X439—Battery Disconnect Harness
Terminal Switch
CG01926,0000317 -19-05FEB13-1/1

TM100419 (02APR13) 40-15-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=131
Wire Harness Routings

Rear Chassis Harness Routing


B
A
C

F
G

T8130000164 —UN—07FEB13
J

I H

A—X401—Primary Extractor D—X240—Engine Coolant Level H—X114—Cooling K—X387—Flap Beater


Speed Sensor Low Sensor Harness-to-Engine Harness L— X241—Right Side Light
B—X128—Rear Frame E—X239—Left Side Light I— X118—Rear Frame
Harness-to-Primary Extractor F— X389—Reverse Alarm Harness-to-Engine Harness
Harness G—X388—License Plate Light J— X119—Rear Frame
C—X402—Primary Extractor Harness-to-Engine Harness
CG01926,000031A -19-05FEB13-1/1

TM100419 (02APR13) 40-15-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=132
Wire Harness Routings

Main Track Harness Routing

B C

J
D

F E
H
G

T8130000163 —UN—07FEB13
I

A—X116—Main Track C—X371—Left Height Sensor F— X369—Reverse Light J— X365—Right Speed Sensor
Harness-to-Mainframe D—X372—Left Speed Sensor G—X368—Reverse Light
Harness E—X370—Left Tail Light H—X367—Right Tail Light
B—X366—Right Height Sensor I— X117—Main Track
Harness-to-Elevator Harness
CG01926,0000319 -19-05FEB13-1/1

TM100419 (02APR13) 40-15-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=133
Wire Harness Routings

Elevator Harness Routing

A E

O H
I
L
K

T8130000162 —UN—07FEB13
J

A—X377—Secondary Hood E—X381—Secondary Extractor J— X117—Elevator N—X385—Elevator Diode Module


Rotate SV2 SV1 Harness-to-Main Track 1
B—X379—Elevator Up-Down SV3 F— X378—Bin Flap SV4 Harness O—X386—Elevator Diode Module
C—X380—Elevator G—X375—Elevator Speed K—X382—Right Beacon Light 2
Forward-Reverse SV6 Solenoid L— X383—Right Elevator Light
D—X376—Elevator Unload SV5 H—X374—Left Beacon Light M—X384—Elevator Diode Module
I— X373—Left Elevator Light
CG01926,0000318 -19-08FEB13-1/1

TM100419 (02APR13) 40-15-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=134
Group 20
Sensors and Switches
Other Material
Number Name Use
PM38697 (U.S.) Pipe Sealant with TEFLON® Seal threads to prevent escape
of liquid or gases.

TEFLON is a trademark of Du Pont Co.


PW66162,0000956 -19-08FEB13-1/1

Specifications
Item Measurement Specification

Fuel Level Sensor Cap Screws Torque 1.0—1.47 N·m


(9—13 lb.-in.)
Hydraulic Temperature Sensor Torque 32 N·m
(24 lb.-ft.)
Crop Divider Position Sensor Length 210 mm
Control Rod (8.25 in.)
Air Filter Restriction Switch Torque 11 N·m
(97 lb.-in.)
PW66162,000098E -19-13FEB13-1/1

Replace Engine Sensors and Switches—Use


CTM
For complete repair information, the component technical
manual (CTM) is also required. Use the appropriate
component technical manual in conjunction with this
machine manual.

P15127 —UN—10JAN08
PW66162,00008F9 -19-10JAN13-1/1

TM100419 (02APR13) 40-20-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=135
Sensors and Switches

Remove and Install Engine Access Door


Switch
NOTE: Switch cannot be repaired. If defective,
it must be replaced.

T8120002614 —UN—07JAN13
1. Park machine on level surface, shut off engine, and
remove key.
2. Disconnect batteries. (See Battery Disconnect Switch
in Section 40, Group 05.)
3. Open engine access door.
4. Disconnect electrical harness connector (B).
5. Remove mounting nut and engine access door switch A—Engine Access Door Switch B—Electrical Harness
(A). Connector

6. Replace switch as necessary.


7. Install in reverse order of removal.
PW66162,00008CD -19-07JAN13-1/1

TM100419 (02APR13) 40-20-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=136
Sensors and Switches

Remove and Install Fuel Level Sensor


1. Shut off engine and remove key.
2. Disconnect batteries. (See Battery Disconnect Switch
in Section 40, Group 05.)
IMPORTANT: Avoid damaging fuel injection system.
Remove all dirt and contamination around
fuel level sensor before removing.

NOTE: Surround fuel level sensor mounting area with


disposable cloth or paper to minimize fuel spill.
Sensor cannot be repaired. If defective,

T8130000255 —UN—28JAN13
it must be replaced.

3. Locate platform plate (B) between fuel tank fill neck


(A) and rear of cab (E).
4. Remove cap screws (F) and platform plate.
5. Remove side cap screws (H), upper cap screws (G),
and front lower cooling package shield (I).
6. Disconnect electrical connector (J).
7. Remove screws (C), fuel level sensor (B), and gasket
from tank.
8. Replace fuel level sensor as necessary.
9. Install fuel level sensor in reverse order using the
following special instructions:
• Use a new gasket between tank and sensor.
• Tighten sensor cap screws to specification.

T8130000259 —UN—28JAN13
Specification
Fuel Level Sensor Cap
Screws—Torque................................................................ 1.0—1.47 N·m
(9—13 lb.-in.)

A—Fuel Tank Fill Neck F— Cap Screw (5 used)


B—Platform Plate G—Upper Cap Screw (2 used)
C—Cap Screw (5 used) H—Side Cap Screw (6 used)
D—Fuel Level Sensor I— Front Lower Cooling
E—Rear of Cab Package Shield
J— Electrical Connector

T8130000260 —UN—28JAN13

PW66162,000093C -19-28JAN13-1/1

TM100419 (02APR13) 40-20-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=137
Sensors and Switches

Remove and Install Hydraulic Oil


Temperature Sensor
NOTE: Hydraulic temperature sensor is located
inside pump access door on the forward side
of hydraulic reservoir.
Approximate capacity of hydraulic reservoir
is 397 L (105 gal.).
Sensor cannot be repaired. If defective,
it must be replaced.

T8120002615 —UN—07JAN13
1. Shut off engine and remove key.
2. Open hydraulic pump access door.
3. Clean sensor and surrounding area.
4. Drain hydraulic reservoir to a level below hydraulic
oil temperature sensor (A). (See Drain Hydraulic
Reservoir in Section 70, Group 05.)
5. Disconnect connector (B) and remove sensor.
A—Hydraulic Oil Temperature B—Connector
6. If necessary, replace sensor O-ring and sensor. Sensor

7. Lubricate O-ring, install sensor, and tighten to


specification.
8. Connect harness connector.
Specification
Hydraulic Temperature 9. Fill hydraulic reservoir. (See Hydraulic Oil in Section
Sensor—Torque............................................................................32 N·m 10, Group 15 for recommended oil.)
(24 lb.-ft.)
PW66162,00008CE -19-07JAN13-1/1

TM100419 (02APR13) 40-20-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=138
Sensors and Switches

Remove and Install Hydraulic Reservoir


Level Switch
NOTE: Hydraulic reservoir level switch is located on
the forward side of hydraulic reservoir.
Approximate capacity of hydraulic reservoir
is 397 L (105 gal.).
Switch cannot be repaired. If defective, it
must be replaced.

1. Park machine on level surface, shut off engine, and

T8120002616 —UN—07JAN13
remove key.
2. Disconnect batteries. (See Battery Disconnect Switch
in Section 40, Group 05.)
3. Drain hydraulic reservoir to a level below hydraulic
reservoir level switch. (See Drain Hydraulic Reservoir
in Section 70, Group 05.)
4. Disconnect electrical connector (C).
A—Adapter Bushing C—Electrical Connector
5. Clean hydraulic reservoir level switch (B) and B—Hydraulic Reservoir Level
surrounding area. Switch

6. Remove adapter bushing (A) with level switch.


7. If necessary, remove adapter bushing from level
switch.
PW66162,00008D0 -19-13FEB13-1/2

8. Install hydraulic reservoir level switch in reverse order


using the following special instructions:
• Apply Pipe Sealant with TEFLON® to threads of
hydraulic level switch and adapter bushing before
installation.

T8120002272 —UN—26NOV12
IMPORTANT: Arrow stamped on switch must point
upward for level switch to function correctly.

• Install level switch with arrow (A) pointing upward.


• Fill hydraulic reservoir. (See Hydraulic Oil in Section
10, Group 15 for recommended oil.)

A—Arrow

PW66162,00008D0 -19-13FEB13-2/2

TM100419 (02APR13) 40-20-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=139
Sensors and Switches

Remove and Install Crop Divider Position


Sensor (If Equipped)
1. Park machine on level surface.
2. Lower topper onto safety stop and lower crop dividers.
3. Shut off engine and remove key.
4. Disconnect batteries. (See Battery Disconnect Switch
in Section 40, Group 05.)
5. Clean crop divider position sensor and surrounding

T8130000596 —UN—08FEB13
area.
NOTE: Left-hand crop divider position sensor shown.
Procedure for right-hand side is similar.
Cut tie bands as necessary.

6. Disconnect electrical connector (C).


7. Remove nut and disconnect control rod (A) from lever
(B).
8. Remove nuts, cap screws (D), and crop divider
position sensor.
9. Inspect sensor mounting O-rings and replace as
necessary.
10. Replace sensor as necessary.
11. Install in reverse order using the following special
instructions.

T8130000597 —UN—08FEB13
• Lubricate sensor mounting O-rings.
NOTE: Crop divider shown removed for clarity.
Control rod length is measured from the
inside of each nut (F).

• Check that control rod length (E) is adjusted to


specification. If necessary, loosen nuts (F) to adjust
control rod length.
Specification A—Control Rod D—Cap Screw (2 used)
Crop Divider Position B—Lever E—Distance
C—Electrical Connector F— Nuts (2 used)
Sensor Control
Rod—Length............................................................................... 210 mm
(8.25 in.)
PW66162,0000955 -19-21FEB13-1/1

TM100419 (02APR13) 40-20-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=140
Sensors and Switches

Remove and Install Air Filter Restriction


Switch
NOTE: Switch cannot be repaired and must be
replaced if defective.

1. Open engine access compartment door on left-hand


side of machine.
2. Clean air filter restriction switch and surrounding area.
3. Disconnect electrical connector (B).

T8130000258 —UN—28JAN13
4. Remove air filter restriction switch (A) from intake tube
(C).
5. Install switch in reverse order of removal and tighten
to specification.
Specification
Air Filter Restriction
Switch—Torque............................................................................. 11 N·m
(97 lb.-in.)
A—Air Filter Restriction Switch C—Intake Tube
B—Electrical Connector

PW66162,000093E -19-28JAN13-1/1

TM100419 (02APR13) 40-20-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=141
Sensors and Switches

TM100419 (02APR13) 40-20-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=142
Group 30
Fuses and Relays
Fuse Rating Color
Replacing Fuses
5 Amp Tan
IMPORTANT: Do not replace original fuse with higher 10 Amp Red
rated fuse or machine damage can occur.
15 Amp Blue
20 Amp Yellow
All electrical circuits are protected by fuses. Amperage
rating is marked on each fuse and fuses are color coded 25 Amp Natural (White)
to ensure proper replacement. 30 Amp Green

PW66162,00008A3 -19-09NOV12-1/1

Fuse and Relay Panel Location


IMPORTANT: Do not attempt to service fuse and
relay panel without FIRST disconnecting
batteries. (See Battery Disconnect Switch
in Section 40, Group 05.)

N56385 —UN—22MAR01
Fuse and relay panel is located behind instructional seat
back cushion.
1. Pull upward and remove storage bin (A).
2. Pull upward on knob (B) and remove seat back
cushion (C) to access fuse and relay panel (D).

A—Storage Bin D—Fuse and Relay Panel


B—Knob E—Fuse and Relay
C—Seat Back Cushion Identification Decal

T8120002113 —UN—21FEB13
PW66162,0000837 -19-21FEB13-1/1

TM100419 (02APR13) 40-30-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=143
TM100419 (02APR13)
RELAY BLOCK 1 RELAY BLOCK 2 RELAY BLOCK 3 K4RELAY BLOCK 4 K28
J K1 K2 K3 K4 K5 K6 K7 K8 J
ACC CROP ENGINE ELEVATOR
ELEVATOR BIN FLAP HARVESTING
H POWER DIVIDER WORK HORN H FIELD
(FWD/REV) (OUT) FUNCTIONS
OUTLET RESET LIGHT LIGHTS
G G
Fuse and Relay Identification

F K9 K10 K11 K12 K13 K14 K15 K16 F K29


HARVESTING REVERSE ELEVATOR BIN FLAP SIDE
QUICK
E FUNCTIONS (RESET) (IN) FIELD TURN SIGNAL E
LIGHT STOP LAMP INNER
RESET LIGHTS ROAD
D D LIGHTS
K17 K18 K19 K20 K21 K22 K23 K24
C C
12V PARK BRAKE LOWER
IGNITION ACCESSORY PROPULSION PARK BRAKE WIPERS B K30
B A/C PROPULSION ROAD
COMPRESSOR BLOCK BLOCK ENABLE PROPULSION LIGHTS
RESET
A A OUTER
ROAD

40-30-2
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 LIGHTS
BATTERY BLOCK 1 BATTERY BLOCK 2 HARVESTING ACCESSORY IGNITION 24V BAT
K25
J J
K31
Fuses and Relays

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14


H PRIMARY ABC H
HAZARD LOWER 5A
PUMP ROAD VCU

Continued on next page


LIGHTS LIGHTS SWITCH FRONT
G G FIELD
20A 20A 5A
F15 F16 F17 F18 F19 F20 F21 F22 F23 F26 F27 F28
LIGHTS
K26
F BATTERY ACC TRANS- EXTRACTOR 24V
F
PRESS FAN LIGHT MISSION VCU
24V POWER POWER MOTOR MOTOR F24 JOYSTICK IGNITION PRIMARY
OUTLET OUTLET
SWITCH CONTROLLER FANS TILT F25 PUMP
E COMPRESSOR OPTIONS E
A/C 10A 10A 15A 30A 20A 10A 5A 15A 5A 10A 5A
F29 F30 F31 F32 F33 F34 F35 F36 F37 F38 F39 F40 F41 F42
D SIDE AUTO SIDE AUTO 24V D
ELEVATOR HARVESTING ALTER- CYLINDER COMPRE
ACC 12V WIPER HORN TRAC KNIFE TRAC
FUNCTIONS IGNITION FUNCTION
FIELD BATTERY
K27 LIGHTS BATT FWD/REV ON/OFF NATOR ING SSOR
ECU A/C C
C
20A 10A 20A 15A 10A 10A 10A 5A 5A 15A 15A 10A 5A
24V F43 F44 F45 F46 F47 F48 F49 F50 F51 F52 F53 F54 F55 F56
B IGNITION OUTER BASE- ELEVATOR PROPULSION 24V B
FRONT INNER ELEVATOR WORK KEY PSC-PTP
ECU FIELD ROAD FIELD LIGHTS ROAD SWITCH CUTTER DISCHARGE PARK BRAKE GAUGES ECU
LIGHTS LIGHTS LIGHTS LIGHTS FWD/REV VALVE RESET POWER IGNITION
A A
20A 20A 20A 20A 20A 10A 10A 5A 5A 5A 10A 10A
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

CQ291883 —UN—03AUG12

PW66162,0000838 -19-09NOV12-1/2

PN=144
040213
3520 and 3522 Sugar Cane Harvester Repair
Fuses and Relays

K1—Accessory Power Outlet K25— Primary Pump Relay F19— Light Switch Fuse (20 F40— Cylinder Function Fuse (15
Relay K26— 24 V Air Conditioning Amp) Amp)
K2—Crop Divider Reset Relay Compressor Relay F20— Propulsion Controller F41— AutoTrac Ignition Fuse (10
K3—Elevator Relay (forward and K27— 24 V Ignition ECU Relay Battery Fuse (10 Amp) Amp)
reverse) K28— Elevator Field Lights Relay F21— Extractor Fans Fuse (5 F42— 24 V Air Conditioning
K4—Bin Flap Relay (Out) K29— Inner Road Lights Relay Amp) Compressor Fuse (5 Amp)
K5—(blank) K30— Outer Road Lights Relay F22— (blank) F43— Front Field Lights Fuse (20
K6—Engine Work Light Relay K31— Front Field Lights Relay F23— (blank) Amp)
K7—Harvesting Functions Relay F1— (blank) F24— Tilt Options Fuse (15 Amp) F44— Inner Road Lights Fuse (20
K8—Horn Relay F2— Hazard Lights Fuse (20 Amp) F25— (blank) Amp)
K9—Hydraulic Functions Reset F3— (blank) F26— Multi-Function Lever Fuse F45— Elevator Fields Lights
Relay F4— (blank) (5 Amp) Fuse (20 Amp)
K10— Reverse Light Relay F5— Lower Road Lights Fuse (20 F27— VCU Ignition Fuse (10 F46— Work Lights Fuse (20 Amp)
K11— Elevator Reset Relay Amp) Amp) F47— Outer Road Lights (20
K12— Bin Flap Relay (In) F6— (blank) F28— 24 V Fuel Primary Pump Amp)
K13— (blank) F7— (blank) Fuse (5 Amp) F48— Key Switch (10 Amp)
K14— Side Field Lights Relay F8— (blank) F29— Side Field Lights Fuse (20 F49— Base Cutter Fuse (Forward
K15— Turn Signal Relay F9— (blank) Amp) and Reverse) (10 Amp)
K16— Quick Stop Lamp Relay F10— (blank) F30— Cigarette Lighter Fuse (10 F50— (blank)
K17— 12 V Air Conditioning F11— Automatic Base Cutter Amp) F51— Elevator Unload Fuse (5
Compressor Relay Fuse (5 Amp) F31— Wiper Fuse (20 Amp) Amp)
K18— Ignition Block Relay F12— (blank) F32— Blank F52— Park Brake Reset Fuse (5
K19— Accessory Block Relay F13— VCU Switch Fuse (5 Amp) F33— Horn Fuse (15 Amp) Amp)
K20— Propulsion Enable Relay F14— (blank) F34— AutoTrac Battery Fuse (10 F53— Displays Fuse (5 Amp)
K21— Park Brake Relay F15— Battery Power Outlet Fuse Amp) F54— (blank)
K22— Park Brake Relay Reset (10 Amp) F35— Elevator Fuse (Forward F55— Propulsion Ignition Fuse
K23— Wipers Relay F16— Accessory Power Outlet and Reverse) (10 Amp) (10 Amp)
K24— Lower Road Lights Relay Fuse (10 Amp) F36— Side knife Fuse (On and F56— 24 V Ignition ECU Fuse (10
F17— Pressure Motor Fuse (15 Off) (10 Amp) Amp)
Amp) F37— Harvesting Functions Fuse
F18— Recirculation Fan Motor (5 Amp)
Fuse F38— Alternator Fuse (5 Amp)
F39— Ignition ECU Fuse (15
Amp)
PW66162,0000838 -19-09NOV12-2/2

TM100419 (02APR13) 40-30-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=145
Fuses and Relays

TM100419 (02APR13) 40-30-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=146
Group 40
Charging System
Remove and Install Alternator
1. Shut off engine and remove key.
2. Disconnect batteries. (See Battery Disconnect Switch
in Section 40, Group 05.)
3. Open engine access door.
4. Insert breaker bar in tensioner arm (E) and rotate
breaker bar counterclockwise until tension is released
on belt (D). When tension is released, remove belt
from alternator pulley and slowly return idler arm to its
original position. Remove breaker bar.
5. Slide and position insulators (F and G) to expose wire

T8130000463 —UN—31JAN13
connector nuts.
6. Tag alternator wires. Remove connector nuts and
disconnect wires from alternator (A).
7. Remove cap screw (B); then cap screw (C) and
alternator.
8. Replace or repair alternator as necessary. (See John
Deere Engine Accessories—Alternator Repair in
Section 40, Group 40.) A—Alternator E—Tensioner Arm
B—Cap Screw F— Insulator
9. Install in reverse order using the following special C—Cap Screw G—Insulator
instructions: D—Belt

• Check condition of belt for wear or damage. Replace


as necessary.
• After wires are connected, be sure to position • Ensure that belt is fully engaged into grooves of
each grooved belt pulley.
insulators over wire connectors.
PW66162,000083A -19-31JAN13-1/1

John Deere Engine Accessories—Alternator


Repair
For complete repair information, the component technical
manual (CTM) is also required. Use the appropriate
component technical manual in conjunction with this
machine manual.

P15127 —UN—10JAN08

OUHX357,0000278 -19-29NOV10-1/1

TM100419 (02APR13) 40-40-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=147
Charging System

TM100419 (02APR13) 40-40-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=148
Group 45
Starting System
Remove and Install Starting Motor
1. Tilt cab. (See Cab Tilt Procedure in Section 90, Group
20.)
2. Disconnect battery using battery disconnect. (See
Battery Disconnect Switch in Section 40, Group 05.)
3. Tag and disconnect negative cables (B).
4. Tag and disconnect cables (F), positive booster cable
(C), and solenoid wire (D).

T8130000464 —UN—01FEB13
5. Remove nut (A), cap screws (E) and starting motor.
6. Replace or repair as necessary. (See John Deere
Starting Motor Repair in Section 40, Group 45.)
7. Install in reverse order.

A—Nut D—Solenoid Wire


B—Negative Cable (4 used) E—Cap Screw (2 used)
C—Positive Booster Cable F— Positive Cables (4 used)

PW66162,000083C -19-01FEB13-1/1

John Deere Starting Motor Repair


For complete repair information, the component technical
manual (CTM) is also required. Use the appropriate
component technical manual in conjunction with this
machine manual.

P15127 —UN—10JAN08
OUO6083,000107E -19-11MAR09-1/1

TM100419 (02APR13) 40-45-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=149
Starting System

TM100419 (02APR13) 40-45-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=150
Section 50
Power Train
Contents

Page

Group 05—Pump Drive Gear Case


Other Material................................................ 50-05-1
Specifications ................................................ 50-05-1
Pump Drive Gear Case Exploded
View ........................................................... 50-05-2
Remove and Install Pump Drive
Gear Case ................................................. 50-05-3
Disassemble and Assemble Pump
Drive Gear Case........................................ 50-05-5

TM100419 (02APR13) 50-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 50-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Pump Drive Gear Case
Other Material
Number Name Use
PM37477 (U.S.) Thread Lock and Sealer (Medium To seal and retain threads.
TY9473 (Canadian) Strength)
242 (LOCTITE®)

Loctite is a trademark of Henkel Corporation


PW66162,00008A5 -19-12NOV12-1/1

Specifications
Item Measurement Specification

Pump Gear Case Cap Screws Torque 271 N·m


(200 lb.-ft.)
Drive Coupling Bolts Torque 50 N·m
(37 lb.-ft.)
TB90758,000028F -19-01MAR13-1/1

TM100419 (02APR13) 50-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=153
Pump Drive Gear Case

Pump Drive Gear Case Exploded View

CM002500287 —UN—26SEP07

Continued on next page PW66162,00008A4 -19-12NOV12-1/2

TM100419 (02APR13) 50-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=154
Pump Drive Gear Case

1— Housing 7— O-ring 13— Shaft 20— Pipe Bushing


2— Ball Bearing 8— Adapter Plate 14— Bearing 21— Tube
3— Spur Gear 9— Socket Head Screw 15— Housing 22— Pipe Plug
4— Spline Coupling 10— Ball Bearing 16— Seal 23— Pipe Plug
5— Adapter Plate 11— Gear 17— Pipe Plug
6— Cap Screw 12— Bearing 18— Cap Screw
19— Fitting
PW66162,00008A4 -19-12NOV12-2/2

Remove and Install Pump Drive Gear Case


IMPORTANT: To prevent contamination, ensure all
hydraulic lines and ports are capped or plugged.

CM073510558 —UN—03MAR08
1. Drain hydraulic tank and pump drive.
2. Disconnect, label, and cap all suction and pressure
lines to pumps. DO NOT disconnect engine drain line.
3. Disconnect electrical harness from pumps.
4. Loosen bolts (B) located on each side of engine
flywheel housing. It is not necessary to remove bolts.
5. To remove load from rear engine mounts, slightly lift
engine and pump drive. Block underneath engine
flywheel housing. 6. Support pump drive and pumps as a single unit.
PW66162,00007CF -19-01MAR13-1/6

7. Remove bolts from flywheel housing located on rear


of pump drive.

CM073510559 —UN—24MAR08
PW66162,00007CF -19-01MAR13-2/6

8. Remove bolts (B), located on each side of pump drive,


that are securing rear engine mount.
NOTE: Coupling and drive shaft may stay with either
the engine or pump drive.
CM073510558 —UN—03MAR08

9. Carefully slide pump drive outward and away from


engine.

Continued on next page PW66162,00007CF -19-01MAR13-3/6

TM100419 (02APR13) 50-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=155
Pump Drive Gear Case

10. Inspect pump drive and drive shaft seal (16) for
damage. Discard and replace at assembly.

CM073510560 —UN—03MAR08
PW66162,00007CF -19-01MAR13-4/6

11. Inspect bolts located in center of drive coupling for


damage and replace if necessary. Ensure spline
located in center of rubber coupling is fully bottomed
on shaft spline. Tighten bolts to specification.

CM073510561 —UN—24MAR08
Specification
Drive Coupling
Bolts—Torque................................................................................50 N·m
(37 lb.-ft.)

PW66162,00007CF -19-01MAR13-5/6

12. Install pump drive shaft (13) into pump drive housing.
Be careful not to damage seal (16).
13. Install pump drive on flywheel housing by meshing
rubber coupling spline with aluminum ring bolted to

CM073510562 —UN—24MAR08
engine flywheel. The pilot, located on pump drive
shaft, must go into the support bearing located in
center of flywheel.

PW66162,00007CF -19-01MAR13-6/6

TM100419 (02APR13) 50-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=156
Pump Drive Gear Case

Disassemble and Assemble Pump Drive


Gear Case
Disassemble

CM073510563 —UN—24MAR08
1. Position pump drive with hydraulic adapter plates (5
and 8) facing upward.

PW66162,00007E4 -19-01MAR13-1/11

2. Remove bolts (6 and 9), and adapter plates from


pump drive housing (1).

CM073510564 —UN—24MAR08
Continued on next page PW66162,00007E4 -19-01MAR13-2/11

TM100419 (02APR13) 50-05-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=157
Pump Drive Gear Case

NOTE: Bearings are slip-fitted into housing and pump


adapter bores and can be removed by hand.

3. Remove gears (3), spline adapters (4), and bearings


(2) from pump drive housing.

CM073510565 —UN—27SEP07
CM073510566 —UN—03MAR08
Continued on next page PW66162,00007E4 -19-01MAR13-3/11

TM100419 (02APR13) 50-05-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=158
Pump Drive Gear Case

4. Bearings are press fit to gear hubs. It may be


necessary to tip gear slightly to clear pinion gear
bearing pocket.

CM073510567 —UN—03MAR08
CM073510568 —UN—03MAR08
PW66162,00007E4 -19-01MAR13-4/11

5. After all gears and bearings have been removed,


remove breather parts (19, 20, and 21).

CM073510569 —UN—24MAR08
Continued on next page PW66162,00007E4 -19-01MAR13-5/11

TM100419 (02APR13) 50-05-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=159
Pump Drive Gear Case

6. Turn gear case over so adapter housing (15) is facing


upward. Remove bolts (18) and lift adapter housing
from pump drive housing.

CM073510570 —UN—03MAR08
CM073510571 —UN—03MAR08
Continued on next page PW66162,00007E4 -19-01MAR13-6/11

TM100419 (02APR13) 50-05-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=160
Pump Drive Gear Case

7. Remove pinion gear (11) and bearings (10 and 12).

CM073510572 —UN—24MAR08
CM073510573 —UN—27SEP07
Continued on next page PW66162,00007E4 -19-01MAR13-7/11

TM100419 (02APR13) 50-05-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=161
Pump Drive Gear Case

8. Remove bearings (2, 10, and 12) from hubs of gears


(3 and 11) using a gear puller or arbor press.

CM073510574 —UN—24MAR08
CM073510575 —UN—03MAR08
Continued on next page PW66162,00007E4 -19-01MAR13-8/11

TM100419 (02APR13) 50-05-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=162
Pump Drive Gear Case

9. Remove oil seal (16) by driving outward or pulling


outward toward engine side of adapter housing (15).

CM073510576 —UN—24MAR08
CM073510577 —UN—03MAR08
PW66162,00007E4 -19-01MAR13-9/11

Assemble
1. Clean and inspect all parts for wear or damage. Check
all mating surfaces.
2. Replace all necessary parts. Bolts should not be
reused.
3. Clean old Loctite out of all bolt hole threads.
4. Check around splines and chamfered area of shaft for
burrs, nicks, or sharp edges that can damage seals
when reassembling.
5. Prior to installation, lubricate all seals with O-ring lube

CM073510578 —UN—24MAR08
or grease.
6. Assemble in reverse order of removal.
7. Apply Thread Lock and Sealer (Medium Strength) and
install new bolts (6, 9, and 18) into adapter housing
(15) and adapter plates (5 and 8).
8. Tighten all gear case cap screws to specification.
Specification
Pump Gear Case Cap
Screws—Torque..........................................................................271 N·m
(200 lb.-ft.)
Continued on next page PW66162,00007E4 -19-01MAR13-10/11

TM100419 (02APR13) 50-05-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=163
Pump Drive Gear Case

NOTE: When a repair is made to pump drive, the


oil seal should be replaced.

9. Replace oil seal (16). Lubricate and install oil seal


towards engine side of adapter housing (15). Rubber

CM073510579 —UN—03MAR08
lip of oil seal must point toward inside of pump drive
as shown.

CM073510580 —UN—03MAR08
CM073510581 —UN—06MAR08
PW66162,00007E4 -19-01MAR13-11/11

TM100419 (02APR13) 50-05-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=164
Section 55
Track
Contents

Page

Group 05—Track
Track Component Identification..................... 55-05-1
Track Alignment............................................. 55-05-2
Roller Lubrication........................................... 55-05-2
Idler Assembly ............................................... 55-05-3
Track Shoes .................................................. 55-05-4
Sprocket Tightening....................................... 55-05-7
Rear Axle Maintenance ................................. 55-05-7
Adjust Track Tension ..................................... 55-05-7
Recoil Spring Repair and Adjust.................... 55-05-8
Link Rail......................................................... 55-05-9
Sealed Track Bushings & Pins .................... 55-05-10
Track Bushing Allowable Wear
Chart........................................................ 55-05-11
Internal Pitch Wear ...................................... 55-05-12
Internal Pitch Percentage Worn
Chart........................................................ 55-05-13
Track Rollers ............................................... 55-05-13
Carrier Roller ............................................... 55-05-16
Sprocket Wear Patterns .............................. 55-05-18
Roller Wear.................................................. 55-05-19
Rolling Undercarriage.................................. 55-05-19

Group 10—Final Drive Repair


Essential or Recommended Tools.................. 55-10-1
Specifications ................................................ 55-10-3
Final Drive (S.N. 120701—
)—Exploded View ...................................... 55-10-4
Disassemble Final Drive (S.N.
120701— )................................................. 55-10-5
Assemble Final Drive (S.N.
120701— )............................................... 55-10-12
Final Drive (S.N. —100986)—Ex-
ploded View ............................................. 55-10-26
Disassemble Final Drive (S.N.
—100986)................................................ 55-10-27
Assemble Final Drive (S.N.
—100986)................................................ 55-10-36
Assemble Lifetime Seal (S.N.
—100986)................................................ 55-10-48

TM100419 (02APR13) 55-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 55-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Track
Track Component Identification

CM002500182 —UN—24MAR08
1— Idler Assy-Front 3— Rail Assy-Link 7— Roller Assy-Track 9— Track Shoe
2— Spring Assy-Recoil 4— Bushing 8— Sprocket Assembly
5— Pin
6— Roller Assy-Carrier
PW66162,00006DB -19-23OCT12-1/1

TM100419 (02APR13) 55-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=167
Track

Track Alignment

CM053510242 —UN—27JUL05
A—Sprocket C—Track Shoe F— Hydraulic Track Adjuster
B—Carrier Roller D—Idler G—Track Roller
E—Rear Axle Cover

One of the most important factors to check for obtaining a A simple field test to check the load distribution is to walk
good service life is correct track alignment. All the rollers the machine on a hard surface for about 1 km (5/8 mile).
should be central to a line from the sprocket tooth center Check the rollers for correct oil level prior to this test. Feel
to the front idler center. each roller with your hand and note the temperature of
Another vital check is that all bottom track rollers are level. each one. Any rollers that feel hotter than others would
Misalignment from wear, bearing failure, or a distortion in indicate that they are carrying more than their share of
track frame causes uneven distribution of the uncorrected the load.
uneven load distribution. A new bottom roller should
never be used along with worn ones.
PW66162,00006DC -19-23OCT12-1/1

Roller Lubrication NOTE: If oil flowing from around the fitting is dirty
The track, carrier, and idler rollers are filled with a SAE 30 or mixed with water, keep filling until flowing
engine oil, which has a red dye additive. This allows for oil is absolutely clean.
easy detection of leakage, if a leak occurs. A periodic
visual inspection should be made for signs of leakage. 3. Attach a lubrication gun nozzle and pump oil in until it
Since these are “lifetime” rollers, it is not normally comes out from around the fitting.
necessary to refill them until the shells are due for 4. This indicates correct level. Quickly remove the nozzle
replacement. However, in cane harvester applications, the and refit the plug.
lubrication level should be checked on an annual basis.
An alternative way to lubricate is to place the machine on
To check, use the following procedure: an angle away from the filler plug at approximately 20°. Oil
1. Position the harvester on level ground. can then be fed in with an oil can or gun. Allow time for the
oil to travel down the shaft and out into the bearing areas.
2. Remove the shaft plug and screw in the lubrication
fitting.
PW66162,00006DD -19-22FEB13-1/1

TM100419 (02APR13) 55-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=168
Track

Idler Assembly
Lubrication
Idler is filled with SAE 30 engine oil, which has a red

CM002500195 —UN—23MAY00
dye additive for leak detection. If lubricant is required,
position the plug at 15°. Remove the plug. Lubrication
can be added by means of a low-pressure pump with a
nozzle (P/N 0841338384) filling through the hole in the
idler shell body. Oil to be used is a SAE 30 or SAE 40.
The quantity of lubricant necessary is just a little less than
the full capacity, which is approximately 9.8 cc (0.34 oz.).
Reinstall the plug and tighten.
Idler Tread Wear Measurement
Tread wear is the only measurable wear location on the top flange. It is also caused by the links jumping out of
idler. Tread wear is determined by measuring, with a thread and running on the center flange. If the track is too
broad based depth gauge, from the idler center flange to loose or snaky, the chances of link damage is increased.
the tread surface. The depth gauge should be positioned This can reduce the wear measurement distance and the
so that the ruler is aimed, as closely as possible, toward resulting measurement accuracy.
the center of the idler. The ruler’s base should be flat To remedy, clean the packed material away from the area
on the center flange and parallel to the idler shaft. The behind the idler and correct the problem causing the link
greatest error in measuring idler wear is caused by any to jump track. Top flange wear is not normally critical, but
wear located on top of the center flange; this alters the if wear is extreme, rebuild.
reference point. Abrasive packing conditions usually
cause the greatest amount of center flange wear. If this Flange Side Wear
wear is suspected, some attempt to compensate should be
made when the reading is taken. Remember, idler tread This is caused by side-hill operation or misalignment. This
wear occurs and decreases as center flange wear occurs. reduces link life and makes idler rebuilding questionable.

Swapping Idlers To remedy, install or maintain the track guiding guards,


realign the idler and roller frame or rebuild the idler.
In order to balance wear, idlers can be swapped from
one side to the other. Swapping is best when the ratio of Idlers Percentage Wear Chart
most worn to least worn is greater than 1.5 to 1 and the Inches mm % Worn
average percentage worn is less than 60%. 0.669 17.00 0
Check Idler Flange Wear 0.701 17.80 25
0.740 18.80 50
Examine the idler flanges for excessive wear. Wear on 0.787 20.00 75
just one side may mean the idler is off center. Correct
0.866 22.00 100
with a shim adjustment.
Inches mm % Worn
Excessive wear on both sides may indicate that the
wear strips or shims are worn out. The problem may be 1.031 26.00 0
corrected by adding shims. But new wear strips may be 1.046 26.80 25
needed. Another possible cause of this type of wear is 1.043 27.80 50
that the roller frame could be out of alignment or if there is 1.140 29.00 75
continuous side-hill operation.
1.218 31.00 100
Flange Top Wear
This is commonly caused by mud and debris packing
around the idler which causes abrasive action to the idler
PW66162,00006DE -19-22FEB13-1/1

TM100419 (02APR13) 55-05-3 3520 and 3522 Sugar Cane Harvester Repair
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PN=169
Track

Track Shoes Wear Limits — Service & Destruction


Tighten
Wear limits for all shoes are based on three criteria, in the
The following is the proper procedure for torquing the following order:
track hardware. The initial torque draws the parts together 1. Remaining beam or bending resistance strength for
tightly, an additional 1/3 turn gives the bolt a stretch for the standard width shoe.
good retention. Stretching stresses the bolt until some
permanent deformation occurs, this deformation ensures 2. Remaining grouser base available for regrousering
that the bolts maximum clamping force is used. purposes.
1. Lubricate the bolt threads. 3. Remaining traction-penetration ability of the shoe to
prevent traction losses.
2. Install bolts and nuts with the rounded side of the nut
against the face of the chain link. Torque bolts to 407 Depending on the nature of the shoe and its expected
N·m (300 lb-ft). use, both high and low impact wear limits have been
established.
Inspection Torque
As the degree of impact increases, a shoe is more subject
Inspection procedure for loose bolts should be as follows: to bending. Shoes may require re-grousering before the
1. Mark bolt head and the adjacent surface of the track high impact wear limit is reached to help avoid bending.
shoe. The shoe grouser base is generally less evenly worn,
thus reducing its re-grouseability. The shoe will need
2. Loosen bolt approximately 1/8 of a turn (45°). more penetration to grip a hard surface and it may require
re-grousering before the wear limit is reached.
3. Tighten bolt until the two marks align.
The service point is represented by 100% worn. The
4. Read the torque at this point. If the torque is below destruction point is represented by 120% worn, meaning
400 N·m (300 lb-ft), loosen all four bolts and retighten destruction will be reached in 20% more hours than it
by the torque-turn method. If the torque is higher, it is takes to reach the service limit of 100%. Destruction is
acceptable. the complete loss of grouser and/or if the shoe bends or
Track Shoe Problems breaks.

Grouser Wear Measurement Grouser Wear

Grouser height wear is measured with a broad based This is caused by sliding contact with the surface
depth gauge. Set the base across two adjacent grousers underfoot. It can be accelerated by weight, horsepower,
and use the gauge to measure down to the plate. The speed, impact, abrasiveness, terrain, and all operating
position of the depth gauge should be 1/3 of the way in from variables that cause nonproductive slippage, turning or
the outer edge of the shoe; this eliminates a problem in sliding. This causes a loss of traction, bending strength
measuring in cases of uneven outer-to-inner grouser wear. and the re-grouserability when wear limits are reached
The depth gauge should be perpendicular to the plate in or exceeded.
order to get the most accurate reading. Measurements To remedy this, reduce or eliminate controllable accelerator
should be made to the closest 0.01" (0.25 mm). variables, particularly slippage and unnecessary turning.

Continued on next page PW66162,00006DF -19-23OCT12-1/6

TM100419 (02APR13) 55-05-4 3520 and 3522 Sugar Cane Harvester Repair
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PN=170
Track

CM002500196 —UN—23MAY00

CM002500197 —UN—23MAY00
PW66162,00006DF -19-23OCT12-2/6

Plate Wear and Leading/Training Edge Wear


This is caused by sliding contact with the surface
underfoot. It can be accelerated by weight, horsepower,
speed, impact, abrasiveness, terrain, and all operating

CM053510243 —UN—24MAR08
variables that cause non-production slippage, turning or
sliding. This causes a loss of bending strength and may
prevent the re-grousered life to reach the wear limit, even
if the grouser is in good condition.
To remedy this, reduce or eliminate controllable accelerator
variables, particularly slippage and unnecessary turning.

PW66162,00006DF -19-23OCT12-3/6

Bolt Hole Wallowing Out


This is caused by the loss of clamping between shoe and
link or loose bolts. It is accelerated by having too much
turning resistance, resulting from a too high grouser or

CM002500199 —UN—23MAY00
inadequately tightened hardware. It will cause loose
shoes and loss of service life and rebuildability.
To remedy, properly torque hardware and check after the
first 100 hours of operation, and check periodically at 50
to 100 hours of operation thereafter.

Continued on next page PW66162,00006DF -19-23OCT12-4/6

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PN=171
Track

Self-Locking Track Nut


The self-locking track nut is installed with the rounded
corners against the link. The chamfered edge is away from
the link. Prolong track life by keeping track hardware tight.

CM002500200 —UN—23MAY00
Item Measurement Specification

Bolts Torque 400 N·m (300 lb-ft)


PW66162,00006DF -19-23OCT12-5/6

Sprocket Chain Roller Alignment

CM053510244 —UN—29JUL05

Sprocket Chain Roller Alignment —


Segment Sprocket: 2.19 inches
Solid Sprocket: 2.25
PW66162,00006DF -19-23OCT12-6/6

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PN=172
Track

Sprocket Tightening 2. Tighten segment nuts and disc bolts to specification.


1. Apply Thread Lock and Sealer (High Strength) to the Specification
bolts. Segment Nuts—Torque...............................................................278 N·m
(205 lb.-ft.)
NOTE: Ensure threads are free of oil. Do not use air Disc Bolts—Torque......................................................................529 N·m
tools to install them. Clean bolts and holes in final (390 lb.-ft.)
drive to ensure they are free from grease.
PW66162,00006E1 -19-08MAR13-1/1

Rear Axle Maintenance Specification


Every 250 hours of operation service the rear axle. Outer Nut Locking
Remove rear axle cover. Tighten inner nut to specification Bolts—Torque................................................................................50 N·m
(35 lb.-ft.)
Specification
Inner Nut—Torque.......................................................................815 N·m Pack bearings with grease. Coat the inner cavity walls
(600 lb.-ft.) with grease. Be sure to use silicone to properly seal when
putting the cover back on.
using specialty tool (P/N 0290289270). Tighten outer nut
by hand, then loosen until the three bolt holes in each nut
line up. Tighten outer nut locking bolts to specification.
PW66162,00006E2 -19-08MAR13-1/1

Adjust Track Tension

CM992500057 —UN—24MAR08
A—Track Pin (2 used) B—Carrier Roller (2 used) C—Track Frame
D—Relief Valve

NOTE: Track adjustment procedure should be performed 3. Proper track tension is achieved when the distance
under similar conditions in which the machine is between track chain and track frame (C) is
used. Thoroughly clean track assembly to achieve approximately 1-1/4” to 1-1/2”.
an accurate measurement and adjustment.
4. If track chain is too tight, loosen relief valve (D) until
1. Clean track assembly of all debris. grease escapes (compressing the track adjuster.)
2. Move harvester forward a distance of approximately 5. If track chain is too loose, add grease to the relief
20 m (65 ft.). Allow harvester to come to a complete valve (D) until the proper measurement is reached.
stop when one of the track pins (A) is centered over a
carrier roller (B).
PW66162,00006E3 -19-23OCT12-1/1

TM100419 (02APR13) 55-05-7 3520 and 3522 Sugar Cane Harvester Repair
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PN=173
Track

Recoil Spring Repair and Adjust


Repair
NOTE: Although recoil spring is serviceable, it does not

CM002500186 —UN—24MAR08
normally require servicing. A special track recoil
spring tool is necessary to disassemble unit.

1. Remove the pin located in the nut. A pressure exerted


on flange (2) that is greater than 36,500 N·m (27,500
lb.-ft.) is necessary to remove the nut without causing
any damage.
2. Disassemble the parts in order to repair or change
seals.
3. Rubber seals and all contact surfaces must be clean 1— Nut 5— Seal
2— Flange 6— Seal
and dry at assembly. Put a thin layer of oil on the 3— Cylinder 7— Piston
surfaces of the metal seals. 4— Spring
4. To assemble, compress spring (4) and measure from
the outside of flange (2) to the outside of piston (7) a
length of 390 mm (15.359”). NOTE: Never visually inspect the vent holes or valves
to see if grease or oil is coming out of them.
5. Tighten nut (1) until both pin holes, located on cylinder
Make sure that the vent holes are clean before
(3) and the nut are aligned. Insert the pin into the
the tension is released on the track. Watch
holes and relieve the pressure placed on the flange.
the cylinder to see that it moves.
Adjust
If rocks or debris get between the track and the rollers,
The recoil springs are normally in compression. They are idlers or sprocket, the recoil rod will move toward the rear
held between brackets and stops on the track roller frames. of the machine. The movement of the recoil rod tightens
Normally, the force of the springs is not against the tracks. the track. Since the grease in the cavity cannot be put in
The force against the track for the correct setting of track compression, the piston and bolt move toward the rear of
curve is controlled by the mechanism for track adjustment. the machine. The bolt pushes the pilot toward the rear of
the machine. The pilot pushes on the spring, this puts
Track adjustment is made by the hydraulic mechanism for the spring in a compressed state. The movement of the
track adjustment. Pressurized grease is sent to a cavity pilot and the compression of the spring prevents too much
through a fill valve. This moves recoil rod and front idler tension on the track.
toward the front of machine. Movement of recoil rod and
front idler tightens the track. The tension on the track is Nut (1) is used to keep the recoil spring in compression.
released by a relief valve.
Item Measurement Specification

Recoil Spring Compressed Length 390 mm (15.359 in.)


Fill and Relief Valves Torque 28—42 N·m (20—30 lb.-ft.)
Fork/Bracket Bolts Torque 230 N·m (170 lb.-ft.)
Shaft Diameter 60.00—59.954 mm (2.362—2.360 in.)
Between Shaft & Bushing Max. Clearance 0.386 mm (0.015 in.)
Shaft Max. Permissible Bend 0.00
PW66162,00006E4 -19-21FEB13-1/1

TM100419 (02APR13) 55-05-8 3520 and 3522 Sugar Cane Harvester Repair
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PN=174
Track

Link Rail Link Percentage Worn Chart


Wear Inches mm % Worn
Link Rail Measurement 3.74 95.00 0.00
3.72 94.50 8.00
The only measurable wear position on the link is rail (top)
3.70 94.00 16.00
wear. It is measured with a broad base depth gauge from
3.68 93.50 24.00
the rail surface to the track shoe plate. This dimension
is the rail height. The correct location for track link 3.66 93.00 32.00
measurement is outside of the links at the end of the track 3.64 92.50 40.00
pin. Position the depth gauge as close to the end of the 3.62 92.00 46.00
pin as possible, making sure link and shoe surfaces are 3.60 91.50 52.00
clean. Ensure the gauge is flat against the link rails and 3.58 91.00 58.00
perpendicular to the shoe surface. Measure to the closest
3.56 90.50 64.00
0.25 mm (0.01").
3.54 90.00 70.00
3.52 89.50 76.00
3.50 89.00 82.00
3.48 88.50 88.00
3.46 88.00 94.00
3.44 87.50 100.00
3.42 87.00 106.00
3.40 86.50 112.00
3.38 86.00 118.00
3.36 85.50 124.00
PW66162,00006E6 -19-23OCT12-1/1

TM100419 (02APR13) 55-05-9 3520 and 3522 Sugar Cane Harvester Repair
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PN=175
Track

Sealed Track Bushings & Pins


Bushing and Pin Wear
Since the successful turn-ability and total life of sealed

CM002500187 —UN—22MAY00
track pins and bushings is a function of both internal
and external wear, interpretation of external bushing
wear alone will not accurately determine if and when to
make the turn. However, the type and degree of external
bushing wear is a good indicator of abnormal problems.
Wear Measurement
A small caliper must be used to measure the wear at
the minimum diameter of the bushing, regardless of the
position with respect to vertical and forward or reverse.
This is because the sealed track bushing must have Wear charts for sealed track bushings have the built-in
sufficient strength to resist cracking after the turn. This effect of approximately double the expected wear rate
remaining strength is largely affected by wear before the after the bushing case depth is worn through. The chart
turn. The sealed track bushing receives most of its load in has a faster, yet expected wear rate (approximately three
the later part of its wear life, at the same position where times), after a significant amount of internal wear. The
maximum wear occurs. chart further accelerates wear, due to greater interference
loads and relative motion, between the bushing and the
Wear Limits — Service and Destruction sprocket.
Wear limits for sealed track bushings are determined not The percentage worn charts translate direct component
only on the basis of remaining strength before and after measurements into the percent worn. All percent worn
the turn, but also upon the external wear in later hours. figures shown are based on the percent of time used. This
The “high impact” allowable wear to the service point is allows the charts to be used to directly calculate or project
3.1 mm (0.12"). The “low impact” allowable wear to the the total potential time, or remaining life, until the service
service point is 4.8 mm (0.19"). Destruction or break limit is reached. In most cases, service limit projections
through, is expected to occur within 20% of any additional made from less than 30% worn cannot be considered
hours if the condition continues to exist. Wear limits should accurate. However, such projections can be used to
always be chosen on the basis of the degree of expected determine the subsequent dates for remeasuring wear.
impact, not on the basis of abrasiveness or desired life.
PW66162,00006E8 -19-23OCT12-1/1

TM100419 (02APR13) 55-05-10 3520 and 3522 Sugar Cane Harvester Repair
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PN=176
Track

Track Bushing Allowable Wear Chart


Inches mm Lesser % Worn Greater %
Worn
2.12 53.80 0.00 0.00
2.11 53.60 9.00 7.00
2.10 53.30 18.00 14.00
2.09 53.10 27.00 21.00
2.08 52.80 36.00 28.00
2.07 52.60 45.00 35.00
2.06 52.30 54.00 42.00
2.05 52.10 63.00 49.00
2.04 51.80 72.00 56.00
2.03 51.60 81.00 63.00
2.02 51.30 90.00 70.00
2.01 51.10 96.00 76.00
2.00 50.80 100.00 79.00
1.99 50.50 104.00 82.00
1.98 50.30 108.00 85.00
1.97 50.00 112.00 88.00
1.96 49.80 116.00 91.00
1.95 49.50 120.00 94.00
1.94 49.30 97.00
1.93 49.00 100.00
1.92 48.80 103.00
1.91 48.50 106.00
1.90 48.30 109.00
1.89 48.00 112.00
1.88 47.80 115.00
1.87 47.50 118.00
1.86 47.20 121.00
PW66162,00006E9 -19-23OCT12-1/1

TM100419 (02APR13) 55-05-11 3520 and 3522 Sugar Cane Harvester Repair
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PN=177
Track

CM002500188 —UN—22MAY00
Internal Pitch Wear
Measurement Technique
Sealed track internal wear is measured by determining the
pitch's extended length over four adjacent sections with a
measuring tape calibrated in 5 mm (0.02”) increments.
1. Stretch the track and tape tightly and straight to obtain
an accurate measurement. 3. There is a tendency of users to overtighten tracks to
compensate for the snakiness of an excessive pitch
2. Locate the calibrated side of the tape along an extended track. This, in effect, acts upon bushings,
imaginary line which connects the pin centers. sprockets, and other components.
3. Take the reading from one side of a pin to the same side 4. When the forward drive side external wear is critical,
of the fifth pin away (which includes 4 track sections). there is a loss of strength to the internal bushing walls.
4. The hook located on the tape end should not be This contributes to bushings cracking on the forward
used. The mark at an even increment of inches or drive side, before the pins are turned. There is also a
millimeters should be placed at the 5th pin, leaving the loss of wall strength of the forward drive side after turn,
end of the tape free to measure the fractional part of when the rear drive side external wear was critical
the total length. before the turn.

5. This measurement should be taken at least three Allowable Wear


sections away from any one-piece type master link
joint. It should be repeated at least twice, over different The internal wear is affected by the impact conditions.
sections of the track, on both sides of the machine. When low impact conditions exist, the bushing and pin
wear can extend beyond 100 percent.
Detrimental Effects of Excessive Pinch
The following lists the percentage worn with its
1. Counter-bore depth and elongation wear accelerates corresponding measurement:
wear rates and prevents adequate resealing after the 0% — 686 mm (27 inches)
turn. It also shortens after turn or replacement, pin 100% — 698.5 mm (27.5 inches)
and bushing life. 150% — 711 mm (28 inches)
2. Track snakiness damages other components, which
shortens their total life potential and rebuildability.
PW66162,00006EA -19-23OCT12-1/1

TM100419 (02APR13) 55-05-12 3520 and 3522 Sugar Cane Harvester Repair
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PN=178
Track

Internal Pitch Percentage Worn Chart


Inches mm % Worn
27.00 686.00 0.00
27.05 687.00 10.00
27.10 688.50 20.00
27.15 689.50 30.00
27.20 691.00 40.00
27.25 692.00 50.00
27.30 693.50 60.00
27.35 694.50 70.00
27.40 696.00 80.00
27.45 697.00 90.00
27.50 698.50 100.00
27.55 700.00 105.00
27.60 701.00 110.00
27.65 702.50 115.00
27.70 703.50 120.00
27.75 705.00 125.00
27.80 706.00 130.00
27.85 707.50 135.00
27.90 708.50 140.00
27.95 710.00 145.00
28.00 711.00 150.00
PW66162,00006EB -19-23OCT12-1/1

Track Rollers
The track rollers are fastened to the track roller frames.
The track rollers are in contact with the inside surfaces
of the track links. Flanges on the track rollers prevent

CM002500189 —UN—24MAR08
movement of the track from side to side. The inside
surfaces of the track links cause an equal distribution of
the weight of the harvester along the track.
The flange, located at the center of shaft, and bearings
(3) carry the side load from the roller. The amount of
side movement, or end clearance, of the shaft cannot be
adjusted.
The track rollers have floating metal seals (6) at both ends
of shaft (5).
Each track roller frame holds eight double flanged track
rollers.
Continued on next page PW66162,00006EC -19-23OCT12-1/3

TM100419 (02APR13) 55-05-13 3520 and 3522 Sugar Cane Harvester Repair
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PN=179
Track

Percentage Worn
Inches mm % Worn
8.00 203.00 0.00

CM002500190 —UN—24MAR08
7.98 202.50 4.00
7.96 202.00 8.00
7.94 201.50 12.00
7.92 201.00 16.00
7.90 200.50 20.00
7.88 200.00 24.00
7.86 199.50 28.00
7.84 199.00 31.00
7.82 198.50 34.00
Lubrication 7.80 198.00 37.00
7.78 197.50 40.00
If lubricant is added, when the roller is removed from the
machine, shaft must be in a horizontal position. The slot 7.76 197.00 43.00
located in the end, where the nozzle is installed, must 7.74 196.50 46.00
be pointing downward. 7.72 196.00 49.00
7.70 195.50 52.00
The lubricant is sent into center passage (5) through the
nozzle. The lubricant fills tank (4) in the rollers. When the 7.68 195.00 55.00
tanks are full, the pressure of the oil causes the air and 7.66 194.50 58.00
extra lubricant to exit through the relief threads located 7.64 194.00 61.00
on the nozzle. 7.62 193.50 64.00
When the lubricant is bubble free, remove the nozzle and 7.60 193.00 67.00
install the plug. 7.58 192.50 70.00
7.56 192.00 73.00
Seal Assembly
7.54 191.50 76.00
1. Rubber toric seals, and all surfaces in contact with 7.52 191.00 79.00
them, must be clean and dry at assembly. 7.50 190.50 82.00

2. Apply a thin layer of oil on the surfaces of all contacting 7.48 190.00 85.00
metal seals just before installation. 7.46 189.50 88.00
7.44 189.00 91.00
3. Apply lubricant on all other seals at assembly.
7.42 188.50 94.00
7.40 188.00 97.00
7.38 187.50 100.00
7.36 187.00 103.00
7.34 186.50 106.00
7.32 186.00 109.00
7.30 185.50 112.00
7.28 185.00 115.00
7.26 184.50 118.00
7.24 184.00 121.00

Specifications
Item Measurement Specification

Roller End Clearance 0.40-0.61 mm (0.016-0.024 Inches)


Roller End Maximum Permissible Clearance 1.27 mm (0.050 Inches)
Roller Diameter 54.46 - 54.66 mm (2.144 - 2.152 Inches)
Lubrication Plug Torque 150 - 190 N·m (110-140 lb-ft)

Continued on next page PW66162,00006EC -19-23OCT12-2/3

TM100419 (02APR13) 55-05-14 3520 and 3522 Sugar Cane Harvester Repair
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PN=180
Track

Item Measurement Specification

Roller Bolts Torque 339 N·m to Frame (175 lb-ft) with


Loctite® 271
PW66162,00006EC -19-23OCT12-3/3

TM100419 (02APR13) 55-05-15 3520 and 3522 Sugar Cane Harvester Repair
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PN=181
Track

Carrier Roller
The track carrier rollers give support to the track between
the sprocket and the front idler. The shaft of the track
carrier roller is clamped to a support bracket. The support

CM002500191 —UN—24MAR08
bracket is fastened to the track roller frame.
The track carrier roller must be aligned with the sprocket
and the front idler. The alignment is done by the
movement of the roller shaft inside of the support bracket.
The carrier roller turns on two tapered roller bearings.
Lubrication
If lubricant is added with the roller removed from the
machine, the shaft must be in a horizontal position.
1— Shaft 4— End Cover
Lubricant is sent through the nozzle and into the center 2— Metal Seal 5— Plug
of end cover (4). The lubricant fills the cavity between 3— Bearings
the shaft (1) and the roller. When the cavity is full, the
pressure of the oil causes the air and extra lubricant to
exit through the relief threads located in the nozzle. 3. Just before installation, apply a thin layer of oil on the
When the lubricant is bubble free, remove the nozzle and surfaces of all contacting metal seals.
install the plug. Torque the plug to 150-190 N·m (110- 4. Apply lubricant to all other seals at assembly.
140 lb-ft).
5. Assemble the ground face of the plate to the end of
Assembly the shaft and bearing.
1. Assemble the shaft flush with the back of the bracket. 6. Before installation, apply lubricant to the inside of the
Make an adjustment, if necessary, for track alignment. collar assembly.
2. Rubber toric seals and all surfaces in contact with
them must be clean and dry at assembly.
Item Measurement Specification

Two bolts Torque with 271 Loctite® 38-52 N·m (90 lb-ft)

Continued on next page PW66162,00006F0 -19-23OCT12-1/2

TM100419 (02APR13) 55-05-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=182
Track

Percentage Worn
Inches mm % Worn
6.24 158.50 0.00
6.22 158.00 4.00
6.20 157.50 8.00
6.18 157.00 12.00
6.16 156.50 16.00
6.14 156.00 20.00
6.12 155.50 24.00
6.10 155.00 28.00
6.08 154.50 32.00
6.06 154.00 36.00
6.04 153.50 40.00
6.02 153.00 44.00
6.00 152.50 48.00
5.98 152.00 52.00
5.96 151.50 56.00
5.94 151.00 60.00
5.92 150.50 64.00
5.90 150.00 68.00
5.88 149.50 72.00
5.86 149.00 76.00
5.84 148.50 80.00
5.82 148.00 84.00
5.80 147.50 88.00
5.78 147.00 92.00
5.76 146.50 96.00
5.74 146.00 100.00
5.72 145.50 104.00
5.70 145.00 108.00
5.68 144.50 112.00
5.66 144.00 116.00
5.64 143.50 120.00
PW66162,00006F0 -19-23OCT12-2/2

TM100419 (02APR13) 55-05-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=183
Track

Sprocket Wear Patterns


Sprocket Replacement
Wear is caused by dirt packing in the sprocket teeth or

CM002500194 —UN—23MAY00
around bushing, temporarily increasing the sprocket pitch.
Normally this condition only occurs when sprocket, pins,
and bushings are new. The problem is relieved after
some internal wear has taken place, because the sprocket
pitch has changed very little, if at all. There is no need to
replace the sprocket.
Use sprocket wear gauge to measure wear. Its function is
to indicate whether there is sufficient wear material left, in
the sprocket tooth, to provide structural life to match the
expected remaining life, that will be used with it, following
a bushing turn or replacement.
Use the gauge on or near bushing turn or replacement
time only (bushing turned or replaced at 90-110
percentage worn).
Gauge is designed to ignore the sprocket tooth tip
conditions. It determines the ratio of root tooth wear
compared to tooth side wear. Wear on the tooth sides is
the determining factor in reusability.
Gauge should be placed into one or more teeth, with the
point at the root aimed at the center of sprocket.
If the point of gauge touches the tooth root, the sprocket
tooth does not have enough wear material left to support
the back side of the turned bushing that caused the
wear already present on the sprocket. It will not support
the wear life of the replacement bushing, assuming its
expected wear life potential is equal to the wear life
obtained on the bushing that caused the wear already
present on the sprocket.
If the two side tips touch and the root tip does not touch,
then the segment can be expected to provide as much
wear life as already provided by the bushing sides that
ran against it.
The past and projected sprocket life should be thought of in
terms of the bushing (sides) life it has or will be expected to
provide, not in terms of actual hours on the sprocket itself.
It would be best not to reuse sprocket with turned (or
replaced) bushings.
Tip Gouged
This is caused by a snaky track and/or interference with the
inner link sides. If the gouging is limited to either the inner
or outer sprocket, the cause is probably misalignment
of the sprocket and/or the roller frame. This shortens
sprocket life and makes rebuilding of links questionable.
To remedy this, if caused by worn guiding guards, replace
wear strip. If caused by misalignment, realign roller frame
and/or sprocket.
PW66162,00006F3 -19-21FEB13-1/1

TM100419 (02APR13) 55-05-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=184
Track

Roller Wear carrier roller rebuilding as questionable. To remedy this,


realign or rebuild the carrier roller .
Diagnosis
How to Measure Roller Wear
Thread wear is caused by normal usage, and will cause
the roller flange to hit the pin boss of the links. To remedy Using large calipers, gauge the diameter of the roller
this, rebuild before the flange hits the pin boss. thread. Place the calipers against a steel ruler to find
the diameter measurement. Compare the worn diameter
Flange wear is caused by side-hill operation, to the “Percentage Worn Chart” to determine the roller
misalignment, snaky track, or the flange striking the link assembly’s wear.
pin boss. It will reduce the link life, and make rebuilding
the roller questionable. To remedy this, install or maintain Wear Specifications
the track guiding guards, realign the roller frame, adjust
the track to reduce snakiness, or rebuild the rollers.
Threads worn off center is caused by roller misalignment
and side-hill operation. It reduces link life and renders
Item Measurement Specification

Carrier Roller 0 % Wear 158.5 mm (6.24 Inches)


Carrier Roller 100 % Wear 146.0 mm (5.74 Inches)
Carrier Roller Totally Worn Wear 143.5 mm (5.64 Inches)
Track Roller 0 % Wear 203.0 mm (8.0 Inches)
Track Roller 100 % Wear 187.5 mm (7.38 Inches)
Track Roller Totally Worn Wear 184.0 mm (7.24 Inches)
PW66162,00006F5 -19-22FEB13-1/1

Rolling Undercarriage clearance is 17.2 mm (0.69"), the roller radius wear is


3.8 mm (0.15") and the link wear is 4.6 mm (0.18"): Pin
Flange to Boss Measurement Boss Clearance
= 17.55 mm - (3.8 + 4.6)
If the track roller guards make the pin-boss-to-roller flange
= 17.5 mm - 8.4 mm
measurement difficult to obtain, you can acquire it by
= 9.1 mm
subtracting the link wear plus the roller wear, from the
clearance, when the parts are new. For example, if the
PW66162,00006FA -19-23OCT12-1/1

TM100419 (02APR13) 55-05-19 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=185
Track

TM100419 (02APR13) 55-05-20 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=186
Group 10
Final Drive Repair
Essential or Recommended Tools RECOMMENDED TOOLS, as noted, are suggested to
NOTE: Order tools from the SERVICEGARD™ Catalog. perform the job correctly. Some tools may be available
from local suppliers or may be fabricated.
ESSENTIAL TOOLS listed are required to perform
the job correctly and are obtainable only from the
SERVICEGARD™ Catalog.
SERVICEGARD is a trademark of Deere & Company
TB90758,0000295 -19-04MAR13-1/8

Internal 2 Jaw Puller ......................................... D01302AA


Track
TB90758,0000295 -19-04MAR13-2/8

Spring Compressor............................................. JDG1451


Track

N64174 —UN—03OCT03
TB90758,0000295 -19-04MAR13-3/8

Torque Multiplier ................................................. JDG1455 Track


TB90758,0000295 -19-04MAR13-4/8

Torque Multiplier ................................................. JDG1782


Track

N64173 —UN—03OCT03

Continued on next page TB90758,0000295 -19-04MAR13-5/8

TM100419 (02APR13) 55-10-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=187
Final Drive Repair

Seal Installer....................................................... JDG1785


Track

N64177 —UN—03OCT03
TB90758,0000295 -19-04MAR13-6/8

Bearing Installer.................................................. JDG1786


Track

N64175 —UN—03OCT03
TB90758,0000295 -19-04MAR13-7/8

Safety Plate ........................................................ JDG1787


Track

N64178 —UN—03OCT03

TB90758,0000295 -19-04MAR13-8/8

TM100419 (02APR13) 55-10-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=188
Final Drive Repair

Specifications
Item Measurement Specification

Final Drive Seals Stand-Out Height Variation Level +/- 1.5 mm


(+/- 0.06 in.)
Final Drive Ring Nut Torque (Torque Multiplier Input) 100 N·m
(74 lb.-ft.)
Final Drive Ring Nut Torque (Torque Multiplier Output) 3078 N·m
(2278 lb.-ft.)
Cover Cap Screws Torque 76 N·m
(56 lb.-ft.)
Mounting Flange-to-Drive Coupler Depth 111.4—112.2 mm
(4.386—4.425 in.)
Ring Nut Torque 6249 N·m
(4609 lb.-ft.)
End Cover Socket Head Cap Screws Torque 25 N·m
(18 lb.-ft.)
Fill Plug Torque 30 N·m
(22 lb.-ft.)
Level Plug Torque 8 N·m
(71 lb.-in.)
TB90758,0000296 -19-05MAR13-1/1

TM100419 (02APR13) 55-10-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=189
Final Drive Repair

Final Drive (S.N. 120701— )—Exploded View

10 15

10
7 9 14
13
11
12
8
11

9
7
9 10
6
21
1
22

22

3
2 20 21

19
5 3 28
4 2

18

17

29
16 28
29
28
29
28
29
28
29
28
25
24 11 27
36
24
35
23
34
26 33
N89787 —UN—27OCT10

32
25
31
24
30
24
23

Continued on next page TB90758,0000250 -19-25FEB13-1/2

TM100419 (02APR13) 55-10-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=190
Final Drive Repair

1— Socket Head Cap Screw (24 11— Bronze Bushing (3 used) 21— O-Ring (2 used) 29— Fiber Disk (5 used)
used) 12— Sun Gear 22— Mechanical Face Seal (2 30— O-Ring
2— Plug (2 used) 13— Retaining Ring used) 31— Piston
3— O-Ring (2 used) 14— Planet Pinion Gear 23— Retaining Ring (4 used) 32— Inner Spring (12 used)
4— Plug 15— Sun Gear 24— Secondary Gear (4 used) 33— Outer Spring (12 used)
5— O-Ring 16— Lock Nut 25— Spacer (4 used) 34— O-Ring
6— Cover 17— Spacer 26— Housing 35— Spring Retainer
7— O-Ring (2 used) 18— Bearing 27— Coupler 36— Retaining Ring
8— Ring Gear 19— Hub 28— Steel Disk (6 used)
9— Retaining Ring 20— Wheel Studs (10 used)
10— Spur Gear (3 used)

TB90758,0000250 -19-25FEB13-2/2

Disassemble Final Drive (S.N. 120701— )


1. Remove hydrostatic drive motor.
2. Remove final drive from machine.
3. Before disassembly, clean final drive thoroughly.

N64115 —UN—02OCT03
NOTE: Refer to exploded view when disassembling
and assembling final drive.

4. Place hub on a clean workbench, with hydrostatic


drive motor mounting flange facing upward.
5. Install disk (A), bar (B), and forcing screw from
JDG1451 Spring Compressor.2 Tighten forcing screw
to compress brake assembly and remove retaining A—Disk
1
C—Retaining Ring
ring (C). B—Bar
1

6. Slowly remove screw to release spring tension.


Remove tool.
1
Included in JDG1451 Spring Compressor
2
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page TB90758,0000251 -19-05MAR13-1/16

TM100419 (02APR13) 55-10-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=191
Final Drive Repair

7. Remove spring retainer (A) and springs (B).

A—Retainer B—Spring (12 inner and 12


outer used)

N64116 —UN—02OCT03
N89860 —UN—01NOV10
TB90758,0000251 -19-05MAR13-2/16

8. Remove brake shaft (A) and brake piston (B) using


an inside puller.

A—Brake Shaft B—Brake Piston

N89861 —UN—01NOV10

Continued on next page TB90758,0000251 -19-05MAR13-3/16

TM100419 (02APR13) 55-10-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=192
Final Drive Repair

9. Remove O-ring (A).


10. Remove brake disks (B) and separator plates.

A—O-Ring B—Brake Disk (6 steel and 5


fiber used)

N89758 —UN—22OCT10
TB90758,0000251 -19-05MAR13-4/16

11. Turn final drive hub over and remove socket head cap
screws (A) and end cover (B).

A—Socket Head Cap Screw (24 B—End Cover


used)

N89759 —UN—22OCT10
TB90758,0000251 -19-05MAR13-5/16

NOTE: First stage reduction assembly is available


only as an assembly. Individual components
are not serviceable.

12. Remove first stage sun gear (A).


13. Remove first stage reduction assembly (B).

A—First Stage Sun Gear B—First Stage Reduction


Assembly
N89760 —UN—27OCT10

Continued on next page TB90758,0000251 -19-05MAR13-6/16

TM100419 (02APR13) 55-10-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=193
Final Drive Repair

14. Remove retaining rings (A) from second reduction


assembly planet gears.

A—Retaining Ring (4 used)

N64128 —UN—02OCT03
TB90758,0000251 -19-05MAR13-7/16

15. Remove second reduction assembly planet gears (A)


using D01302AA Internal 2 Jaw Puller1 or equivalent.

A—Second Reduction Planet


Gear (4 used)

N64129 —UN—02OCT03
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
TB90758,0000251 -19-05MAR13-8/16

16. Remove spacers (A) from planet gear pedestals.

A—Spacer (4 used) N64130 —UN—02OCT03

Continued on next page TB90758,0000251 -19-05MAR13-9/16

TM100419 (02APR13) 55-10-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=194
Final Drive Repair

17. Remove ring gear (A) from hub (B).


18. Remove spacer ring (C) from hub (B).

A—Ring Gear C—Spacer Ring


B—Hub

N89761 —UN—26OCT10
N89762 —UN—22OCT10
Continued on next page TB90758,0000251 -19-05MAR13-10/16

TM100419 (02APR13) 55-10-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=195
Final Drive Repair

19. Remove threaded ring nut (B) as described in the


following steps.
a. Using an electric drill and a small drill bit (A), drill a
hole starting in stake mark (C) as shown.
b. Drill two additional holes (D) as shown.

N70774 —UN—16AUG05
IMPORTANT: Do not drill into spindle threads
when enlarging holes.

c. Use next size drill bit and enlarge drilled holes.


d. Repeat Sub-step (c) until material between holes
is removed.

A—Electric Drill C—Stake Mark


B—Threaded Ring Nut D—Holes

N70773 —UN—16AUG05
N70757 —UN—12AUG05
TB90758,0000251 -19-05MAR13-11/16

e. Using a cold chisel (A) in drilled area, split threaded


ring.
f. Repeat Sub-steps (a—d) on opposite stake point.
g. Remove two halves of threaded ring.
N90933 —UN—03JAN11

A—Cold Chisel

Continued on next page TB90758,0000251 -19-05MAR13-12/16

TM100419 (02APR13) 55-10-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=196
Final Drive Repair

20. Position hub assembly in press, and press flanged


hub (B) from hub housing (A).

A—Hub Housing B—Flanged Hub

N89765 —UN—27OCT10
TB90758,0000251 -19-05MAR13-13/16

21. Remove first half-seal assembly (A).

A—Half-Seal Assembly

N64143 —UN—02OCT03
TB90758,0000251 -19-05MAR13-14/16

22. Remove second half-seal assembly (A) by prying


lightly with a screwdriver.

A—Half-Seal Assembly

N64138 —UN—02OCT03

Continued on next page TB90758,0000251 -19-05MAR13-15/16

TM100419 (02APR13) 55-10-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=197
Final Drive Repair

23. Position hub assembly in press, and press bearing


(A) from hub housing (B).
IMPORTANT: Ensure all foreign material is out of
bearing assembly, or premature bearing
failure can occur.

N89786 —UN—26OCT10
24. Clean and inspect all parts, replace as necessary.

A—Bearing B—Hub Housing

TB90758,0000251 -19-05MAR13-16/16

Assemble Final Drive (S.N. 120701— )


Before assembling hub, read and follow guidelines to
ensure proper operation and avoid premature component
failure.
Inspect all parts for excessive wear and damage, replace

N70948 —UN—26AUG05
as necessary.
In case of damaged gears, for example a planet, do not
replace the single gear, but the whole reduction stage.
Always replace all O-rings.
Threaded ring nut cannot be reused, always install new
threaded ring nut.
The unit must be cleaned as thoroughly as possible. A—Threaded Ring Nut B—Spindle
Remove all dirt and debris to prevent final drive failure.
Assemble unit on a bench in clean work area free of dust correctly, torque multiplier can be used to
and dirt. turn nut on and off several times.
1. Before beginning assembly procedure, do the
following: c. Screw new threaded ring nut (A) onto spindle (B)
by hand. Threaded ring nut must turn on by hand
a. Clean threads of spindle to remove any thread lock for correct assembly.
material.
d. Remove threaded ring nut.
b. Inspect threads of spindle. Repair any damaged
threads using a thread file. e. Clean spindle and threaded ring nut in clean solvent
to remove any foreign material. Blow dry using
IMPORTANT: Threaded ring nut can easily be cross compressed air.
threaded. Ensure nut is started correctly.
If nut cannot be started correctly, or will f. Repeat Sub-step (c) to ensure threaded ring nut
not thread on at least two threads by hand threads all of the way onto spindle by hand.
once started, replace ring nut.

IMPORTANT: If threaded ring nut can only be


turned on a few threads and it is started
Continued on next page TB90758,0000252 -19-04MAR13-1/27

TM100419 (02APR13) 55-10-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=198
Final Drive Repair

IMPORTANT: If seals are to be reused, keep A


seal rings together as a matched set with
seal ring faces together. E

2. Inspect metal face seals to determine if seals can be


reused.
a. The narrow, highly polished sealing area (E) must
be in the outer half (D) of seal ring face (C).
b. Sealing area must be uniform and concentric with C
ID and OD of seal ring (A).
B
c. Sealing area must not be chipped, nicked, or
scratched.
D

A—Seal Ring D—Outer Half of Seal Ring Face

N75868 —UN—24APR07
B—Worn Area (Shaded Area) E—Sealing Area (Dark Line)
C—Seal Ring Face

TB90758,0000252 -19-04MAR13-2/27

d. Illustration shows examples of worn seal rings (A).


I—Sealing area (D) is in inner half of seal ring face
(C).
II—Sealing area (D) not concentric with ID and OD
of seal ring.

T85080 —UN—05DEC96
A—Seal Ring C—Inner Half of Seal Ring Face
B—Worn Area (Shaded Area) D—Sealing Area (Dark Line)

Continued on next page TB90758,0000252 -19-04MAR13-3/27

TM100419 (02APR13) 55-10-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=199
Final Drive Repair

A B

F F

C C

E E

N54714 —UN—11AUG00
D D

A—Seat D—Sealing Surfaces F— Half Seal Surfaces


B—Seat E—Half Seal (2 used)
C—O-Ring (2 used)

3. Before installing half seals, do the following: the half seals. Any Moly on surfaces that contact
O-rings (C) MUST be cleaned and dried before
a. Carefully clean surfaces (A, B, and F), if necessary, installing half seals.
metal brushes or solvent can be used. Surfaces in On half seals that are reused, a thin film of oil on
contact with O-rings (C) MUST be perfectly clean sealing surfaces during assembly will be sufficient.
and dry.
4. Seal rings, O-rings, and housings must be clean and
b. Ensure sure sealing surfaces (D) of half seals are free of any oil film, dust, or other foreign matter. Use
free from scratches, nicks or foreign substances, a solvent that evaporates quickly, leaves no residue,
metal ring surfaces MUST be perfectly clean and dry. and is compatible with the rubber O-rings. (Follow all
c. Carefully clean sealing surface of half seals to safety guidelines for use of the solvent.) Seal ring and
remove dust and fingerprints. If new seals are used, housing should be wiped clean. Use a solvent-soaked
lubricate with Moly from tube that is supplied with cloth or paper towel that are lint free.
seal, taking care not to get any Moly on the rest of
Continued on next page TB90758,0000252 -19-04MAR13-4/27

TM100419 (02APR13) 55-10-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=200
Final Drive Repair

5. After all components have been wiped clean, O-rings


should be installed on seal rings so they rest in
radius of seal ring. Insure O-rings are not twisted, by
inspecting mold line on outside diameter of O-ring for

N55266 —UN—05OCT00
true tracking around seal rings. Twisted O-rings (D) will
cause non-uniform face load that can result in leakage.
If a twist is apparent, it can be eliminated by gently
pulling a section of O-ring (B) away from seal ring (A)
and letting it “snap” back. Repeating this in several
places around ring will eliminate any twist in O-ring.

A—Seal Ring D—Twisted O-Ring


B—O-Ring E—Incorrect O-Ring Seating
C—Correct O-Ring Seating C

N75869 —UN—24APR07
E

TB90758,0000252 -19-04MAR13-5/27

6. Position flanged hub (B) on press and install bearing


(A).

A—Bearing B—Flanged Hub

N89855 —UN—29OCT10
Continued on next page TB90758,0000252 -19-04MAR13-6/27

TM100419 (02APR13) 55-10-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=201
Final Drive Repair

7. Assemble first half-seal by installing O-ring (A) on


steel ring (B).
8. Install half-seal assembly onto JDG1785 Seal
Installer1 (C).

A—O-Ring C—JDG1785 Seal Installer

N64144 —UN—02OCT03
B—Steel Ring

N64145 —UN—02OCT03
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
TB90758,0000252 -19-04MAR13-7/27

9. Install half-seal assembly on hub housing until


JDG1785 Seal Installer1 bottoms out on housing.

N75873 —UN—24APR07
A A
Remove installer ring.
NOTE: Seal stand-out height will vary, however it is
important that the seal is evenly installed and
does not exceed specified variation around
entire circumference.

Remove the installation tool. Using a dial indicator,


check seal stand-out height (A) at several places A—Stand-Out Height
around the circumference of the ring. If the seal does Dimension
not meet specification, inspect the O-ring for twists
or obvious deformities. If seal is not in specification,
remove repeat Steps 7—9 until seal is installed to
specification.
Specification
Final Drive
Seals—Stand-Out Height
Variation........................................................................ Level +/- 1.5 mm
(+/- 0.06 in.)
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page TB90758,0000252 -19-04MAR13-8/27

TM100419 (02APR13) 55-10-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=202
Final Drive Repair

10. Assemble second half-seal by installing O-ring (A) on


steel ring (B).
11. Install half-seal assembly onto JDG1785 Seal
Installer1 (C).

A—O-Ring C—JDG1785 Seal Installer

N64144 —UN—02OCT03
B—Steel Ring

N64145 —UN—02OCT03
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
TB90758,0000252 -19-04MAR13-9/27

12. Install half-seal assembly onto flanged hub until


JDG1785 Seal Installer1 (A) bottoms out on hub.
Remove installer ring.
13. Check seal stand-out height.

A—JDG1785 Seal Installer

N64146 —UN—02OCT03

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page TB90758,0000252 -19-04MAR13-10/27

TM100419 (02APR13) 55-10-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=203
Final Drive Repair

14. Lightly lubricate surface of steel ring (A) with clean oil.

A—Steel Ring

N64148 —UN—02OCT03
TB90758,0000252 -19-04MAR13-11/27

15. Lightly lubricate lapped surface of steel ring with clean


oil before assembly of hub.
16. Use JDG1786 Bearing Installer1 (A), press flanged
hub (B) onto hub housing (C).
17. Press flanged hub until it contacts hub housing
shoulder.

A—JDG1786 Bearing Installer C—Hub Housing


B—Flanged Hub

N89856 —UN—29OCT10
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
TB90758,0000252 -19-04MAR13-12/27

18. Install JDG1787 Safety Plate1 (A) and cap screw.


Install nut over hub stud.

A—JDG1787 Safety Plate

N89857 —UN—29OCT10

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page TB90758,0000252 -19-04MAR13-13/27

TM100419 (02APR13) 55-10-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=204
Final Drive Repair

19. Install ring nut (B).


20. Align dowel pins in JDG1782 Torque Multiplier1 (C)
with holes (A) in ring nut (B).
IMPORTANT: Output of torque multiplier turns in
opposite direction of input. Tighten ring nut by

N89763 —UN—22OCT10
turning input of multiplier counterclockwise.

21. Tighten ring nut to specification using torque multiplier


(C).
Specification
Final Drive Ring
Nut—Torque (Torque
Multiplier Input)............................................................................100 N·m
(74 lb.-ft.)

Specification
Final Drive Ring
Nut—Torque (Torque
Multiplier Output).......................................................................3078 N·m
(2278 lb.-ft.)

22. Remove JDG1782 Torque Multiplier1 (C) and JDG1787


Safety Plate1 (D).

N89764 —UN—28OCT10
A—Hole C—JDG1782 Torque Multiplier
B—Ring Nut D—JDG1787 Safety Plate

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page TB90758,0000252 -19-04MAR13-14/27

TM100419 (02APR13) 55-10-19 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=205
Final Drive Repair

IMPORTANT: Ensure ring nut does not move, loose


ring nut may cause damage to threads of hub.

23. Stake ring nut near two seats (A), 180° apart.

A—Seats

N64157 —UN—02OCT03
N64158 —UN—02OCT03
TB90758,0000252 -19-04MAR13-15/27

NOTE: Align holes on ring gear and hub.

24. Install spacer ring (C).


25. Install new O-rings onto ring gear (A) and install onto
hub (B).

N89761 —UN—26OCT10
A—Ring Gear C—Spacer Ring
B—Hub

N89762 —UN—22OCT10

Continued on next page TB90758,0000252 -19-04MAR13-16/27

TM100419 (02APR13) 55-10-20 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=206
Final Drive Repair

26. Install spacers (A), as shown, with bevel facing down.

A—Spacers

N64159 —UN—02OCT03
TB90758,0000252 -19-04MAR13-17/27

27. Position second reduction assembly planet gears (A)


with radiused edge of inner bearing race (B) facing
down. Install using appropriate sized driver and rubber
mallet.

A—Planet Gear (4 used) B—Inner Bearing Race

N64160 —UN—02OCT03
Continued on next page TB90758,0000252 -19-04MAR13-18/27

TM100419 (02APR13) 55-10-21 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=207
Final Drive Repair

28. Install retaining rings (A).

A—Retaining Ring (4 used)

N64128 —UN—02OCT03
TB90758,0000252 -19-04MAR13-19/27

29. Install first stage reduction assembly (B).


30. Install first stage sun gear (A).

A—First Stage Sun Gear B—First Stage Reduction


Assembly

N89760 —UN—27OCT10
Continued on next page TB90758,0000252 -19-04MAR13-20/27

TM100419 (02APR13) 55-10-22 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=208
Final Drive Repair

IMPORTANT: Overfilling of final drive can cause


premature bearing failure.

31. Install end cover (B).


32. Install socket head cap screws (A). Tighten to
specification.
Specification
Cover Cap
Screws—Torque............................................................................76 N·m

N89759 —UN—22OCT10
(56 lb.-ft.)

A—Socket Head Cap Screw (18 B—Cover


used)

TB90758,0000252 -19-04MAR13-21/27

33. Turn hub over and install brake shaft (A).


34. Alternately install steel and fiber brake disks (B),
starting with steel disk.

A—Brake Shaft B—Brake Disks

N64161 —UN—02OCT03
Continued on next page TB90758,0000252 -19-04MAR13-22/27

TM100419 (02APR13) 55-10-23 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=209
Final Drive Repair

35. Install O-ring (A).


36. Install O-ring (C) onto piston (B).

A—O-Ring C—O-Ring
B—Piston

N89858 —UN—29OCT10
N89859 —UN—01NOV10
TB90758,0000252 -19-04MAR13-23/27

37. Install brake piston (A) and springs (B).

A—Brake Piston B—Spring (12 inner and 12


outer used)

N89862 —UN—01NOV10

Continued on next page TB90758,0000252 -19-04MAR13-24/27

TM100419 (02APR13) 55-10-24 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=210
Final Drive Repair

38. Install spring retainer (A).

A—Spring Retainer

N64116 —UN—02OCT03
TB90758,0000252 -19-04MAR13-25/27

39. Install disk (A), bar (B), and forcing screw from
JDG1451 Spring Compressor.2 Tighten forcing screw
to compress brake assembly and install retaining ring
(C).
40. Slowly remove screw to release spring tension.
Remove tool.

N64115 —UN—02OCT03
1
A—Disk C—Retaining Ring
1
B—Bar

2
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
1
Included in JDG1451 Spring Compressor
TB90758,0000252 -19-04MAR13-26/27

41. Using a depth gauge, measure distance from mounting


flange (A) to brake shaft (B). If measurement is not
within specification, final drive must be disassembled.
Specification
Mounting Flange-to-Drive
Coupler—Depth............................................................ 111.4—112.2 mm

N64182 —UN—07OCT03
(4.386—4.425 in.)

42. Perform brake check:


a. Using auxiliary hydraulic power source to brake
port, pressurize brakes to 50 bar (750 psi).
b. Brakes must hold pressure for 3 minutes. If brakes
do not hold pressure, gear case has not been
assembled correctly, or seals are damaged. Repair A—Mounting Flange B—Brake Shaft
as required.
IMPORTANT: Overfilling of final drive can cause
premature bearing failure. 43. Install hydrostatic drive motor.
TB90758,0000252 -19-04MAR13-27/27

TM100419 (02APR13) 55-10-25 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=211
Final Drive Repair

Final Drive (S.N. —100986)—Exploded View

19

20
21
22
23
24
25
18 1
26

2 3
27
28
29
30
4
31
5

14 6
8
9 7

11
10

T8130000874 —UN—05MAR13
12
32 13

15

17 16

1— Socket Head Cap Screw 11— Spacer 19— Flanged Hub 27— Brake Piston
2— Seal 12— 2nd Reduction 20— Spacer Ring 28— Spring
3— Plug 13— Spacer 21— Brake Shaft 29— Spring Retainer Disc
4— Plug 14— Spacer 22— Brake Disc Unit 30— Circlip
5— Seal 15— Ring Nut 23— Brake Disc Unit 31— O-Ring Seal
6— End Cover 16— Gear Case Housing 24— Spacer Ring 32— Cap Screw
7— O-Ring Seal 17— 1st Half Seal and 2nd Half 25— O-Ring Seal
8— Line Up Pin Seal 26— O-Ring Seal
9— 1st Stage Sun Gear 18— O-Ring Seal
10— 1st Reduction
TB90758,0000272 -19-05MAR13-1/1

TM100419 (02APR13) 55-10-26 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=212
Final Drive Repair

Disassemble Final Drive (S.N. —100986)


1. Remove final drive from machine. Thoroughly clean
exterior of final drive.
2. Install JDG1451 Spring Compressor1 (B) on flanged

T8130000845 —UN—25FEB13
hub (C).
3. Turn cap screw (A) until it contrasts the force of
internal springs.

A—Cap Screw C—Flanged Hub


B—JDG1451 Spring
Compressor

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
TB90758,0000273 -19-05MAR13-1/23

4. Using proper snap ring pliers, remove circlip (A) and


JDG1451 Spring Compressor.1

A—Circlip

T8130000846 —UN—25FEB13
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
TB90758,0000273 -19-05MAR13-2/23

5. Remove spring retainer disc (A).

A—Spring Retainer Disc

T8130000847 —UN—25FEB13

Continued on next page TB90758,0000273 -19-05MAR13-3/23

TM100419 (02APR13) 55-10-27 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=213
Final Drive Repair

6. Remove springs (A) from brake piston (B).

A—Spring B—Brake Piston

T8130000848 —UN—25FEB13
TB90758,0000273 -19-05MAR13-4/23

7. Insert inside puller into hole of brake shaft (B), expand


lower end of puller into internal release of brake shaft
and remove it and brake piston (A).

A—Brake Piston B—Brake Shaft

T8130000849 —UN—05MAR13
T8130000850 —UN—05MAR13
A B

Continued on next page TB90758,0000273 -19-05MAR13-5/23

TM100419 (02APR13) 55-10-28 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=214
Final Drive Repair

8. Insert an inside puller into hole of brake shaft (A),


expand lower end of puller into internal release of
brake shaft and remove spacer (B).

A—Brake Shaft B—Spacer

T8130000851 —UN—05MAR13
B

T8130000852 —UN—05MAR13
TB90758,0000273 -19-05MAR13-6/23

9. Remove O-ring seal (A) from flanged hub.

A—O-Ring Seal

T8130000853 —UN—25FEB13
Continued on next page TB90758,0000273 -19-05MAR13-7/23

TM100419 (02APR13) 55-10-29 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=215
Final Drive Repair

10. Remove spacer ring (A).

A—Spacer Ring

T8130000854 —UN—25FEB13
TB90758,0000273 -19-05MAR13-8/23

11. Remove O-ring seal (A) from spacer ring (B).

A—O-Ring Seal B—Spacer Ring

T8130000855 —UN—25FEB13
TB90758,0000273 -19-05MAR13-9/23

12. Remove brake disc unit (A—B).

A—Brake Disc Unit B—Brake Disc Unit

T8130000856 —UN—25FEB13

Continued on next page TB90758,0000273 -19-05MAR13-10/23

TM100419 (02APR13) 55-10-30 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=216
Final Drive Repair

13. Remove spacer ring (A).

A—Spacer Ring

T8130000857 —UN—25FEB13
TB90758,0000273 -19-05MAR13-11/23

14. Remove socket head cap screws (A), and remove end
cover.

A—Sock Head Cap Screw

T8130000858 —UN—25FEB13
TB90758,0000273 -19-05MAR13-12/23

15. Remove O-ring seal (A) from end cover groove (B).

A—O-Ring Seal B—End Cover Groove

T8130000859 —UN—25FEB13

Continued on next page TB90758,0000273 -19-05MAR13-13/23

TM100419 (02APR13) 55-10-31 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=217
Final Drive Repair

16. Remove 1st reduction (B) from gear case housing (A).

A—Gear Case Housing B—1st Reduction

T8130000860 —UN—05MAR13
B

T8130000861 —UN—05MAR13
TB90758,0000273 -19-05MAR13-14/23

NOTE: This operation should be done only when


necessary to replace sun gear.

17. Remove 1st stage sun gear (A) from 1st reduction (B).

T8130000862 —UN—25FEB13
A—1st Stage Sun Gear B—1st Reduction

Continued on next page TB90758,0000273 -19-05MAR13-15/23

TM100419 (02APR13) 55-10-32 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=218
Final Drive Repair

18. Using snap ring pliers, remove circlip (A) from planet
assemblies of 2nd reduction (B).

A—Circlip B—2nd Reduction

T8130000863 —UN—25FEB13
TB90758,0000273 -19-05MAR13-16/23

19. Using a puller, remove planet assemblies of 2nd


reduction (A).

A—2nd Reduction

T8130000864 —UN—25FEB13
TB90758,0000273 -19-05MAR13-17/23

20. Remove spacer (A).

A—Spacer

T8130000865 —UN—25FEB13

Continued on next page TB90758,0000273 -19-05MAR13-18/23

TM100419 (02APR13) 55-10-33 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=219
Final Drive Repair

21. Using JDG1455 Torque Multiplier1 (A), loosen ring nut


(B).

A—JDG1455 Torque Multiplier B—Ring Nut

T8130000866 —UN—05MAR13
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
TB90758,0000273 -19-05MAR13-19/23

22. Remove ring nut (A).

A—Ring Nut

T8130000867 —UN—25FEB13
TB90758,0000273 -19-05MAR13-20/23

23. Using a press, remove flanged hub (A) from gear case
housing (B).

A—Flanged Hub B—Gear Case Housing

T8130000868 —UN—25FEB13

Continued on next page TB90758,0000273 -19-05MAR13-21/23

TM100419 (02APR13) 55-10-34 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=220
Final Drive Repair

24. Using a puller, turn cap screws (A) until bearing inner
ring comes out.
NOTE: In case of oil leakage, it may be necessary to
check and eventually replace lifetime seal, which
means both steel rings and O-rings.

T8130000869 —UN—25FEB13
25. Remove first half seal (B).
26. Using a flat head screwdriver, remove second half
seal (C).

A—Cap Screws C—2nd Half Seal


B—1st Half Seal

T8130000870 —UN—25FEB13
T8130000871 —UN—25FEB13
Continued on next page TB90758,0000273 -19-05MAR13-22/23

TM100419 (02APR13) 55-10-35 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=221
Final Drive Repair

27. Remove bearing inner ring (B) from gear case housing
(A).
28. Remove bearing balls (C) from gear case housing.
29. Gear case disassembly ends with above operation.

T8130000872 —UN—25FEB13
Repair or replace parts as necessary.

A—Gear Case Housing C—Bearing Balls


B—Inner Ring

T8130000873 —UN—25FEB13
TB90758,0000273 -19-05MAR13-23/23

Assemble Final Drive (S.N. —100986)


1. When proceeding with gear case reassembly, use
special instructions listed:
• In case of damaged gears, for example a planet, do D
not replace single gear, but whole reduction stage.
• Always replace O-ring and seal rings of part to
be reassembled after having carefully cleaned
seats and having applied some grease on seats C
themselves and on O-rings.
• Always replace components that seem to be
damaged or have excessive wear, with original
spare parts.

T8130000875 —UN—05MAR13
2. Fit lower ball row (D) in gear case housing, holding A
inner raceway (C) with spacers (A) and (B).

A—Spacer C—Inner Raceway


B—Spacer D—Lower Ball Row B

Continued on next page TB90758,0000276 -19-02APR13-1/31

TM100419 (02APR13) 55-10-36 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=222
Final Drive Repair

3. Remove spacer (B). Drop lower ball row (C). Assemble


inner raceway (D).

A—Spacer C—Lower Ball Row


B—Spacer D—Inner Raceway D

T8130000881 —UN—05MAR13
A
B

TB90758,0000276 -19-02APR13-2/31

4. Support gear case housing (B) and lower flanged hub


(A) inside gear case.

A—Flanged Hub B—Gear Case Housing

T8130000931 —UN—04MAR13
Continued on next page TB90758,0000276 -19-02APR13-3/31

TM100419 (02APR13) 55-10-37 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=223
Final Drive Repair

5. Using a press and stopper, push flanged hub against


shoulder of gear case housing until assembly of unit
is complete.

CM073510528 —UN—03MAR08
TB90758,0000276 -19-02APR13-4/31

6. Install ring nut (A).

A—Ring Nut

T8130000932 —UN—04MAR13
TB90758,0000276 -19-02APR13-5/31

7. Using JDG1455 Torque Multiplier1 , tighten ring nut


to specification.
Specification
Ring Nut—Torque......................................................................6249 N·m

CM073510530 —UN—03MAR08
(4609 lb.-ft.)

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page TB90758,0000276 -19-02APR13-6/31

TM100419 (02APR13) 55-10-38 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=224
Final Drive Repair

8. Staking detail.

CM073510532 —UN—03MAR08
TB90758,0000276 -19-02APR13-7/31

9. Install spacers (A) on pins (B) of flanged hub.

A—Spacers B—Pins

T8130000933 —UN—04MAR13
TB90758,0000276 -19-02APR13-8/31

10. Place planet gears (A) on pins of flanged hub (B),


checking that groove is toward end cover.

A—Planet Gears B—Flanged Hub

T8130000934 —UN—04MAR13

Continued on next page TB90758,0000276 -19-02APR13-9/31

TM100419 (02APR13) 55-10-39 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=225
Final Drive Repair

11. Using a rubber hammer and stopper, push planet


gears (A) against flanged hub (B) shoulder.

A—Planet Gears B—Flanged Hub

T8130000935 —UN—04MAR13
TB90758,0000276 -19-02APR13-10/31

12. Install circlips (B) in flanged hub groove (A).

A—Circlips B—Flanged Hub Groove

T8130000936 —UN—04MAR13
TB90758,0000276 -19-02APR13-11/31

13. Install 1st reduction (A).

A—1st Reduction

T8130000937 —UN—04MAR13

Continued on next page TB90758,0000276 -19-02APR13-12/31

TM100419 (02APR13) 55-10-40 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=226
Final Drive Repair

14. Using a rubber hammer, install 1st stage sun gear (A).

A—1st Stage Sun Gear

T8130000938 —UN—04MAR13
TB90758,0000276 -19-02APR13-13/31

15. Install O-ring (B) into end cover groove (A)

A—End Cover Groove B—O-Ring

T8130000939 —UN—04MAR13
TB90758,0000276 -19-02APR13-14/31

16. Attach end cover to gear case housing using socket


head cap screws (A), tighten to specification.
Specification
End Cover Socket Head

T8130000940 —UN—04MAR13
Cap Screws—Torque....................................................................25 N·m
(18 lb.-ft.)

A—Socket Head Cap Screws

Continued on next page TB90758,0000276 -19-02APR13-15/31

TM100419 (02APR13) 55-10-41 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=227
Final Drive Repair

17. Turn gear case upside down, install spacer (A).

A—Spacer

T8130000941 —UN—04MAR13
TB90758,0000276 -19-02APR13-16/31

18. Using a rubber hammer, tap spacer (A) against


shoulder inside brake shaft (B).

A—Spacer B—Brake Shaft

T8130000942 —UN—04MAR13
TB90758,0000276 -19-02APR13-17/31

19. Install brake shaft (A).

A—Brake Shaft

T8130000943 —UN—04MAR13

Continued on next page TB90758,0000276 -19-02APR13-18/31

TM100419 (02APR13) 55-10-42 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=228
Final Drive Repair

20. Install brake disc package in following order: First,


insert one sintered bronze disc unit (A) with external
teeth.

A—Brake Disc Unit

T8130000944 —UN—04MAR13
TB90758,0000276 -19-02APR13-19/31

21. Insert an internal toothed stee brake disc unit (B).


Repeat operation until all six sintered bronze discs
and five steel discs have been installed.

B—Brake Disc Unit

T8130000945 —UN—04MAR13
TB90758,0000276 -19-02APR13-20/31

22. Lubricate seal seat inside flanged hub groove (A) with
oil and install O-ring (B).

A—Flanged Hub Groove B—O-Ring

T8130000946 —UN—04MAR13

Continued on next page TB90758,0000276 -19-02APR13-21/31

TM100419 (02APR13) 55-10-43 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=229
Final Drive Repair

23. Install O-ring (A) into brake spacer inner groove (B).

A—O-Ring B—Inner Groove

T8130000947 —UN—04MAR13
TB90758,0000276 -19-02APR13-22/31

24. Install brake spacer ring (A) inside flanged hub.

A—Brake Spacer Ring

T8130000948 —UN—04MAR13
CQ280020 —UN—27JUN07
Continued on next page TB90758,0000276 -19-02APR13-23/31

TM100419 (02APR13) 55-10-44 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=230
Final Drive Repair

NOTE: Lubricate grooves already fitted.

25. Install O-ring seal (A) into seat in flanged hub groove
(B).

T8130000949 —UN—04MAR13
A—O-Ring Seal B—Flanged Hub Groove

TB90758,0000276 -19-02APR13-24/31

26. Insert brake piston (A) into flanged hub, being careful
not to damage seals already fitted.

A—Brake Piston

T8130000950 —UN—04MAR13
TB90758,0000276 -19-02APR13-25/31

27. Install springs (B) in seats in brake piston (A).

A—Brake Piston B—Spring

T8130000951 —UN—04MAR13

Continued on next page TB90758,0000276 -19-02APR13-26/31

TM100419 (02APR13) 55-10-45 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=231
Final Drive Repair

28. Install spring retainer disc (A).

A—Spring Retainer Disc

T8130000952 —UN—04MAR13
TB90758,0000276 -19-02APR13-27/31

29. Install JDG1451 Spring Compressor1 (A) on flanged


hub (C) and turn cap screw (B) until it contrasts the
force of spring.

A—JDG1451 Spring C—Flanged Hub

T8130000953 —UN—04MAR13
Compressor
B—Cap Screw

1
For further information, see SERVICEGARD, online tool
catalog or your John Deere dealer.
TB90758,0000276 -19-02APR13-28/31

30. Install circlip (A) and remove JDG1451 Spring


Compressor.1

A—Circlip

T8130000954 —UN—04MAR13

1
For further information, see SERVICEGARD, online tool
catalog or your John Deere dealer.
Continued on next page TB90758,0000276 -19-02APR13-29/31

TM100419 (02APR13) 55-10-46 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=232
Final Drive Repair

31. Install plug (A) into filler hole and tighten socket head
cap screws to specification.
Specification
Fill Plug—Torque...........................................................................30 N·m

T8130000955 —UN—04MAR13
(22 lb.-ft.)

A—Plug

TB90758,0000276 -19-02APR13-30/31

32. Install plug (A) into level hole and tighten to


specification.
Specification
Level Plug—Torque.........................................................................8 N·m

T8130000956 —UN—04MAR13
(71 lb.-in.)

33. Fill with appropriate oil. (See Final Drive Gear Oil in
Section 10, Group 15.)

A—Plug

TB90758,0000276 -19-02APR13-31/31

TM100419 (02APR13) 55-10-47 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=233
Final Drive Repair

Assemble Lifetime Seal (S.N. —100986)

A B

C C

T8130000882 —UN—05MAR13
D D
E E

F F

A—Seat D—O-Ring F— Sealing Surface


B—Seat E—Metal Ring

1. Carefully clean seats (A) and (B) using, if necessary, 3. Carefully clean lapped surface of metal ring and
metal brushes or solvent (surfaces in contact with remove dust or finger prints. Apply a thin oil film,
O-ring (D) must be perfectly clean and dry). taking care not to oil other components.
2. Ensure that sealing surfaces (F) of metal rings (E)
are free from scratches, dings, or foreign substances.
Metal ring surfaces must be clean and dry.
TB90758,0000278 -19-05MAR13-1/5

4. Assemble half seal (A) on tool.

A—Half Seal

T8130000957 —UN—05MAR13
Continued on next page TB90758,0000278 -19-05MAR13-2/5

TM100419 (02APR13) 55-10-48 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=234
Final Drive Repair

5. Assemble half seal (A) on gear case housing (B).

A—Half Seal B—Gear Case Housing

T8130000958 —UN—05MAR13
TB90758,0000278 -19-05MAR13-3/5

6. Using same tool, install other half seal (B) onto flanged
hub (A).

A—Flanged Hub B—Half Seal

T8130000959 —UN—05MAR13
TB90758,0000278 -19-05MAR13-4/5

7. Clean metallic faces of seal (A) and apply thin film of oil.

A—Half Seal

T8130000960 —UN—05MAR13

TB90758,0000278 -19-05MAR13-5/5

TM100419 (02APR13) 55-10-49 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=235
Final Drive Repair

TM100419 (02APR13) 55-10-50 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=236
Section 57
Wheel
Contents

Page

Group 05—Wheel
Other Material................................................ 57-05-1
Specifications ................................................ 57-05-1
Jack Locations............................................... 57-05-1
Remove and Install Wheel
Assembly ................................................... 57-05-2
Remove and Install Front Wheel
Bearings .................................................... 57-05-3
Remove and Mount Tire onto
Wheel Assembly........................................ 57-05-4

TM100419 (02APR13) 57-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 57-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Wheel
Other Material
Number Name Use
PM37566 (U.S.) Loctite®Anti-Seize Lubricant To prevent seizing of components.

Loctite is a trademark of Henkel Corporation


PW66162,0000987 -19-13FEB13-1/1

Specifications
Item Measurement Specification

Front Wheel Cap Screw Torque 230 N·m


(170 lb.-ft.)
Rear Wheel Cap Screw Torque 529 N·m
(390 lb.-ft.)
Front Wheel Spindle Nut Torque 47 N·m
(35 lb.-ft.)
PW66162,0000988 -19-13FEB13-1/1

Jack Locations
IMPORTANT: Do NOT support machine weight
with lifting device. Position blocks or stands
under machine after lifting.

CQ280287 —UN—27MAR08
Use jack locations (A and B) to lift harvester.

A—Rear Jack Locations (2 B—Front Jack Locations (2


used) used)

CQ280288 —UN—27MAR08

PW66162,0000891 -19-01MAR13-1/1

TM100419 (02APR13) 57-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=239
Wheel

Remove and Install Wheel Assembly 5. Install wheel assembly in reverse order of removal
using the following special instructions:
CAUTION: Avoid serious injury. Wheel weights
must be removed before rear wheel removal. • Clean and inspect all fastening hardware before
installation and replace as necessary.
For some applications, tires can be filled with • Apply Anti-Seize Lubricant to wheel cap screws
fluid. Use suitable equipment when handling before installation.
wheel assemblies to avoid injury. • Start wheel cap screws by hand to prevent thread
damage.
1. Loosen wheel cap screws before lifting harvester off • Tighten wheel cap screws to specification.
the ground.
Specification
2. Raise machine with an appropriate lifting device. Front Wheel Cap
Support machine with blocks or stands. (See Jack Screw—Torque............................................................................230 N·m
Locations in Section 57, Group 05.) (170 lb.-ft.)
Rear Wheel Cap
3. Place wheel assembly lift under wheel and attach a Screw—Torque............................................................................529 N·m
safety chain around the upper portion of tire. (390 lb.-ft.)
4. Remove three evenly spaced wheel cap screws • Check tire air pressure. (See Operators Manual for
and install threaded dowels in their place. Remove recommended tire air pressure.)
remaining wheel cap screws and pull wheel assembly
outward and away from machine.
PW66162,0000892 -19-28FEB13-1/1

TM100419 (02APR13) 57-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=240
Wheel

Remove and Install Front Wheel Bearings


1. Remove front wheel. (See Remove and Install Wheel
Assembly in Section 57, Group 05.)

CM002500247 —UN—26MAR08

1— Dust Cap 4— Washer 7— Hub 10— Seal


2— Cotter Pin 5— Outer Bearing Cone 8— Inner Bearing Cup
3— Spindle Nut 6— Outer Bearing Cup 9— Inner Bearing Cone
Continued on next page PW66162,00009E1 -19-02APR13-1/2

TM100419 (02APR13) 57-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=241
Wheel

IMPORTANT: Seal must be replaced when 9. Pack both bearing cones with grease.
removed. Each bearing cone and cup
must be replaced as a set. 10. Insert inner bearing into hub. Lubricate and install
new seal.
2. Remove dust cap (1), cotter pin (2), and spindle nut
(3) from spindle. 11. Clean seal mating surface on spindle with emery cloth.

NOTE: Catch washer (4) and outer bearing cone 12. Slide hub onto spindle. Install outer bearing cone,
(5) as hub is removed. washer, and spindle nut.
13. Tighten spindle nut to specification.
3. Pull hub (7) outward and remove with washer and
outer bearing cone. Specification
Front Wheel Spindle
4. Remove and discard seal (10). Nut—Torque..................................................................................47 N·m
(35 lb.-ft.)
5. Remove inner bearing cone (9).
NOTE: If necessary, loosen spindle nut the minimum
6. Inspect bearing cones and bearing cups (6 and 8) for
amount required to insert cotter pin in spindle.
wear or damage. Replace as necessary.
NOTE: To aid in removal, position a punch in the cut 14. Install cotter pin.
out area of hub to drive out bearing cups.
15. Rotate hub by hand to ensure that hub spins smoothly.
7. If necessary remove and replace bearing cups. 16. Install dust cap.
8. If removed, use an appropriate tool to install new 17. Install front wheel. (See Remove and Install Wheel
bearing cups into hub. Ensure that each bearing cup Assembly in Section 57, Group 05.)
is driven against hub shoulders.
PW66162,00009E1 -19-02APR13-2/2

Remove and Mount Tire onto Wheel


Assembly

CAUTION: Explosive separation of tire from wheel


can cause serious injury or death.

1. Before attempting any demounting operation, always


completely deflate the tire.
2. If tire is flat, check for a plugged valve stem by running
a wire through it. Inspect parts for wear or damage
and replace if necessary.

CM19989999022 —UN—02NOV99
3. Make sure that all parts are clean and free of dirt,
paint, rust, oil, grease, or other foreign material before
assembly.
4. Install valve stem into rim base.
5. Apply soap to the bead of tire and mount the tire on rim.
6. Clear area of personnel.

CAUTION: Avoid personal injury or death. Do


Not stand in front of, or over tire. When inflating
tires, use a clip-on chuck and an extension hose. 8. Install valve stem cap.
Over inflation can cause the tire to explode.
If possible, use a safety cage.

7. Connect pressure regulating valve to valve stem and


stand to one side. Inflate tire until the side flanges of
the tire slide outward against rim. Adjust tire pressure.
PW66162,000070B -19-21FEB13-1/1

TM100419 (02APR13) 57-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=242
Section 60
Steering and Brakes
Contents

Page

Group 10—Steering Valve


Specifications ................................................ 60-10-1
Steering Valve Exploded View
(Wheel Harvester) ..................................... 60-10-2
Disassembly/Reassembly ............................. 60-10-3
Reassembly Requirements ........................... 60-10-3
Troubleshooting............................................. 60-10-7
Adjust Steering Relief Valve .......................... 60-10-8

Group 15—Steering Arms and Pivots


Specifications ................................................ 60-15-1
Steering Linkage Exploded View................... 60-15-2
Check Front Axle Toe-In ................................ 60-15-3
Adjust Front Axle Toe-In ................................ 60-15-4

TM100419 (02APR13) 60-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 60-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 10
Steering Valve
Specifications
Item Measurement Specification

Steering Relief Valve Pressure 17 237 kPa


(172 bar)
(2500 psi)
PW66162,0000986 -19-13FEB13-1/1

TM100419 (02APR13) 60-10-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=245
Steering Valve

Steering Valve Exploded View (Wheel Harvester)

CM053510256 —UN—08AUG05

1— Cap Screw 6— Drive 11— Centering Spring 15— Seal


2— End Cap 7— Housing Valve 12— Retainer Spring 16— Dust Seal
3— O-ring 8— Sleeve Spool 13— Bearing Race
4— Gerotor 9— Centering Pin 14— Needle Thrust Bearing
5— Spacer Plate 10— Spring Spacer
PW66162,0000851 -19-21FEB13-1/1

TM100419 (02APR13) 60-10-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=246
Steering Valve

Disassembly/Reassembly that retains these parts should be removed first.


Safely retain these parts and remember to reinstall
Cleanliness is extremely important when repairing a these parts last after reassembly.
steering control unit. Work in a clean area. Before
disconnecting lines, clean port area of unit thoroughly. 1. Clamp unit in a vise, meter end up. Clamp lightly on
Use a wire brush to remove foreign material and debris the edges of port face sides. Use protective material
from around exterior joints of the unit. on vise jaws. Housing distortion could result if jaws
Although not all drawings show the unit in a vise, we are over tightened.
recommend that you keep the unit in a vise during 2. Carefully disassemble the steering control unit in the
disassembly and reassembly. Follow the clamp vertical position. If it is not kept vertical, the pin that
procedures. links the sleeve, spool and drive could possibly slip
NOTE: Notice placement of check ball and roll pin and dead bolt; it will lock these parts in the housing
(manual steering check valve), the cap screw before it is completely out.
PW66162,0000852 -19-06NOV12-1/1

Reassembly Requirements
Assure that all parts are free from rust, other contaminants,
nicks and burrs at time of reassembly.

CM073510467 —UN—19MAR08
Lubricate O-ring seals with mobilith SCH220 high
temperature grease. If the O-ring seals used in meter
section are lubricated with petroleum jelly for assembly
purposes, the amount of petroleum jelly used should be
minimal to avoid spreading jelly on the surfaces that form
the interfaces between end cap and gerotor ring and
between gerotor ring and spacer plate.
1. Sealing lips/surfaces of the shaft seal should be
protected against deforming, cutting or abrasion
during installation. Sealing surface area of the shaft
must be free from scratches, dents and other defects
detrimental to seal performance and life.
2. Spool must rotate smoothly inside the sleeve with less
than 0.111 N·m (1 lb-in) torque (finger force) when
both parts are lubricated with system oil.
3. Installation of spring spacers (10) and springs (11).
Hold spring retainer (12) at an angle as shown.
Continued on next page PW66162,0000853 -19-06NOV12-1/4

TM100419 (02APR13) 60-10-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=247
Steering Valve

CM073510468 —UN—19MAR08
4. Insert spring spacers (10) and springs (11) one at a then position spring retainer (12) correctly over all
time in sequence noted by reference numbers 2-9 (A these parts. Adjust alignment of spring parts with a
— Standard Torque), 2-8 (B — Medium Torque), small screwdriver.
Continued on next page PW66162,0000853 -19-06NOV12-2/4

TM100419 (02APR13) 60-10-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=248
Steering Valve

CM073510469 —UN—20SEP07
1— Gerotor Meter Star Valley 2— Drive Marked Parallel with Pin
Align with Mark on Drive 3— Pin Location Reference Align
Spline A, B, and C

5. Timing of drive with respect to the gerotor star is


critical. The pin slot in drive must be aligned with the
valley of the gerotor star contour.
Continued on next page PW66162,0000853 -19-06NOV12-3/4

TM100419 (02APR13) 60-10-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=249
Steering Valve

NOTE: Seven cap screws for meter section should be


torqued evenly with less than 5 percent variation.
Tightening torque variation 31-37 N·m (275-325
lb-in) to satisfy travel limit slip rate and input
torque requirements is permissible.

6. Torque all cap screws to 11-17 N·m (100-150 lb-in.)


evenly, then to final torque in sequence shown to 31 -
37 N·m (275 - 325 lb-in).
7. When the input drive at spline is rotated, gerotor star
shall rotate smoothly with less than 60 percent of
torque as specified after reassembly and tightening
of the seven cap screws to final torque level in the

CM053510258 —UN—08AUG05
previous step. Complete assembly should rotate
smoothly with less input torque than the valves
specified in the final test specification when warmed to
60 – 66°C (140 – 150°F).
8. Housing meter (gerotor) end, spacer plate, gerotor ring
and end cap shall form pressure tight (zero leakage)
at 275 bar (4000 PSI) interfaces after reassembly and
tightening of the seven cap screws.
PW66162,0000853 -19-06NOV12-4/4

TM100419 (02APR13) 60-10-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=250
Steering Valve

Troubleshooting steering control valve is not the cause of most problems.


The following is a list of steering problems and their
Most steering problems can be corrected if the problem possible cause along with suggested corrections.
is properly defined. The entire steering system should be
evaluated before removing any components. Usually the
Symptom Problem Solution

Slow Steering, Hard Steering or Worn or Malfunctioning Pump Repair or replace pump.
Loss of Power Assist
Leaking or kinked supply line for load Trace the hose and tighten fittings or
sensor. replace hose.

Malfunctioning priority valve. Check for sticking spring or spool.

Check system pressure at the steering


valve inlet for proper setting. If
necessary, replace the priority valve
relief cartridge.

Wander - The tendency to deviate Air in system due to low oil level, Check the system and add system
from Operator directed course cavitating pump, loose fittings, kinked fluid.
hose, etc.
Worn mechanical linkage. Repair or replace.

Binding of linkage or cylinder rod. Repair or replace.

Loose cylinder piston. Repair or replace.

Severe wear in steering valve. Repair or replace.

Drift - The tendency to deviate from Worn or damaged steering linkage. Repair or replace linkage and align
Non-Operator directed course: front end.

Slip - When a slow movement of Leakage of cylinder piston seals. Replace piston seals.
steering wheel fails to cause any
movement of steered wheels:
Erratic Steering Air in system due to low oil level, Check system and add system fluid.
cavitating pump, loose fittings, kinked
hose, etc.
Loose cylinder piston. Repair or replace cylinder.

Thermal shock damage.1 Repair or replace steering valve.

Spongy or Soft Steering Air in system due to low oil level, Check system for the above and add
cavitating pump, loose fittings, kinked system fluid to correct.
hose, etc.
Air in hydraulic system. (Most likely Bleed air from system.
air is trapped in cylinders or lines.)
Low oil level. Add oil and check for leaks.

Free Wheeling, (Steering Wheel Steering column upper shaft is loose Tighten steering wheel nut, repair or
turns freely with no feeling of or damaged. replace column.
pressure and no action on steered
wheels.)
Lower splines of column may be Repair or replace column.
disengaged or broken.
Continued on next page PW66162,0000854 -19-06NOV12-1/2

TM100419 (02APR13) 60-10-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=251
Steering Valve

Symptom Problem Solution

Steering valve gerotor is low on Starting engine will usually cure this
oil. (This can happen on start-up, problem.
after repair, or after long periods of
non-use.)
No flow to steering unit caused by low Add oil and check for leaks or ruptured
oil. hose.

Internal steering valve damaged due Repair or replace the valve.


to thermal shock.
1
Thermal shock is a condition caused when the hydraulic system is operated for some time without turning the steering wheel.
This may cause the oil in the hydraulic system to be hot and the steering valve may relatively cool (more than a 10° C (50° F)
temperature differential.) When the steering wheel is turned quickly the result is a temporary seizure and possible damage to
internal parts of the steering valve. This seizure may be followed by total free wheeling.
PW66162,0000854 -19-06NOV12-2/2

Adjust Steering Relief Valve 2. Adjust relief valve to specification.


NOTE: Rotate hex head screw clockwise to Specification
increase pressure. Steering Relief
Valve—Pressure..................................................................... 17 237 kPa
Rotate hex head screw counterclockwise
(172 bar)
to decrease pressure.
(2500 psi)
1. To adjust steering relief valve pressure, remove tank
port fitting and insert a 7/32 inch Allen Wrench into hex
head screw in port.
PW66162,000088E -19-13FEB13-1/1

TM100419 (02APR13) 60-10-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=252
Group 15
Steering Arms and Pivots
Specifications
Item Measurement Specification

Front Axle Toe-In Distance 0—6.35 mm


(0—0.25 in.)
PW66162,000088F -19-08NOV12-1/1

TM100419 (02APR13) 60-15-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=253
Steering Arms and Pivots

Steering Linkage Exploded View


NOTE: Right-hand side shown. Left-hand side is similar.

CM053510260 —UN—26MAR08

Continued on next page PW66162,000088B -19-13FEB13-1/2

TM100419 (02APR13) 60-15-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=254
Steering Arms and Pivots

1— Grease Fitting (4 used) 8— Trunnion Assembly 14— Nut-SL 22— Nut


2— Grease Fitting 9— Cap Screw (4 used) 15— Dust Cap 23— Cylinder Extension
3— Cotter Pin 10— Ball Bushing (4 used) 16— Steering Cylinder 24— Nut-SL
4— Washer 11— Strut Assembly 17— Washer 25— Cotter Pin
5— Seal 12— Wheel Hub 18— Bushing 26— Ball Joint
6— Snap Ring 13— Nut (4 used) 19— Ball Joint
7— Bearing 20— Nut-SL
21— Cotter Pin
PW66162,000088B -19-13FEB13-2/2

Check Front Axle Toe-In


1. Park machine on a firm level surface and position
wheels for straight forward travel.
2. Shut off engine and remove key.
3. Clean front tires.
4. Mark a line (A) in the center of each tire on the front
and rear; and on the center line (B) as shown.
5. Measure from line-to-line on rear of each tire. Record
measurement for rear dimension (C).
6. Measure from line-to-line on front of each tire. Record
measurement for front dimension (D).
7. Subtract front dimension from rear dimension to obtain
toe-in dimension. Check that front axle toe-in is to
specification.
Specification
Front Axle Toe-
In—Distance..........................................................................0—6.35 mm
(0—0.25 in.)

If toe-in is not to specification, adjust front axle toe-in.


(See Adjust Front Axle Toe-In in Section 60, Group 15.)

A—Line C—Rear Dimension


B—Center Line D—Front Dimension

N42173UX —UN—15JAN97

PW66162,000088C -19-08NOV12-1/1

TM100419 (02APR13) 60-15-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=255
Steering Arms and Pivots

Adjust Front Axle Toe-In


1. Park machine on a firm and level surface.
2. Position both front wheels straight forward. Check
wheel position by obtaining the same measurement

CM053510262 —UN—09AUG05
from front (B) and rear (A) of the tire at center line (C)
to the side wall of harvester (D).

A—Rear C—Center Line


B—Front D—Side Wall of Harvestor

CM053510263 —UN—09AUG05
Continued on next page PW66162,000088D -19-08NOV12-1/2

TM100419 (02APR13) 60-15-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=256
Steering Arms and Pivots

CM053510261 —UN—09AUG05
A—Fittings (2 used) B—Jam Nut
C—Adjustment Cylinder
Assembly

3. Disconnect hydraulic hoses from fittings (A) on 7. Repeat procedure for the opposite front wheel.
steering cylinder.
8. Repeat adjustment procedure until toe-in is to
4. Loosen jam nut (B). specification. (See Check Front Axle Toe-In in Section
5. Rotate adjustment cylinder assembly (C) clockwise 60, Group 15.)
until front of the tire moves inward 3.2 mm (0.25 in.).
6. Tighten jam nut (B) and connect hydraulic hoses.
PW66162,000088D -19-08NOV12-2/2

TM100419 (02APR13) 60-15-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=257
Steering Arms and Pivots

TM100419 (02APR13) 60-15-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=258
Section 70
Hydraulic System
Contents

Page
Page
Group 05—Hydraulic Reservoir
Specifications ................................................ 70-05-1 Disassemble and Assemble Base
Drain Hydraulic Reservoir.............................. 70-05-1 Cutter Lift Cylinders (Track
Remove and Install Hydraulic Filter Harvester)................................................ 70-20-28
Assemblies ................................................ 70-05-2 Remove and Install Knockdown Tilt
Cylinder (Optional)................................... 70-20-31
Group 10—Hydraulic Pumps Remove and Install Crop Divider
Specifications ................................................ 70-10-1 Tilt Cylinders (Optional) ........................... 70-20-33
Multiple Gear Pump Repair ........................... 70-10-2 Disassemble and Assemble
Piston Pump ................................................ 70-10-27 Knockdown Tilt and Crop Divider
Tilt Cylinder (Optional) ............................. 70-20-35
Group 15—Hydraulic Valves Remove and Install Elevator Lift
Specifications ................................................ 70-15-1 Cylinders.................................................. 70-20-39
Remove and Install Floating Crop Disassemble and Assemble
Divider Valves ............................................ 70-15-2 Elevator Lift Cylinders.............................. 70-20-41
Remove and Install Improved Remove and Install Elevator
Height Control Valve .................................. 70-15-4 Discharge Flap Cylinder .......................... 70-20-46
Repair Control Valve...................................... 70-15-5 Disassemble and Assemble
Repair Steering Priority Valve Elevator Discharge Flap
(Wheel Harvester) ................................... 70-15-10 Cylinder ................................................... 70-20-47
Remove and Install Elevator
Valve ........................................................ 70-15-15 Group 25—Hydraulic Motors
Other Material................................................ 70-25-1
Group 20—Hydraulic Cylinders Specifications ................................................ 70-25-1
Specifications ................................................ 70-20-1 Remove and Install Topper
Other Material................................................ 70-20-1 Gathering Disk Motor (Whole
Remove and Install Topper Topper) ...................................................... 70-25-2
Cylinder ..................................................... 70-20-2 Disassemble and Assemble Topper
Remove and Install Cab Tilt Gathering Disk, Scroll, Side
Cylinder ..................................................... 70-20-3 Knife, Butt-Lifter, Feed Roller,
Remove and Install Elevator Swing and Elevator Motors .................................. 70-25-3
Cylinders.................................................... 70-20-5 Remove and Install Chopper
Disassemble and Assemble Motor ....................................................... 70-25-11
Topper, Cab Tilt, and Elevator Disassemble and Assemble
Swing Cylinders—Use CTM ...................... 70-20-6 Chopper Motor......................................... 70-25-15
Remove and Install Steering Topper Severing Disk (Whole
Cylinders (Wheel Harvester) ..................... 70-20-7 Topper) and Secondary Extractor
Disassemble and Assemble Fan Motors Exploded View...................... 70-25-29
Steering Cylinders (Wheel Disassemble and Assemble Topper
Harvester).................................................. 70-20-8 Severing Disk (Whole Topper)
Remove and Install Crop Divider and Secondary Extractor Fan
Lift Cylinders............................................ 70-20-11 Motors...................................................... 70-25-30
Disassemble and Assemble Crop Repair Base Cutter and Primary
Divider Lift Cylinders................................ 70-20-13 Extractor Motors ...................................... 70-25-41
Remove and Install Base Cutter Lift Cooling Package Motor ............................... 70-25-58
Cylinders (Wheel Harvester) ................... 70-20-17 Disassemble and Assemble
Disassemble and Assemble Base Secondary Extractor Rotate
Cutter Lift Cylinders (Wheel Motor ....................................................... 70-25-65
Harvester)................................................ 70-20-20 Repair Fixed Displacement Ground
Remove and Install Base Cutter Lift Drive Motor (Track Harvester) ................. 70-25-84
Cylinders (Track Harvester)..................... 70-20-26

Continued on next page

TM100419 (02APR13) 70-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

Page

Variable Displacement Ground


Drive Motor Exploded View
(Optional)................................................. 70-25-86
Repair Variable Displacement
Ground Drive Motor (Wheel
Harvester)................................................ 70-25-88

Group 30—Accumulators
Special Tools ................................................. 70-30-1
Specifications ................................................ 70-30-1
Charge Crop Divider and Base
Cutter Accumulators .................................. 70-30-2
Charge Topper and Elevator
Accumulators............................................. 70-30-4

TM100419 (02APR13) 70-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Hydraulic Reservoir
Specifications
Item Measurement Specification

Hydraulic Filter Assembly Cover Torque 35 N·m


Cap Screws (25 lb.-ft.)
PW66162,0000933 -19-22JAN13-1/1

Drain Hydraulic Reservoir


1. Park machine on level surface.
2. Lower topper boom, adjustable knockdown roller, base
cutter, and elevator. Lower crop divider to ground.

T8120002629 —UN—22JAN13
3. Shut off engine and remove key.
4. Disconnect batteries using battery disconnect switch.
(See Battery Disconnect Switch in Section 40, Group
05.)
5. Clean hydraulic reservoir and surrounding area.
NOTE: Approximate capacity of hydraulic reservoir
is 397 L (105 gal.).
Hydraulic reservoir is vented. However, removing
reservoir vent (A) allows oil to drain easier.

T8120002630 —UN—22JAN13
6. Remove reservoir vent (A).
7. Place an appropriate container under reservoir.
8. Remove drain plug (B) and drain reservoir.
9. Install drain plug and reservoir vent when draining is
complete.

A—Open Coupler B—Drain Plug

PW66162,00009E2 -19-02APR13-1/1

TM100419 (02APR13) 70-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=261
Hydraulic Reservoir

Remove and Install Hydraulic Filter


Assemblies
IMPORTANT: Avoid hydraulic system contamination.
Clean filter assembly cover and surrounding

T8120002629 —UN—22JAN13
area before removal.
Prevent seal damage. Do NOT pry cover
off with sharp tools.

1. Remove vent (A) to release pressure in hydraulic


reservoir.
2. Clean cover and surrounding area.
3. Remove cap screws (B) and lift cover (C) from
reservoir.
4. Carefully lift filter assemblies (D) out of tank.
5. Place cover over opening to prevent contaminants

T8130000252 —UN—22JAN13
from entering reservoir.
6. Remove lower spring assembly (E) from filter
assembly.
7. Slide filter element (F) from assembly rod. Discard
element.
8. Clean all contaminates from magnet (G).
9. Inspect filter seal (H) and replace as necessary.
10. Install new filter element on assembly rod and install
lower spring assembly. Tighten nut until it stops. Do
NOT tighten further.

T8130000251 —UN—22JAN13
11. Repeat necessary steps for remaining filter
assemblies.
12. Insert filter assemblies into hydraulic reservoir.
13. Verify that cover O-ring is properly seated and
undamaged. Lubricate O-ring.
14. Install cover and tighten cap screws to specification.
Specification
Hydraulic Filter
Assembly Cover Cap
Screws—Torque............................................................................35 N·m
T8120002372 —UN—29NOV12
(25 lb.-ft.)

15. Install vent.


16. Check hydraulic reservoir oil level. (See Hydraulic Oil
in Section 10, Group 15 for recommended oil.

A—Vent E—Lower Spring Assembly


B—Cap Screw (8 used) F— Filter Element
C—Cover G—Magnet
D—Filter Assembly (3 used) H—Seal

PW66162,0000930 -19-13FEB13-1/1

TM100419 (02APR13) 70-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=262
Group 10
Hydraulic Pumps
Specifications
Item Measurement Specification

Piston Pump Valve Cartridge Torque 89 N·m


(66 lb.-ft.)
Piston Pump Control Cap Screws Torque 16 N·m
(142 lb.-in.)
Shaft Seal Retainer Plate Cap Torque 9.5 N·m
Screws (84 lb.-in.)
Charge Pump Cover cap Screws Torque 13.5 N·m
(119 lb.-in.)
PW66162,000099F -19-22FEB13-1/1

TM100419 (02APR13) 70-10-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=263
Hydraulic Pumps

Multiple Gear Pump Repair

CM073510081 —UN—20AUG07

Continued on next page PW66162,00009B5 -19-11MAR13-1/62

TM100419 (02APR13) 70-10-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=264
Hydraulic Pumps

1— Seal 11— Housing 21— Gear 31— Housing


2— Cover 12— Shaft 22— Housing 32— Housing
3— Plug 13— Gear 23— Washer 33— Shaft
4— Bushing 14— Housing 24— Stud 34— Seal
5— Seal 15— Housing 25— Shaft 35— Nut
6— Plate 16— Housing 26— Plate 36— Gear Case
7— Gear 17— Washer 27— Seal 37— Gear
8— Seal 18— Bolt 28— Seal 38— Gear Case
9— Dowel Pin 19— Nut 29— Dowel Pin
10— Gear Housing 20— Gear 30— Bushing

Service instructions familiarize you with multiple pumps,


their component parts, position of parts, method of 14. Bushing Installation Tool
disassembly and assembly, and pump care. 15. Scale (1/32 or 1/64 inch graduations)
To facilitate the repair of these pumps, and before any work 16. Small screwdriver
is done, we suggest you first read all of the repair steps.
17. Torque Wrench
The first requirement for good maintenance of hydraulic
equipment is cleanliness. Make sure that you perform all 18. Vise with 6 in. minimum open spread
repair work in a clean area.
19. Seal Installation Tool from kit D01045AA
It is important to air blast all parts and wipe them with a
20. Special Steel Sleeve (0290244683)
clean, lintless cloth before assembly.
21. Awl
Use caution in gripping all parts in a vise to avoid
damaging machined surfaces. Repair Precautions
A pump must be driven in the direction of rotation for which • If it is necessary to pry off sections, take extreme care
it is was built, otherwise the pressure blows shaft seal. not to mar or damage machined surfaces. Excessive
Check all replacement parts before installation. force while prying can result in misalignment and
component damage.
Suggested Tools • If parts are difficult to install during assembly, tap gently
with a soft-headed hammer. Never use a metal hammer.
1. Arbor Press • All gears are closely matched and must be kept as sets
2. 1-1/2 in. diameter steel ball. when removed from the pump. Handle with care to
avoid damage to the journals or teeth. Avoid touching
3. Bearing Puller gear journals.
4. Bushing Removal Tool from kit D01045AA.
• Never hammer bushings into bores, use an arbor press.
Bushing and Seal Removal Tools
5. Clean lintless cloths
Remove bushings in double and triple pumps from their
6. Deburring tool (an old file with cutting teeth ground off)
bores by using a bushing removal tool.
7. Machinist Hammer
The seal removal tool can be easily made from an old
8. Soft Hammer screwdriver. Heat the tip and bend to 90°. Grind the tip
to fit the notch behind the shaft seal.
9. Permatex form-a-gasket number C2 non-hardening
sealant or equivalent To install bushings, use JDG11606 Bushing Installer.
10. Medium grit carborundum stone The special steel sleeve (0290244683) is used to insert
the drive shaft through the lip seal without damage.
11. Seal Removal Tool
The seal installation tool (0290244684) is used to install
12. Snap Ring Pliers the lip seal into the housing.
13. Prick Punch
Continued on next page PW66162,00009B5 -19-11MAR13-2/62

TM100419 (02APR13) 70-10-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=265
Hydraulic Pumps

Disassemble
IMPORTANT: If it is necessary to pry off sections, take
extreme care not to mar or damage machined
surfaces. Excessive force while prying can result

CM073510082 —UN—06MAR08
in misalignment and can seriously damage parts.
All gears are closely matched and must be kept
as sets when removed from the pump. Handle
with care to avoid damage to the journals or
teeth. Avoid touching gear journals.

1. Position pump in a vise with drive shaft facing


downward.
NOTE: Marked line on pump sections aids in assembly.

2. Mark a line across all pump sections.


PW66162,00009B5 -19-11MAR13-3/62

3. Remove four hex nuts (19), washer (17), stud bolts


(18), hex nuts (35), stud bolts (24) and washers (23).

CM073510083 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-4/62

NOTE: If prying is necessary, be careful not to


damage the machine surfaces. Keep all gearsets
together, gears are a matched set.
Do not remove dowel pins (29). Pins can remain

CM073510084 —UN—06MAR08
in either port end cover or gear housing.

4. Lift off port end cover (16).


5. Remove thrust plate (26) from gear housing (31).

Continued on next page PW66162,00009B5 -19-11MAR13-5/62

TM100419 (02APR13) 70-10-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=266
Hydraulic Pumps

NOTE: If prying is necessary, take care not to


damage machine surfaces.

6. Remove gear housing (31) from housing (22).

CM073510085 —UN—06MAR08
22— Housing 31— Gear Housing

PW66162,00009B5 -19-11MAR13-6/62

NOTE: Label and retain gearset together. Gears


are a matched set.

7. Remove the two gears (20) from housing (22).

CM073510086 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-7/62

NOTE: Do not remove dowel pins (29). Pins can remain


in either housing (22) or gear housing.

8. Carefully lift or pry housing (22) from gear housing (32).

CM073510087 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-8/62

TM100419 (02APR13) 70-10-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=267
Hydraulic Pumps

9. Remove connecting shaft (33), thrust plate (26), and


gearset (21). Keep gears together; they are a matched
set. Be careful not to damage the machined surfaces
of the gears.

CM073510088 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-9/62

NOTE: Do not remove dowel pins (9). Pins can remain


in either gear housing or housing (14).

10. Carefully lift or pry gear housing (32) from housing (14).

CM073510089 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-10/62

11. Remove thrust plate (26) and connector shaft (25).

CM073510090 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-11/62

TM100419 (02APR13) 70-10-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=268
Hydraulic Pumps

NOTE: Do not remove dowel pins (9). Pins can remain


in either housing (14) or gear housing.

12. Remove housing (14) from gear housing (36).

CM073510091 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-12/62

13. Remove thrust plate (6) and gearset (37) from gear
housing (36).

CM073510092 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-13/62

NOTE: Do not remove dowel pins (9). Pins can remain


in gear housing or housing (15).

14. Remove gear housing (36) from housing (15).

CM073510093 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-14/62

TM100419 (02APR13) 70-10-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=269
Hydraulic Pumps

15. Remove thrust plate (6) and connector shaft (12) from
housing (15).

CM073510094 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-15/62

NOTE: Do not remove dowel pins (9). Pins can remain


in housing (15) or gear housing.

16. Remove housing (15) from gear housing (10).

CM073510095 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-16/62

17. Remove thrust plate (6) and gearset (13) from gear
housing (10).

CM073510096 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-17/62

TM100419 (02APR13) 70-10-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=270
Hydraulic Pumps

NOTE: Do not remove dowel pins (9). Pins can remain


in gear housing or housing (11).

18. Remove gear housing (10) from housing (11).

CM073510097 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-18/62

19. Remove thrust plate (6) and connector shaft (12) from
housing (11).

CM073510098 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-19/62

NOTE: Do not remove dowel pins (9). Pins can remain


in either housing (11) or gear housing.

20. Remove housing (11) from gear housing (38).

CM073510099 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-20/62

TM100419 (02APR13) 70-10-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=271
Hydraulic Pumps

21. Remove thrust plate (6), gear housing (38), gear


assembly (7) and remaining thrust plate (6) from cover
(2).

CM073510100 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-21/62

CM073510101 —UN—06MAR08
22. Using a bushing puller, remove all bushings (30) and
(4) from their respective housings. Inspect all bushings
for scoring or discoloration. Replace as necessary.
Continued on next page PW66162,00009B5 -19-11MAR13-22/62

TM100419 (02APR13) 70-10-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=272
Hydraulic Pumps

23. Place front cover (2) in a vise with the mounting flange
facing downward.
24. Insert a seal removing tool into the notch between lip
seal and front cover. Remove and discard lip seal (1).

CM073510102 —UN—06MAR08
25. Remove and discard all O-rings and seals.
Clean and Inspect
Clean and inspect all parts for wear or damage. Replace
if necessary. All gear assemblies are a matched set and
cannot be ordered separately.
Replace gear housings if either has wear in excess of
0.13 mm (0.005 in.) cutout. Use the following method
to determine cutout:
PW66162,00009B5 -19-11MAR13-23/62

Place a straight edge across the bore. If you can slip a


0.13 mm (0.005 in.) feeler gauge under the straight edge
in the cutout area, replace the gear housing.
1. Pressure pushes the gears against the housing on the
low-pressure side. As the hubs and bushings wear,
the cutout becomes more pronounced. Excessive

T5921AH —UN—25OCT88
cutout in a short time indicates excessive pressure
or oil contamination. If the relief valve settings are
within prescribed limits, check for shock pressures or
tampering. Check an oil sample and the tank itself for
contamination.
2. Where cutout is moderate, 0.13 mm (0.005 in.) or
less, the gear housing is in good condition and can
be reused.
4. Drive shaft (7) must be replaced if any wear is
3. Gears which exhibit any scoring on the gear hub must detectable in seal area or at drive coupling. Maximum
be replaced. Any scoring, grooving, or burring of the allowable wear is 0.05 mm (0.002 in.). Wear in the
outer tooth diameter requires replacement. Nicking, shaft seal area indicates oil contamination. Wear or
grooving, or fretting of teeth surfaces requires gear damage to splines requires shaft replacement.
replacement.
PW66162,00009B5 -19-11MAR13-24/62

5. Thrust plates (6) seal the gear sections at the sides


of the gears. Wear here allows internal slippage and
oil bypass within the pump. A maximum of 0.05 mm
(0.002 in.) wear is allowable. Replace thrust plates if
they are scored, eroded, or pitted.
CM073510103 —UN—06MAR08

6. Check the center of the thrust plates (6) where the


gears mesh. Erosion here indicates oil contamination.
Pitted thrust plates indicate cavitation or oil aeration.
Discolored thrust plates indicate overheating, probably
due to insufficient oil.

Continued on next page PW66162,00009B5 -19-11MAR13-25/62

TM100419 (02APR13) 70-10-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=273
Hydraulic Pumps

7. Dowel pins (9) must be replaced if either the dowel


or dowel hole is damaged. If damaged, the dowel or
machined housing or both must be replaced. If more
than reasonable force is required to seat dowel pins;
the cause can be deburred or dirty parts, cocked

CM073510104 —UN—06MAR08
dowel pin in hole, or improper pin-to-hole fit.

PW66162,00009B5 -19-11MAR13-26/62

8. Bushings (4) and (30) must be replaced if gears are


replaced. Bushings fit into bore with a “heavy” press fit.

CM073510105 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-27/62

9. All sealing parts: lip seal (1), channel seals (5), and
square seals (8) and (28) must be replaced.

CM073510106 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-28/62

TM100419 (02APR13) 70-10-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=274
Hydraulic Pumps

10. Examine check assembly (3) located in front cover


(2). Ensure that it is in the proper position and tightly
seated.

CM073510107 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-29/62

Assembly
1. Rub a medium grit carborundum stone over the
machined surfaces. If bushings (4) or (3) were
removed or a new section is used, debur bores with

CM073510108 —UN—06MAR08
fine emery cloth. Wash in a solvent, blow dry with air
and wipe with a clean lintless cloth before assembly.
2. Place front cover (2) in a vise with mounting face
downward.
3. Any bushings (4) or (30) removed from front cover (2),
housing (11), housing (15), housing (14), housing (22)
and housing (16) should be assembled in the drive
bores (bores in which the gear shafts and connector
shafts pass through) with the bushing groove facing
toward the top of the pump (12 o’clock). Assemble specified in step 3. Be sure to support the housings so
bushings into drive bores (bores which do not house they are square and level.
the connector shafts) with bushing groove facing 5. Repeat step 1.
toward the bottom of the pump (six o’clock).
6. After installing the bushings in all housings, ensure
NOTE: Bushings must be pressed into the bores that the dowel pins are in position. Examine all dowel
flush with housing face. pins and before inserting, make certain the hole is
clean and free from burrs. Gently start pin (9) straight
4. If removed, install bushings using JDG11606 Bushing into the hole and tap lightly with a soft hammer.
Installer. Be sure that the grooves are positioned, as
PW66162,00009B5 -19-11MAR13-30/62

NOTE: Before inserting new lip seal (1) into front


cover (2), coat outer edge and recess with
non-hardening gasket sealant.
Do not damage the lip of seal during installation.
CM073510109 —UN—06MAR08

7. With metal side of lip facing upward and spring facing


toward gear, press seal into mounting flange side of
front cover using seal installer from kit D01300AA.
Press inward until seal is flush with recess and wipe
off excess sealant.

Continued on next page PW66162,00009B5 -19-11MAR13-31/62

TM100419 (02APR13) 70-10-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=275
Hydraulic Pumps

CM073510110 —UN—06MAR08
8. Lubricate O-rings (8) with clean hydraulic oil and
install into grooves located on both sides of each gear
housing.
PW66162,00009B5 -19-11MAR13-32/62

9. Position gear housing (38) over the front cover (2)


and dowel pin (9). Tap it with a soft hammer until it
rests tightly against the cover. Be sure that the large
rounded area is located on the inlet side.

CM073510111 —UN—24MAR08
PW66162,00009B5 -19-11MAR13-33/62

NOTE: Flat side of seal must face away from


the thrust plate.

10. Install seal (5) into the grooves in thrust plate (6).

CM073510112 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-34/62

TM100419 (02APR13) 70-10-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=276
Hydraulic Pumps

NOTE: Seal (5) must face shaft end cover (2). Relief
groove, located in the thrust plate (6), must
face the outlet side of pump.

11. Carefully slip the thrust plate (6) through gear housing

CM073510113 —UN—06MAR08
(38) and into place onto the shaft end cover (2).

PW66162,00009B5 -19-11MAR13-35/62

12. Slide the driven gear from set (7) through housing and
into bushing (4) located in front cover (2).
Coat steel sleeve tool (0290244683) with grease.
13. Lightly grease drive shaft from set (7) and insert inside

CM073510114 —UN—06MAR08
sleeve tool.
NOTE: Avoid damaging lip seal (1).

14. Slide sleeve tool and drive shaft through end cover (2)
with a twisting motion until integral gear rests against
thrust plate (6).
15. Remove sleeve tool and lubricate gears with clean
hydraulic oil.

CM073510115 —UN—06MAR08
Continued on next page PW66162,00009B5 -19-11MAR13-36/62

TM100419 (02APR13) 70-10-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=277
Hydraulic Pumps

16. Slip thrust plate (6) with seals over gear journals and
into housing bore. The flat side of the seal must face
upward with the relief groove facing outlet side.

CM073510116 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-37/62

17. Position housing (11) over gear housing (38) so


bushing (6) in housing (11) receives the journals of
drive and driven gears (7).
18. Line up dowel holes over the dowel pins. With sections

CM073510117 —UN—06MAR08
aligned, squeeze or alternately tap over each dowel
until the sections are together.

Continued on next page PW66162,00009B5 -19-11MAR13-38/62

TM100419 (02APR13) 70-10-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=278
Hydraulic Pumps

19. Insert connecting shaft (12) into splines of the drive


gear from set (7).
Position gear housing (10) over housing (11) and
dowel pin. Tap it with a soft hammer until it rests tightly

CM073510118 —UN—06MAR08
against cover. Be careful not to pinch the seal. Be sure
that the large round area is located on the inlet side.

CM073510119 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-39/62

20. Place thrust plate (6) in gear housing (10).


Insert gear assembly (13) into bushings located in
housing (11). Make certain gears are in contact with
the face of the thrust plate (6).

CM073510120 —UN—06MAR08
CM073510121 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-40/62

TM100419 (02APR13) 70-10-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=279
Hydraulic Pumps

21. Slip thrust plate (6) with seal over gear journal (13)
and into gear housing (10).

CM073510122 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-41/62

22. Position housing (15) over gear housing (10) so the


bushings receive the journals of the drive and driven
gears (13).
23. Line up the dowel holes over dowel pins. With the

CM073510123 —UN—06MAR08
sections aligned, squeeze or alternately tap over each
dowel until the parts are seated together.

PW66162,00009B5 -19-11MAR13-42/62

24. Insert connecting shaft (12) into the splines of the


drive gear from set (13).

CM073510124 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-43/62

TM100419 (02APR13) 70-10-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=280
Hydraulic Pumps

25. Position gear housing (36) over housing (15) and


dowel pin. Tap it with a soft hammer until it rests tightly
against the housing (15). Be careful not to pinch the
seal. Be sure that the large round area is located on
the inlet side.

CM073510125 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-44/62

26. Place thrust plate (6) into gear housing (36).

CM073510126 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-45/62

NOTE: Make certain gears are in contact with the


face of thrust plate (6).

27. Insert gear assembly (37) into bushings located in


housing (36).

CM073510127 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-46/62

TM100419 (02APR13) 70-10-19 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=281
Hydraulic Pumps

28. Slip thrust plate (6) with seal over gear journal (37)
and into gear housing (36).

CM073510128 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-47/62

29. Position housing (14) over gear housing (36) so the


bushings receive the journals of the drive and driven
gears (37). Line up the dowel holes over dowel pins.
With sections aligned, squeeze or alternately tap over
each dowel until seated together.

CM073510129 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-48/62

30. Insert connecting shaft (25) into the splines of the


drive gear, from set (37).

CM073510130 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-49/62

TM100419 (02APR13) 70-10-20 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=282
Hydraulic Pumps

CM073510131 —UN—06MAR08

31. Replace the four hex nuts (19), washer (17) and studs 33. After the fasteners are tight and there is no internal
(18). Thread the four studs (18), washers (17) and hex binding, cross torque the nuts (19) to 272 N·m (250
nuts (19) into the front cover (2) and cross tighten. lb.-ft.).
32. Rotate the drive shaft with a wrench to make certain
there is no binding in pump.
Continued on next page PW66162,00009B5 -19-11MAR13-50/62

TM100419 (02APR13) 70-10-21 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=283
Hydraulic Pumps

34. Position gear housing (32) over housing (14) and


dowel pins. Tap it with a soft hammer until it rests
tightly against the housing (14). Be careful not to pinch
the seal. Be sure that the large round area is located
on the inlet side.

CM073510132 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-51/62

35. Place thrust plate (26) in gear housing (32).

CM073510133 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-52/62

NOTE: Make certain gears are in contact with the


face of the thrust plate (26).

36. Insert gear assembly (21) into bushings located in


housing (14).

CM073510134 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-53/62

TM100419 (02APR13) 70-10-22 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=284
Hydraulic Pumps

37. Slip thrust plate (26) with seal over gear journal (21)
and into gear housing (32).

CM073510135 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-54/62

38. Position housing (22) over gear housing (32) so the


bushings receive the journals of the drive and driven
gears (21). Line up dowel holes over the dowel pins.
With sections aligned, squeeze or alternately tap over
each dowel until housings are seated together.

CM073510136 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-55/62

39. Insert connecting shaft (33) into the splines of the


drive gear from set (21).

CM073510137 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-56/62

TM100419 (02APR13) 70-10-23 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=285
Hydraulic Pumps

40. Position gear housing (31) over housing (22) and


dowel pin. Tap it with a soft hammer until it rests tightly
against the housing (22). Be careful not to pinch the
seal. Be sure that the large round area is located on
the inlet side.

CM073510138 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-57/62

41. Place thrust plate (26) in gear housing (31).

CM073510139 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-58/62

NOTE: Make certain gears are in contact with the


face of the thrust plate (26).

42. Insert gear assembly (20) into bushings located in


housing (22).

CM073510140 —UN—06MAR08

Continued on next page PW66162,00009B5 -19-11MAR13-59/62

TM100419 (02APR13) 70-10-24 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=286
Hydraulic Pumps

43. Slip thrust plate (26) with seal over gear journal (20)
and into gear housing (31).

CM073510141 —UN—06MAR08
PW66162,00009B5 -19-11MAR13-60/62

44. Position end cover (16) over the gear journals (20).
Align dowel pins with holes in opposite housing. Be
careful not to pinch the seal. Tap end cover lightly in
the center to engage dowel pins and to move the parts
together.

CM073510142 —UN—06MAR08
Continued on next page PW66162,00009B5 -19-11MAR13-61/62

TM100419 (02APR13) 70-10-25 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=287
Hydraulic Pumps

45. Replace the four hex nuts (35), washers (23) and
studs (24). Thread the four studs, washers, and nuts
into housing and cross tighten.
46. Rotate the drive shaft with a wrench to make certain

CM073510143 —UN—06MAR08
there is no binding in pump.
47. After all fasteners are tight and there is no internal
binding, cross torque nuts (35) to 272 N·m (250 lb.-ft.).
Start-Up Procedure
1. Before installing a new or rebuilt pump, back off main
relief valve until spring tension on the adjusting screw
is relieved. This avoids the possibility of damage to
replacement pump, in the event relief valve setting
has been increased beyond recommended pressure 6. Operate pump at least 2 minutes at no load and
prior to removal. moderate speed (not over 1500 rpm). If the pump
2. Before connecting any hoses to the pump, fill all ports becomes excessively hot, shut down immediately and
with clean hydraulic oil. locate the problem.

3. After pump installation, operate the pump at least 7. Gradually increase pressure on the pump in 34 bar
2 minutes at no load and low rpm (400 minimum). (500 psi) increments until desired test pressure has
During this break-in period, pump must run free and been reached. This should take about 5 minutes.
not develop an excessive amount of heat. If the pump 8. Delivery should run close to rated performance figures
operates properly, speed and pressure can then be which are averaged from testing several pumps. A
increased to normal operating settings. 5% lower reading may be used as a rate minimum if
4. Adjust main relief valve to specification while the pump new or relatively new parts have been used. When
is running at maximum operating speed. rebuilding a pump with parts from the original pump
(which, while worn, appear satisfactory for use) a 10%
Recommended Test Procedure to 15% lower reading should be used, depending upon
the performance expected from the equipment.
1. Be sure that there is an adequate supply of system oil
for pump. A minimum of 1 L (0.26 gal.) of oil for each 9. Measure the outlet at normal operating speed and
L/min. (gpm) of pump capacity is required. at zero pressure, then again at 69 bar (1000 psi) (or
the operating pressure of the equipment) and allow a
2. If only one section of the tandem pump is being tested, volume decrease approximating the list below. It is
make sure that all other sections, not being tested a suggested reference only which makes allowance
are adequately supplied with oil. If any of the other for reused parts. At test speeds other than 1800 rpm,
sections run dry, or if plugs are left in the ports, serious L/min. (gpm) delivery will vary almost proportionately,
or permanent damage can result. but the same (drop off) figures can be used.
3. Use a good quality hydraulic oil rated at 150 SSU at 100 psi 1000 psi 2000 psi 3000 psi
38 °C (100 °F) with the oil temperature held at 46° to 10—30 gpm 1-1/2 — 3 gpm 2 — 3-1/2 gpm 2-1/2 — 4 gpm
52 °C (115° to 125 °F). 30—50 gpm 2—3 gpm 2-1/2 — 4 gpm 3 — 4-1/2 gpm
4. The suction line must be of adequate size with no more 50—70 gpm 2-1/2 — 3-1/2 3—5 gpm 3-1/2 — 5-1/2
than 17 kPa (5 in.) of mercury vacuum near pump gpm gpm
inlet. Feed line must provide a feed flow velocity not in
6.9 bar 69 bar 138 bar 207 bar
excess of 2.4 m per second (eight feet per second).
38—113.6 L 5.7—11.4 L 7.6—13 L 9.5—15 L
5. Feeding hot oil into a cold pump can cause the pump 113.6—189 L 7.6—11.4 L 9.5—15.1 L 11.4—17 L
to seize. Jog the pump by momentarily starting the 189—265 L 9.5—13.2 L 11.4—18.9 L 13.2—20.8 L
driving engine to equalize pump and oil temperatures
gradually.
PW66162,00009B5 -19-11MAR13-62/62

TM100419 (02APR13) 70-10-26 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=288
Hydraulic Pumps

Piston Pump
IMPORTANT: Absolute cleanliness is essential when Replace gaskets and O-rings when making
working on the hydraulic system. Contamination repairs. All gasket sealing surfaces must be
can result in serious damage or inadequate cleaned prior to installation. Lubricate O-rings
operation. Clean parts with clean solvent with clean hydraulic oil prior to assembly.
and dry with compressed air.

CM073510144 —UN—23AUG07

Continued on next page PW66162,0000861 -19-22FEB13-1/11

TM100419 (02APR13) 70-10-27 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=289
Hydraulic Pumps

1— Pressure Relief Valve 11— O-ring 22— Round Retainer 32— O-ring
2— Cylindrical Roller Bearing 12— Control 23— Shim 33— O-ring
3— Pin 13— O-ring 24— Gasket Kit 34— O-ring
4— Plug 14— Coupling 25— Nut 35— Piston
5— Plug 15— Valve 26— O-ring 36— O-ring
6— Plug 16— O-ring 27— Bolt 37— Ring
7— Filter 17— Link 28— Pressure Relief Valve 38— Sway Block
8— Plate 18— Dowel Pin 29— Spring 39— Orifice
9— Swash Plate 19— Spring 30— O-ring
10— Cylinder Block 20— Cover 31— Kit
21— Lever
PW66162,0000861 -19-22FEB13-2/11

Replace Multifunction Valve Cartridges


1. Using a 1-1/4” wrench, remove valve cartridges (28).
2. Inspect each cartridge for damage.

CM073510154 —UN—07MAR08
3. Remove and discard seals (30) and (61).
4. Lubricate and install new seals.
5. Install valve cartridges and tighten to specification.
Specification
Piston Pump Valve
Cartridge—Torque.........................................................................89 N·m
(66 lb.-ft.)

28— Valve Cartridges (2 used) 61— Seal


30— Seal

CM073510155 —UN—23AUG07
Continued on next page PW66162,0000861 -19-22FEB13-3/11

TM100419 (02APR13) 70-10-28 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=290
Hydraulic Pumps

Replace Manual and Electrical Displacement Control


IMPORTANT: Thoroughly clean external surfaces
prior to removal of control.
Protect exposed surfaces and cavities on pump

CM073510147 —UN—06MAR08
from damage and foreign material.

1. Using a 5 mm hex (Allen) wrench, remove cap screws


(76) and lift control (15) from pump.
2. Remove and discard gasket (24).
3. Install a new gasket on pump.
NOTE: Make sure that control orifice and spring are in
the proper position in the new control.
15— Control 76— Cap Screws (6 used)
24— Gasket
4. Engage the pin located on control linkage into the
mating hole of linkage attached to swash plate.
5. Position control and align the gasket and install Specification
cap screws. Tighten pump control cap screws to Piston Pump Control Cap
specification. Screws—Torque............................................................................16 N·m
(142 lb.-in.)

PW66162,0000861 -19-22FEB13-4/11

Replace Charge Pressure Relief Valve


NOTE: Before removing the screw adjustable relief valve
plug, mark plug, locknut, and housing to maintain
original adjustment when assembling.

CM053510146 —UN—07MAR08
1. Remove the screw adjustable charge relief valve plug.
Loosen the locknut with a 1-1/16” wrench and unscrew
the plug with a large screwdriver.
2. Remove spring and relief valve poppet.
3. Inspect poppet and mating seat in the end cap for
damage or foreign material.
4. Install relief valve poppet and spring.
A—Alignment Marks
5. Install an O-ring on the plug assembly.
6. Install the plug and torque to 68 N·m (50 lb.-ft.).
7. Install the plug with its locknut, aligning the marks 8. Check the charge pressure and adjust, if necessary.
made at disassembly, and torque the locknut 52 N·m
(38 lb.-ft.).
Continued on next page PW66162,0000861 -19-22FEB13-5/11

TM100419 (02APR13) 70-10-29 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=291
Hydraulic Pumps

Replace Orifice Check Valve


NOTE: Thoroughly clean external surfaces before
removal of control.
Protect exposed surfaces and cavities on the pump

CM002500137 —UN—07MAR08
housing from damage and foreign material.

1. Using a 5 mm hex (Allen) wrench, remove cap screws


and control from pump.
2. Orifice check valve is located at the surface of the
pump housing face, in control assembly (4). Remove
spring retainer (1) and spring (2) from valve cavity and
then remove orifice check valve (3).
3. Install a new orifice check valve. Install spring and 1— Spring Retainer 3— Orifice Check Valve
spring retainer to hold the orifice check valve in 2— Spring 4— Control Assembly
position.
4. Install control in reverse order of removal.
Continued on next page PW66162,0000861 -19-22FEB13-6/11

TM100419 (02APR13) 70-10-30 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=292
Hydraulic Pumps

Replace Shaft Seal


NOTE: Refer to pump breakdown in the beginning
of this section.

CM073510148 —UN—07MAR08
1. Using a 5 mm hex (Allen) wrench, remove cap screws
(69) and retainer plate (68).
IMPORTANT: Do Not remove shaft (62). After
seal carrier is removed, the shaft is free
and can fall out of pump.

2. Seal carrier (65) should move out of the bore by


approximately 6 mm (1/4 in.). Outward spring force on
shaft will tend to overcome the fiction from the O-ring
on the retainer plate outer diameter. If seal carrier
does not move from bore upon removal of bolts, pry it
from bore or lightly tap shaft end with a soft mallet.
3. Using an arbor press, remove seal (66) from seal

CM073510149 —UN—07MAR08
carrier. Discard seal.

62— Shaft 68— Retainer Plate


65— Seal Carrier 69— Cap Screws
66— Seal

CM073510150 —UN—07MAR08
Continued on next page PW66162,0000861 -19-22FEB13-7/11

TM100419 (02APR13) 70-10-31 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=293
Hydraulic Pumps

4. Inspect seal carrier for damage and replace as


necessary.
IMPORTANT: Do not damage seal during installation.

CM073510152 —UN—07MAR08
5. Using an arbor press, install a new seal in seal carrier.
6. Inspect seal contact area on shaft (62) for rust, wear,
or contamination.
7. Wrap spline end of shaft with transparent tape to
prevent damage to seal lip during installation.
8. Lubricate outer diameter of seal carrier (65) and inner
diameter of seal with petroleum jelly.
9. Install seal carrier and seal over the shaft and into the
62— Shaft 66— Seal
seal carrier cavity. 65— Seal Carrier 67— O-Ring

PW66162,0000861 -19-22FEB13-8/11

10. Install retainer plate (68) and cap screws (69). Tighten
retainer plate cap screws to specification.
Specification
Shaft Seal Retainer Plate

CM073510153 —UN—07MAR08
Cap Screws—Torque...................................................................9.5 N·m
(84 lb.-in.)

68— Retainer Plate 69— Cap Screws

Continued on next page PW66162,0000861 -19-22FEB13-9/11

TM100419 (02APR13) 70-10-32 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=294
Hydraulic Pumps

Disassemble and Assemble Charge Pump


Assemble
1. Remove cap screws (15) and auxiliary mounting pad
(13) from end cap (1).
2. Using a 10 mm wrench, remove cap screws (11) and
cover retainer (10).
NOTE: Note location of pin(s).

3. Remove cover (9), bushing (8), shaft (4), gerotor (6),


pin (5) and key (3).

CM002500139 —UN—17MAY00
4. Inspect valve plate, gerotor assembly, shaft spline
and bearings for wear, damage, or foreign material.
Replace if necessary.

1— End Cap 9— Cover


3— Key 10— Cover Retainer
4— Shaft 11— Cap Screw (6 used)
5— Pin 13— Auxiliary Mounting Pad
6— Gerotor 15— Cap Screw (4 used)
8— Bushing

Continued on next page PW66162,0000861 -19-22FEB13-10/11

TM100419 (02APR13) 70-10-33 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=295
Hydraulic Pumps

NOTE: Outer valve plate, gerotor assembly, and inner


valve plate must be replaced as an assembly.
Prior to installation, lubricate all surfaces
of gerotor assembly.

1. Assembly is in reverse order of disassembly. Alignment


pin location (B) determines pump rotation. Use
alignment pin to keep parts in order during assembly.
NOTE: Key on pump shaft goes into keyway
closest to spline.

2. Install inner valve plate, gerotor assembly, shaft, key,


and outer valve plate into charge pump cavity. Use

CM053510147 —UN—21JUL05
alignment pin (B) to orient the plates and eccentric
outer ring.
3. After stacking parts, carefully remove the alignment
pin from the cavity without disturbing aligned parts.
4. Lubricate and install pin into charge pump cover.
5. Gerotor assembly must be oriented according to the
direction of input rotation. For pumps with an auxiliary
mounting pad, the charge pump cover can be installed A—Discharge C—Inlet
two different ways. Always install cover with small port B—Alignment Pin
hole towards charge inlet port (C). Failure to do so can
result in loss of charge pressure.
NOTE: Do not damage O-ring located on outer diameter Specification
of cover during assembly. Charge Pump Cover cap
Screws—Torque.........................................................................13.5 N·m
6. Install charge pump cover and align pin into previously (119 lb.-in.)
aligned parts located in cavity.
7. Install charge pump cover, retainer, and cap screws.
Tighten charge pump cover cap screws to specification.
PW66162,0000861 -19-22FEB13-11/11

TM100419 (02APR13) 70-10-34 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=296
Group 15
Hydraulic Valves
Specifications
Item Measurement Specification

Control Valve 11/16 in. Tie Rod Nuts Torque 68 N·m


(50 lb.-ft.)
Control Valve 3/4 in. Tie Rod Nut Torque 104 N·m
(77 lb.-ft.)
Control Valve Inlet Section Pressure 17 900 kPa
Relief Valve (179 bar)
(2 600 psi)
Steering Priority Valve Relief Valve Pressure 17 237 kPa
(172 bar)
(2500 psi)
PW66162,00009A4 -19-26FEB13-1/1

TM100419 (02APR13) 70-15-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=297
Hydraulic Valves

Remove and Install Floating Crop Divider


Valves
IMPORTANT: Absolute cleanliness is essential
when working on the hydraulic system.
Contamination can result in serious damage
or inadequate operation.

X9811 —UN—23AUG88
NOTE: Left-hand side shown, procedure for
right-hand side is similar.

1. Park machine on level surface.


2. Lower crop dividers and topper.
3. Shut off engine and remove key.
4. Clean floating crop divider valve and surrounding area.
5. Remove cap screws (B) and shield (A).

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.

T8130000695 —UN—21FEB13
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
Avoid personal injury. Before floating crop A—Shield C—Locking Nut
divider valve removal, pressure must be relieved B—Cap Screws (2 used) D—Manual Bleed Valve
with manual bleed valve (D).

6. Loosen locking nut (C).


7. Rotate manual bleed valve (D) counterclockwise until
light resistance is felt.
Continued on next page PW66162,0000945 -19-22FEB13-1/2

TM100419 (02APR13) 70-15-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=298
Hydraulic Valves

8. Tag and disconnect electrical connectors (G).


9. Tag and disconnect hoses (A), (B), (D), and (E).
10. Cap and plug hoses and fittings.
11. Remove cap screws (C), mounting plate (F), and
floating crop divider valve.
12. Repair or replace floating crop divider valve as
necessary.
13. Install in reverse order of removal using the following
special instructions:

T8130000696 —UN—22FEB13
• Rotate manual bleed valve clockwise until light
resistance is felt. Holding valve in position, tighten
locking nut.
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)

A—Hose E—Hose
B—Hose F— Mounting Plate
C—Cap Screws (2 used) G—Electrical Connectors (2
D—Hoses (2 used) used)

PW66162,0000945 -19-22FEB13-2/2

TM100419 (02APR13) 70-15-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=299
Hydraulic Valves

Remove and Install Improved Height Control


Valve
IMPORTANT: Absolute cleanliness is essential
when working on the hydraulic system.
Contamination can result in serious damage
or inadequate operation.

X9811 —UN—23AUG88
1. Park machine on level surface.
2. Lower crop dividers and topper.
3. Shut off engine and remove key.
4. Clean improved height control valve and surrounding
area.
5. Disconnect electrical connectors (B).

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically

T8130000467 —UN—04FEB13
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.

6. Tag and disconnect hoses (C).


7. Cap and plug hoses and fittings. A—Cap Screw (2 used) C—Hose (10 used)
B—Electrical Connectors (6 D—Improved Height Control
8. Remove cap screws (A) and improved height control used) Valve
valve.
9. Repair or replace improved height control valve as
necessary. • Check hydraulic reservoir oil level and fill as
10. Install in reverse order of removal using the following necessary. (See Hydraulic Oil in Section 10, Group
special instructions: 15 for recommended oil.)
PW66162,0000944 -19-21FEB13-1/1

TM100419 (02APR13) 70-15-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=300
Hydraulic Valves

Repair Control Valve


Valve Assembly

CM053510246 —UN—29JUL05
1— Valve Assembly 10— Cap 17— Tie Rod 23— O-ring
2— Bolt 11— Bolt 18— Hex Nut 24— O-ring
3— Flange 12— Spool 19— Tie Rod 25— SAE Plug
4— Tube 13— Inlet Section Assembly 20— Hex Nut 26— Plug
5— Bolt 14— Body 21— Relief Cartridge Valve 27— O-ring
6— Washer 15— Outlet Section 22— Retainer
7— Spring 16— O-ring
8— O-ring
9— Relief Valve
Continued on next page PW66162,0000850 -19-26FEB13-1/11

TM100419 (02APR13) 70-15-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=301
Hydraulic Valves

Disassemble 3. Mark the port boss closest to the back cap on each
IMPORTANT: All repair work must be performed work section with a “B” (for back cap end).
in a clean area. 4. Mark the port boss closest to the spool clevis on each
Mark sections of the valve bank aid in assembly. work section with an “A” (for spool end).
NOTE: Mark relief valves before removal to aid in
1. Clean control valve. assembly. Inlet and mid-inlet relief valves are
2. Take a waterproof, quick-drying marker and mark each marked with their casting number only.
casting with a sequential number. Start by marking
the inlet casting as #1 and finish by marking the outlet 5. If necessary, remove relief valves from valve bank.
with the highest number.

CM073510450 —UN—19MAR08
6. Remove the three tie rods that hold valve bank
together. Separate valve sections.
PW66162,0000850 -19-26FEB13-2/11

Assemble
1. Lay out valve components on a clean, flat working
surface. The inlet section includes an O-ring.
CM073510451 —UN—19MAR08

Continued on next page PW66162,0000850 -19-26FEB13-3/11

TM100419 (02APR13) 70-15-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=302
Hydraulic Valves

2. The spool section (14) includes an O-ring (16) and


possibly a load check poppet and load check spring.

CM073510452 —UN—19MAR08
PW66162,0000850 -19-26FEB13-4/11

3. Tools required for basic valve assembly include a 3/4


in. and 11/16 in. open or box end wrench and a torque
wrench with thin wall sockets.

CM073510453 —UN—19MAR08
PW66162,0000850 -19-26FEB13-5/11

4. Assemble tie rod nuts to one end of each tie rod with
one or two threads showing.
NOTE: Ensure that the large tie rod (17) passes
through top hole of the section.

CM073510454 —UN—19MAR08
5. Insert the tie rods through the rod holes in the inlet
section (13).
6. Position inlet section on its end with the tie rods
upward as shown.
7. Lubricate and install O-ring (6) into groove in inlet
section.

Continued on next page PW66162,0000850 -19-26FEB13-6/11

TM100419 (02APR13) 70-15-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=303
Hydraulic Valves

8. With the O-ring side upward, install first spool section


(14) onto inlet section (13).
9. Lubricate and install O-ring (16).
10. Install load check poppet (nose down) and spring

CM073510455 —UN—19MAR08
(behind poppet) into load check cavity as shown.
NOTE: Load checks are compressed by each
section during assembly.

11. Repeat necessary steps for each spool section

PW66162,0000850 -19-26FEB13-7/11

12. Position end section (15) on the last section as shown


and hand tighten tie rod nuts. The end section in
this picture is a “turn around” section without ports.
Universal outlet/power beyond section and power
beyond and closed center sections are also used as

CM073510456 —UN—19MAR08
end sections. These end sections do not have O-ring
grooves.

PW66162,0000850 -19-26FEB13-8/11

13. Position the valve assembly with mounting pads of the


end sections on a flat surface.
NOTE: Applying pressure to end sections on a flat surface
aligns end sections and spool sections.

CM053510250 —UN—19MAR08
14. Apply downward pressure to end sections and tighten
tie rod nuts to approximately 14 N·m (124 lb.-in.).
15. Tighten the two 11/16 in. tie rod nuts to specification.
16. Tighten 3/4 in. tie rod nut to specification.
Specification
Control Valve 11/16 in.
Tie Rod Nuts—Torque...................................................................68 N·m
(50 lb.-ft.)
18. Install auxiliary valves and plugs and torque to proper
Control Valve 3/4 in. Tie
specifications.
Rod Nut—Torque.........................................................................104 N·m
(77 lb.-ft.)

17. Check for proper spool movement.


NOTE: The load check and spring can be omitted from
assembly in certain circuit conditions.
Continued on next page PW66162,0000850 -19-26FEB13-9/11

TM100419 (02APR13) 70-15-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=304
Hydraulic Valves

Adjust Relief Settings


1. The inlet section (13) of the valve has a relief cartridge
valve (21).
2. Adjust inlet section relief valve to specification.

CM073510448 —UN—19MAR08
Specification
Control Valve Inlet
Section Relief
Valve—Pressure..................................................................... 17 900 kPa
(179 bar)
(2 600 psi)

13— Inlet Section 21— Relief Cartridge Valve

PW66162,0000850 -19-26FEB13-10/11

3. The main relief and port reliefs are adjusted by


loosening the locking nut (A) with a 1-1/8 in. wrench.
Using a 1/4 in. Allen wrench, screw inward to increase
pressure and outward to decrease. After adjusting,
tighten the locking nut (A).

CM073510449 —UN—19MAR08
A—Locking Jam Nut

PW66162,0000850 -19-26FEB13-11/11

TM100419 (02APR13) 70-15-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=305
Hydraulic Valves

Repair Steering Priority Valve (Wheel Harvester)

CM073510457 —UN—18SEP07

1— Adjusting Screw 4— Ball Holder 7— O-ring 11— O-ring


2— Cover 5— Ball 8— Screen 12— O-ring
3— Spring 6— Relief Valve 9— Seat
10— Housing
Continued on next page PW66162,0000864 -19-12FEB13-1/11

TM100419 (02APR13) 70-15-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=306
Hydraulic Valves

1. Remove relief valve (6) from housing (10).

CM073510458 —UN—18SEP07
PW66162,0000864 -19-12FEB13-2/11

2. Inspect the ball (5) seating on the ball holder (4).

CM073510459 —UN—18SEP07

Continued on next page PW66162,0000864 -19-12FEB13-3/11

TM100419 (02APR13) 70-15-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=307
Hydraulic Valves

3. Inspect the O-ring (7); discard after inspection.

CM073510460 —UN—18SEP07
PW66162,0000864 -19-12FEB13-4/11

4. Inspect seat (9), screen (8) and ring (7) for damage. If
damaged, replace the relief.

CM073510461 —UN—18SEP07

Continued on next page PW66162,0000864 -19-12FEB13-5/11

TM100419 (02APR13) 70-15-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=308
Hydraulic Valves

5. Remove adjusting screw (1) from relief valve (6).


Be careful, since there is a small amount of spring
pressure exerted on the adjusting screw (1).

CM073510462 —UN—18SEP07
PW66162,0000864 -19-12FEB13-6/11

6. Remove cover (2), spring (3), ball holder (4) and ball
(5). Inspect for damage; replace the entire relief valve
(6) if necessary.

CM073510463 —UN—18SEP07

Continued on next page PW66162,0000864 -19-12FEB13-7/11

TM100419 (02APR13) 70-15-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=309
Hydraulic Valves

7. Inspect ball seat (9) for scratches or debris. Remove


any debris; replace entire valve (6) if damaged.

CM073510464 —UN—18SEP07
PW66162,0000864 -19-12FEB13-8/11

8. Install ball (5), ball holder (4), spring (3) and cover (2)
into relief valve (6).

CM073510463 —UN—18SEP07
PW66162,0000864 -19-12FEB13-9/11

CM073510465 —UN—18SEP07
9. Install adjusting screw (1) into relief valve (6).

Continued on next page PW66162,0000864 -19-12FEB13-10/11

TM100419 (02APR13) 70-15-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=310
Hydraulic Valves

10. Install seat (9), screen (8) and O-ring (7) into housing
(10).
11. Adjust relief valve to specification.
Specification
Steering Priority Valve
Relief Valve—Pressure.......................................................... 17 237 kPa
(172 bar)
(2500 psi)

CM073510466 —UN—18SEP07
PW66162,0000864 -19-12FEB13-11/11

Remove and Install Elevator Valve


IMPORTANT: Absolute cleanliness is essential
when working on the hydraulic system.
Contamination can result in serious damage
or inadequate operation.

1. Park machine on level surface.


2. Lower crop dividers, topper, and elevator.
3. Shut off engine and remove key.

T8130000468 —UN—04FEB13
4. Clean elevator valve and surrounding area.
5. Loosen cap screws (A) and remove elevator valve
shield (B).

A—Cap Screw (4 used) B—Elevator Valve Shield

Continued on next page PW66162,0000946 -19-21FEB13-1/2

TM100419 (02APR13) 70-15-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=311
Hydraulic Valves

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands

X9811 —UN—23AUG88
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.

NOTE: Cut tie bands as necessary.

6. Tag and disconnect hoses (A) from elevator valve (B).


7. Cap and plug hoses and fittings.
8. Disconnect electrical connectors (D).
9. Remove cap screws (C) and elevator valve.

T8130000469 —UN—04FEB13
10. Repair or replace elevator valve as necessary.
11. Install in reverse order of removal using the following
special instructions:
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)

A—Hose (15 used) C—Cap Screws (4 used)


B—Elevator Valve D—Electrical Connectors (6
used)

T8130000470 —UN—04FEB13

PW66162,0000946 -19-21FEB13-2/2

TM100419 (02APR13) 70-15-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=312
Group 20
Hydraulic Cylinders
Specifications
Item Measurement Specification

Piston Lock Nut Torque 257—284 N·m


(190—210 lb.-ft.)
Bypass Pressure Pressure 344—861 kPa
(3—8.6 bar)
(50—125 psi)
Thrust Washer and Nut Torque 393—420 N·m
(290—310 lb.-ft.)
Cylinder Head Torque 338—406 N·m
(250—300 lb.-ft.)
Set Screw Torque 0.5—1.6 N·m
(5—15 lb.-in.)
Cycling Pressure Pressure 1378 kPa
(13.7 bar)
(200 psi)
Test Stand Pressure Pressure 17 236 kPa
(172 bar)
(2500 psi)
Piston Lock Nut Torque 691—718 N·m
(510—530 lb.-ft.)
Cylinder Cap Torque 122—135 N·m
(90—100 lb.-ft.)
Cylinder Cap Torque 711—779 N·m
(525—575 lb.-ft.)
Lock Nut Torque 393—420 N·m
(290—310 lb.-ft.)
Set Screw Torque 3.3—3.9 N·m
(30—35 lb.-in.)
Piston Lock nut Torque 339—373 N·m
(250—275 lb.-ft.)
Locking Collar Torque 203—271 N·m
(150—200 lb.-ft.)
Set Screw Torque 20—33 N·m
(15—25 lb.-ft.)
TB90758,000032B -19-27MAR13-1/1

Other Material
Number Name Use
PM38654 (U.S.) Thread Lock and Sealer (High Used to seal and lock threads.
271 (LOCTITE®) Strength)

PM37477 (U.S.) Thread Lock and Sealer (Medium Used to seal and lock threads.
242 (LOCTITE®) Strength)

Loctite is a trademark of Henkel Corporation

TB90758,000028D -19-27FEB13-1/1

TM100419 (02APR13) 70-20-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=313
Hydraulic Cylinders

Remove and Install Topper Cylinder


1. Park machine on level surface.
2. Check that cylinder safety stop (A) is in the upward
position.

X9811 —UN—23AUG88
3. Lower topper, shut off engine, and remove key.
4. Clean topper cylinder (D) and surrounding area.
5. Using an appropriate lifting device, support topper
assembly to remove weight from cylinder.

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands

T8120002359 —UN—03JAN13
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
A—Safety Stop D—Topper Cylinder
B—Hose E—Front Pin
6. Tag and disconnect hose (B). C—Rear Pin

7. Cap and plug hose and fitting.

CAUTION: Approximate weight of topper 11. Install in reverse order of removal using the following
cylinder is 35 kg (77 lb.). special instructions:

8. Remove nut and front pin (E).


• Grease cylinder pins.
• Check hydraulic reservoir oil level and fill as
9. Remove nut, rear pin (C), and topper cylinder. necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)
10. Replace or repair topper cylinder as necessary. (See
appropriate CTM.)
TB90758,000032C -19-02APR13-1/1

TM100419 (02APR13) 70-20-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=314
Hydraulic Cylinders

Remove and Install Cab Tilt Cylinder


1. Park machine on level surface.

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before

X9811 —UN—23AUG88
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type 4. Clean cab tilt cylinder and surrounding area.
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department CAUTION: Avoid injury or death. Attach lifting
in Moline, Illinois, U.S.A. device to cab in a manner that allows technician
to work safely under cab in the tilted position.
2. Shut off engine and remove key.
5. Attach an appropriate lifting device and support cab
3. Tilt cab. (See Cab Tilt Procedure in Section 90, Group in the tilted position.
20.
Continued on next page TB90758,000022E -19-02APR13-1/2

TM100419 (02APR13) 70-20-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=315
Hydraulic Cylinders

IMPORTANT: Open valve on jack to relieve


hydraulic pressure on cab tilt cylinder
before disconnecting hoses.

6. Tag and disconnect hoses (A and C).


7. Cap and plug hoses and fittings.

CAUTION: Approximate weight of cab tilt


cylinder is 10 kg (22 lb.).

8. Remove nut, washers, and lower pin (D) from cable


end (B) and cab tilt cylinder (H).

T8120001396 —UN—11SEP12
9. Remove nut (E).
10. Remove upper pin (F) and washer from cable end
(G), and safety stop (I). Place safety stop aside and
remove cab tilt cylinder.
11. Replace or repair cab tilt cylinder as necessary. (See
Disassemble and Assemble Topper, Cab Tilt, and
Elevator Swing Cylinders—Use CTM in Section 70,
Group 20.)
12. Install in reverse order of removal using the following
special instructions:
• Grease lift cylinder pins.
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)

A—Hose F— Upper Pin


B—Cable End G—Cable End
C—Hose H—Cab Tilt Cylinder
D—Lower Pin I— Safety Stop
E—Nut

T8120001397 —UN—11SEP12
TB90758,000022E -19-02APR13-2/2

TM100419 (02APR13) 70-20-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=316
Hydraulic Cylinders

Remove and Install Elevator Swing Cylinders


NOTE: Remove and install procedure is same for
left-hand and right-hand side cylinder.

1. Park machine on level surface.

X9811 —UN—23AUG88
2. Relieve hydraulic pressure.
3. Shut off engine and remove key.
4. Clean cylinder and surrounding area.

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically

T8130000448 —UN—05FEB13
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.

CAUTION: To avoid injury when removing


cylinders, use appropriate support device
to stabilize elevator to ensure elevator A—Hydraulic Hoses (2 used)
does not move.

5. Disconnect hydraulic hoses (A) from T-fitting. Cap


and plug all openings.
Continued on next page TB90758,000022F -19-28MAR13-1/2

TM100419 (02APR13) 70-20-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=317
Hydraulic Cylinders

CAUTION: Approximate weight of elevator


swing cylinder is 47 kg (104 lb.).

6. Remove cap screw (C), lock nut (A), and remove pin
(B) from cylinder end.
7. Remove cap screws (D and E) and remove cylinder.
8. Repair or replace cylinder as necessary. (See

T8130000449 —UN—05FEB13
Disassemble and Assemble Topper, Cab Tilt, and
Elevator Swing Cylinders-Use CTM in Section 70,
Group 20.)
9. Install in reverse order using the following special
instructions:
• Grease cylinder pins.
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)

A—Lock Nut D—Cap Screw (5 used)


B—Pin E—Cap Screw (5 used)
C—Cap Screw

T8130000450 —UN—05FEB13
TB90758,000022F -19-28MAR13-2/2

Disassemble and Assemble Topper, Cab Tilt,


and Elevator Swing Cylinders—Use CTM
For complete repair information the component technical
manual (CTM) is also required. Use the appropriate
component manual in conjunction with this machine
manual.

P15127 —UN—10JAN08

Service ADVISOR™ Manuals Tab

TB90758,000032D -19-28MAR13-1/1

TM100419 (02APR13) 70-20-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=318
Hydraulic Cylinders

Remove and Install Steering Cylinders


(Wheel Harvester)
1. Park machine on level surface.
2. Relieve hydraulic pressure.

X9811 —UN—23AUG88
3. Shut off engine and remove key.
NOTE: Right-hand cylinder shown. Procedure for
left-hand side is similar.

4. Clean steering cylinder (A) and surrounding area.

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.

T8130000583 —UN—06FEB13
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.

5. Tag and disconnect hoses (C). Cap and plug hoses


and fittings.

CAUTION: Approximate weight of steering


cylinder is 15 kg (32 lb.).

6. Remove cotter pin and nut (B).


7. Remove upper cylinder end by lightly tapping on end

T8130000584 —UN—06FEB13
of steering castings, while prying on cylinder to loosen
from tapered bores.
8. Remove cotter pin and nut (D).
9. Remove cylinder.
10. Replace or repair steering cylinder as necessary.
(See Disassemble and Assemble Steering Cylinders
(Wheel Harvester) in Section 70, Group 20.)
A—Steering Cylinder C—Hoses (2 used)
11. Install in reverse order of removal using the following B—Cotter Pin and Nut D—Cotter Pin and Nut
special instructions:
• Grease cylinder pins.
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.
TB90758,0000232 -19-28MAR13-1/1

TM100419 (02APR13) 70-20-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=319
Hydraulic Cylinders

Disassemble and Assemble Steering Cylinders (Wheel Harvester)

CM073510003 —UN—26MAR08

1— Ball Joint Tie Rod 4— Seal 9— O-ring 14— Barrel


2— Seal 5— Backup Seal 10— Piston 15— Jam Nut
3— Square Wire Wrap 6— O-ring 11— Seal 16— Ball Joint
7— End Cap 12— Wear Ring
8— Rod 13— Nut
Continued on next page TB90758,0000233 -19-28MAR13-1/7

TM100419 (02APR13) 70-20-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=320
Hydraulic Cylinders

1. Remove cylinder from machine. (See Remove and


Install Steering Cylinders (Wheel Harvester) in Section
70, Group 20.)
2. Loosen cap screw (A) and remove tie rod end (B).
IMPORTANT: Clamping cylinder in a vise at the

N61178 —UN—06NOV02
middle or rod end of barrel may damage barrel.
Clamp only at cylinder base end.
Extend rod to remove oil or air between rod
piston and rod guide. Excessive amounts
of trapped oil or air will expand seals and
make disassembly more difficult.

3. Clean outside surface of cylinder with solvent and dry


to prevent dirt and debris from entering cylinder barrel. A—Cap Screw B—Tie Rod End

4. Open both ports and drain all oil from cylinder.


5. Extend rod fully.
TB90758,0000233 -19-28MAR13-2/7

6. Using suitable spanner wrench, turn end cap (B)


counterclockwise to force square wrap wire (A) out of
cylinder. Continue to turn end cap until square wrap
wire comes out of barrel.
7. Remove rod with end cap and piston from barrel.

N61179 —UN—06NOV02
A—Square Wrap Wire B—End Cap

TB90758,0000233 -19-28MAR13-3/7

CM073510004 —UN—03AUG07

A—Rod C—Piston E—End Cap


B—O-ring D—Lock Nut

NOTE: Install rod end in soft-jawed vise in order 8. Remove lock nut (D), piston (C), O-ring (B), and end
to remove lock nut. cap (E) from rod (A).
Continued on next page TB90758,0000233 -19-28MAR13-4/7

TM100419 (02APR13) 70-20-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=321
Hydraulic Cylinders

9. Remove wiper seal (B) and O-ring with backup ring


from end cap.
10. Remove seal (C) and wear ring (D) from piston.

A—End Cap C—Seal


B—Wiper Seal D—Wear Ring

N61182 —UN—06NOV02
T8130000619 —UN—13FEB13
TB90758,0000233 -19-28MAR13-5/7

11. Inspect cylinder barrel for wear or damage. Nicks, A B


burrs, or rust can be removed using emery cloth,
replace as necessary.
12. Replace wear ring (A) and seal (B) on piston head.

T8130001054 —UN—26MAR13
13. Replace rod seal (D), O-ring (E), backup ring (F), and
wiper seal (G) to cylinder head. C

14. Lightly coat seals with clean oil. Oil on seals eases
assembly and prevents seal damage.
15. Install end cap to rod.
16. Position O-ring (C) and piston on rod.
Piston
17. Apply Thread Lock and Sealer (High Strength) to E F
threads of piston end of cylinder rod.

A—Wear Ring E—O-Ring


B—Seal F— Backup Ring
T8130001055 —UN—26MAR13

C—O-Ring G—Wiper Seal


D—Rod Seal
G
D

Cylinder Head

Continued on next page TB90758,0000233 -19-28MAR13-6/7

TM100419 (02APR13) 70-20-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=322
Hydraulic Cylinders

18. Tighten piston lock nut (A) to specification.


Specification
Piston Lock
Nut—Torque...................................................................... 257—284 N·m
(190—210 lb.-ft.)

19. Test cylinder once assembly is complete.

N61187 —UN—06NOV02
• Extend cylinder out and in twice to fill cylinder with oil.
• Extend cylinder out half way. Lock ball/lock valves in
test stand for low-pressure bypass test. Apply
Specification
Bypass Pressure—Pres-
sure................................................................................... 344—861 kPa
(3—8.6 bar)
A—Piston Lock Nut
(50—125 psi)

test (low) pressure to retract port and check for


bypass (rod will creep out if bypassing). 21. Install cylinder (See Remove and Install Steering
• With ball/lock valves in locked position, apply test Cylinders (Wheel Harvester) in Section 70, Group 20.)
(high) pressure to retract port and check for bypass onto machine and bleed steering system.
(rod will creep out if bypassing).
• While retract test pressure is applied at mid stroke, 22. Check the toe-in. (See Check Front Axle Toe-In in
observe for external leaks. Section 60, Group 15.)
• Open ball/lock valves. Fully retract cylinder.
23. Adjust toe-in if necessary. (See Adjust Front Axle
• Check for bypass at fully retracted position. Cylinder
Toe-In in Section 60, Group 15.)
will bypass at fully retracted position.
• Fully extend cylinder, and check for bypass. Cylinder
will bypass in fully extended position.
20. Turn female ball joint end onto cylinder rod until
threads are fully engaged.
TB90758,0000233 -19-28MAR13-7/7

Remove and Install Crop Divider Lift


Cylinders

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before

X9811 —UN—23AUG88
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable 2. Relieve hydraulic pressure.
medical source. Such information is available 3. Shut off engine and remove key.
from Deere & Company Medical Department
in Moline, Illinois, U.S.A. 4. Clean cylinder and surrounding area.

NOTE: Remove and install procedure is same for


left-hand and right-hand side cylinder.

1. Park machine on level surface.


Continued on next page TB90758,0000230 -19-28MAR13-1/2

TM100419 (02APR13) 70-20-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=323
Hydraulic Cylinders

5. Disconnect hydraulic hoses (A). Cap and plug all


openings.

CAUTION: Approximate weight of crop divider


lift cylinder is 13 kg (28 lb.).

6. Remove cap screw (C).


7. Support cylinder and remove pin (B).

T8130000447 —UN—05FEB13
8. Remove cap screw (D), lock nut (E), and remove
cylinder.
9. Replace or repair cylinder as necessary. (See
Disassemble and Assemble Crop Divider Lift Cylinders
in Section 70, Group 20.)
10. Install in reverse order using the following special
instructions:
• Grease cylinder pins.
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)

A—Hydraulic Hoses (2 used) D—Cap Screw


B—Pin E—Lock Nut

T8130000446 —UN—05FEB13
C—Cap Screw

T8130000445 —UN—05FEB13

TB90758,0000230 -19-28MAR13-2/2

TM100419 (02APR13) 70-20-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=324
Hydraulic Cylinders

Disassemble and Assemble Crop Divider Lift Cylinders

CM073510006 —UN—26MAR08

1— Cylinder Rod 5— Nut 9— Seal 14— Wear Ring


2— Barrel 6— Thrust Washer 10— O-Ring 15— Seal
3— Piston 7— Grease Fitting 11— O-Ring 16— Seal
4— Cylinder Head 8— Bushing 12— O-Ring
13— Seal

Continued on next page TB90758,000022A -19-28MAR13-1/9

TM100419 (02APR13) 70-20-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=325
Hydraulic Cylinders

1. Remove cylinder from machine. (See Remove and


CAUTION: Before removing the cylinder from Install Crop Divider Lift Cylinders in Section 70, Group
machine for repair, relieve hydraulic pressure. 20.)
TB90758,000022A -19-28MAR13-2/9

2. Remove set screw from locking collar.


3. Using spanner wrench, turn cylinder head (A) B
counterclockwise until threads on head separate from
the internal threads in barrel (B).

T8130000756 —UN—25FEB13
A—Cylinder Head B—Barrel
A

TB90758,000022A -19-28MAR13-3/9

NOTE: Crop Divider Lift Cylinders are available with three


different style rod ends. Disassemble and assemble B
procedure is the same for all three cylinders. A

4. Remove rod (A) with cylinder head (E), piston (D),

T8130000757 —UN—25FEB13
washer (C), and nut (B) from barrel.
5. Remove nut, washer, cylinder head, and piston
from rod. Inspect components for wear or damage. C
Replace as needed.
D
6. Inspect inside cylinder barrel for wear or damage.
E
Nicks, burrs, or rust may be removed with emery cloth.
Replace as necessary.
NOTE: When removing seals from piston and rod
A—Rod D—Cylinder Head
guide, do not damage, mark, or score any B—Nut E—Piston
surfaces that contact the seals. C—Washer

7. Remove all seals and rings from piston and rod guide,
replace as necessary.
Continued on next page TB90758,000022A -19-28MAR13-4/9

TM100419 (02APR13) 70-20-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=326
Hydraulic Cylinders

8. Replace seals and lightly coat new seals with clean


filtered oil. Oil on seal eases assembly and prevents B
seal damage.
A
A—Seal F— O-Ring
B—Seal G—O-Ring
C—Cylinder Head H—Piston
D—O-Ring I— Seal C
E—Seal

E D
F

T8130000758 —UN—25FEB13
H

I C

TB90758,000022A -19-28MAR13-5/9

9. Carefully push head (B) onto the rod (A). A soft mallet
can be used to tap head onto rod.

A—Rod B—Head
A

T8130000759 —UN—25FEB13
B

TB90758,000022A -19-28MAR13-6/9

10. Install piston (A) onto rod.


NOTE: Loctite will not fully cure for 24 hours.
C
11. Apply Thread Lock and Sealer (High Strength) to rod B T8130000760 —UN—25FEB13

threads. A

12. Install thrust washer (B) and nut (C) to rod. Tighten
to specification.
Specification
Thrust Washer and
Nut—Torque...................................................................... 393—420 N·m
(290—310 lb.-ft.)

A—Piston C—Nut
B—Thrust Washer

Continued on next page TB90758,000022A -19-28MAR13-7/9

TM100419 (02APR13) 70-20-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=327
Hydraulic Cylinders

13. Apply a film of oil to inside of barrel (D) near opening D


to ease assembly. Line up barrel and rod center lines
and push rod assembly into barrel.
C
A—Cylinder Head D—Barrel

T8130000761 —UN—25FEB13
B
B—Rod E—Piston
C—Nut A

TB90758,000022A -19-28MAR13-8/9

14. Push cylinder head (A) into tube until it stops. Push
B
rod (C) fully into barrel (B) to ensure cylinder is fully
retracted.
15. Using spanner wrench, tighten cylinder head into A

T8130000762 —UN—25FEB13
barrel to specification.
Specification
Cylinder Head—Torque..................................................... 338—406 N·m C
(250—300 lb.-ft.)

16. Tighten set screw to specification.


Specification
Set Screw—Torque............................................................. 0.5—1.6 N·m
(5—15 lb.-in.)
A—Cylinder Head C—Rod
NOTE: Start with cylinder in retracted position and extend B—Barrel
cylinder first to prevent fluid dieseling with large
volume of air on retract side of cylinder. Ensure
cylinder cycles freely in both directions. • Change to specified test stand pressure
17. Test cylinder once assembly is complete. Specification
Test Stand
• All cylinder testing should be conducted with oil of Pressure—Pressure............................................................... 17 236 kPa
minimum level of cleanliness of ISO 18/15. (172 bar)
• Cycle cylinder at specified cycling pressure (2500 psi)
Specification and fully extend cylinder and pressurize to full
Cycling Pressure—Pres- pressure for 60 seconds. Check for external leaks.
sure........................................................................................... 1378 kPa • Open lower port on cylinder. Pressurize rod end
(13.7 bar) of cylinder. Watch for fluid running out of lower
(200 psi) port. If fluid continues to stream out for more than a
two or three times to fill with oil and remove any few seconds, the piston seal was damaged during
trapped air. assembly and should be replaced.
TB90758,000022A -19-28MAR13-9/9

TM100419 (02APR13) 70-20-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=328
Hydraulic Cylinders

Remove and Install Base Cutter Lift Cylinders


(Wheel Harvester)

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before

X9811 —UN—23AUG88
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type 2. Lower base cutter.
of injury should reference a knowledgeable
medical source. Such information is available 3. Relieve hydraulic pressure.
from Deere & Company Medical Department 4. Shut off engine and remove key.
in Moline, Illinois, U.S.A.
5. Clean cylinder and surrounding area.
IMPORTANT: Absolute cleanliness is essential
when working on the hydraulic system. 6. Engage cylinder safety stop on cylinder not being
Contamination can result in serious damage removed.
or inadequate operation. Plug and cap all 7. Remove front wheel. (See Remove and Install Wheel
open hoses and fittings. Assembly in Section 57, Group 05.)
NOTE: Remove and install procedure is same for 8. Remove hub assembly.
left-hand and right-hand cylinder.
9. Remove lower end of steering cylinder. (See Remove
and Install Steering Cylinders (Wheel Harvester) in
1. Park machine on level surface.
Section 70, Group 20.)
CAUTION: Before removal of cylinder for
repair, block up machine and relieve all
system pressure. Use cylinder safety stop
on cylinder not being removed.
Continued on next page TB90758,0000225 -19-28MAR13-1/3

TM100419 (02APR13) 70-20-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=329
Hydraulic Cylinders

10. Disconnect hose (A and B). Cap and plug all openings.

CAUTION: Approximate weight of base cutter


lift cylinder is 56 kg (123 lb.).

11. Remove cap screw and nut (C).


12. Remove cylinder pin (D).

A—Hose C—Cap Screw and Nut


B—Hose D—Cylinder Pin

T8130000613 —UN—08FEB13
T8130000614 —UN—13FEB13

Continued on next page TB90758,0000225 -19-28MAR13-2/3

TM100419 (02APR13) 70-20-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=330
Hydraulic Cylinders

13. Remove dust cap (A) from base of cylinder.


14. Remove cotter pin and nut (B) from base of cylinder
barrel.
15. Remove cylinder from machine.
16. Replace or repair cylinder as necessary. (See
Disassemble and Assemble Base Cutter Lift Cylinders
(Wheel Harvester) in Section 70, Group 20.)

T8130000615 —UN—13FEB13
17. Install in reverse order using following special
instructions:
• Grease cylinder pins.
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)

A—Dust Cap B—Cotter Pin and Nut

T8130000618 —UN—13FEB13
TB90758,0000225 -19-28MAR13-3/3

TM100419 (02APR13) 70-20-19 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=331
Hydraulic Cylinders

Disassemble and Assemble Base Cutter Lift


Cylinders (Wheel Harvester)
Disassemble

CM11475579A1 —UN—06MAR08

Continued on next page TB90758,000022B -19-28MAR13-1/17

TM100419 (02APR13) 70-20-20 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=332
Hydraulic Cylinders

1— Cylinder Barrel 7— Stop Tube 12— V-Ring Seal 17— O-ring


2— Nut 8— Cylinder Cap 13— Backup Ring 18— Fitting
3— Washer 9— Ring 14— O-ring 19— O-ring
4— Seal 10— Washer 15— Wear Ring
5— Piston 11— Cap Screw 16— Seal
6— Cylinder Rod

1. 3. Clean exterior with solvent and dry to prevent dirt and


debris from entering cylinder barrel.
CAUTION: Before removing cylinder for repair,
block up machine and relieve all system pressure. IMPORTANT: Clamping cylinder in a vise at middle
or end of barrel may damage barrel. Clamp
Remove cylinder from machine. (See Remove and only at cylinder base end.
Install Base Cutter Lift Cylinders (Wheel Harvester)
in Section 70, Group 20.) 4. Place cylinder in vise.
2. Drain oil from cylinder. Plug and cap fittings and hoses.
TB90758,000022B -19-28MAR13-2/17

5. Remove cap screw (D) and washer (C) from cap (A)
and barrel (B). B

NOTE: Residual oil on the retract side of the piston


A
may be forced out of the retract port when the

T8130000768 —UN—27FEB13
rod is removed from the barrel.

6. Remove cylinder rod assembly from barrel.

A—Cap C—Washer (4 used)


B—Barrel D—Cap Screw (4 used)
C
D

TB90758,000022B -19-28MAR13-3/17

7. Remove nut (C), washer (B), and piston (A) from rod.
C
B
A—Piston C—Nut
B—Washer
A

T8130000769 —UN—27FEB13

Continued on next page TB90758,000022B -19-28MAR13-4/17

TM100419 (02APR13) 70-20-21 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=333
Hydraulic Cylinders

8. Remove piston (D), stop tube (C), and cylinder cap (B)
D
from cylinder rod (A) with gentle blows from a plastic
or hard rubber hammer. C

Clean and Inspect B

T8130000770 —UN—27FEB13
CAUTION: Do Not use a flammable solvent to clean
cylinder parts. An explosion may occur inside A
the cylinder, at the moment of pressurization.

IMPORTANT: Do not reuse seals.

1. Remove old seals by using soft metal tools to avoid


damaging the sealing surfaces of the cylinder cap and
piston. Inspect piston and cylinder cap for wear or A—Cylinder Rod C—Stop Tube
damage. Check for dents and burrs. These may be B—Cylinder Cap D—Piston
repaired with light filing and polishing.
2. Clean cylinder parts thoroughly with solvent before
repacking and reassembly. Inspect barrel with 3. Clean rod assembly and examine surfaces for dents
flashlight for scratches or extreme wear. Light or scratches. Examine pin bore for wear. Replace
scratches can be removed with 600 grit sandpaper bushing, if necessary. Clean threads thoroughly.
dampened in oil. Other barrel defects will require Clean threads of nut and inspect for damage. Check
replacement for optimum seal life. Check ports for fit of nut on male rod threads by turning on nut by hand
accumulations of heavy dirt deposits. for full engagement.
TB90758,000022B -19-28MAR13-5/17

Assemble
B
1. Ensure parts are thoroughly clean before repacking
and reassembly. A

2. Check all seal widths, lengths, and diameters are

T8130000771 —UN—27FEB13
A
same as old ones.
3. Coat all seals with thin coat of hydraulic oil or O-ring
lube before installing into grooves. Use soft metal
tools to stretch and install seals.
4. Install wiper seal (B) into eye end of cylinder cap (A). B

A—Cylinder Cap B—Wiper Seal

TB90758,000022B -19-28MAR13-6/17

5. Install U-cup seal (B) with flat part towards bottom end
of cylinder, into cylinder cap (A).
B
A
A—Cylinder Cap B—U-Cup Seal
T8130000772 —UN—27FEB13

Continued on next page TB90758,000022B -19-28MAR13-7/17

TM100419 (02APR13) 70-20-22 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=334
Hydraulic Cylinders

6. Install backup ring (A) on cylinder cap (B).

A—Backup Ring B—Cylinder Cap A

T8130000773 —UN—27FEB13
B A

TB90758,000022B -19-28MAR13-8/17

7. Install O-ring (A) on cylinder cap (B).

A—O-Ring B—Cylinder Cap A

T8130000774 —UN—27FEB13
B A

TB90758,000022B -19-28MAR13-9/17

8. Install wear ring (A) onto eye of piston (B).

A—Wear Ring B—Piston

T8130000775 —UN—27FEB13
B

A B

Continued on next page TB90758,000022B -19-28MAR13-10/17

TM100419 (02APR13) 70-20-23 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=335
Hydraulic Cylinders

9. Install expander ring (B) and seal (C) onto piston (A).

A—Piston C—Seal
B—Expander Ring

T8130000776 —UN—27FEB13
B

A
A

B
C

TB90758,000022B -19-28MAR13-11/17

10. Install expander ring (B) on end of piston (A).

A—Piston B—Expander Ring

T8130000777 —UN—27FEB13
B

A
A

TB90758,000022B -19-28MAR13-12/17

11. Install O-ring (A) into inner groove of piston (B).

A—O-Ring B—Piston A

T8130000778 —UN—27FEB13
B
A
B

Continued on next page TB90758,000022B -19-28MAR13-13/17

TM100419 (02APR13) 70-20-24 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=336
Hydraulic Cylinders

12. Place rod eye in vise. Lubricate rod (A) lead - in


chamfer, and inside of cylinder cap (B). Align cylinder
cap on rod and tap onto rod with a rubber or plastic
hammer. Ensure cylinder cap slides up and down on A
rod.

T8130000779 —UN—27FEB13
A—Rod B—Cylinder Cap

TB90758,000022B -19-28MAR13-14/17

13. Slide stop tube (B) onto rod (A).

A—Rod B—Stop Tube

T8130000780 —UN—27FEB13
A

TB90758,000022B -19-28MAR13-15/17

14. Slide piston (C) onto rod.


C
15. Install washer (E) over threaded end of rod (A).
B D
16. Wipe any excess oil from rod threads. Apply Thread
Lock and Sealer (High Strength) to external threads E

T8130000781 —UN—27FEB13
of rod.
A
17. Install lock nut (D) and tighten to specification.
Specification
Piston Lock
Nut—Torque...................................................................... 691—718 N·m
(510—530 lb.-ft.)

18. Install rod assembly into barrel. Rod assembly must


be installed straight within barrel. A—Rod D—Lock Nut
B—Stop Tube E—Washer
C—Piston

Continued on next page TB90758,000022B -19-28MAR13-16/17

TM100419 (02APR13) 70-20-25 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=337
Hydraulic Cylinders

19. Apply Thread Lock and Sealer (High Strength) to


cap screws (C) and install with washers (B) through A
cylinder cap and into cylinder barrel (A). Tighten to
specification.

T8130000782 —UN—27FEB13
Specification
Cylinder Cap—Torque....................................................... 122—135 N·m
(90—100 lb.-ft.)

20. Install cylinder on the machine. (See Remove and


Install Base Cutter Lift Cylinders (Wheel Harvester)
in Section 70, Group 20.) B
C
A—Cylinder Barrel C—Cap Screw (4 used)
B—Washer (4 used)

TB90758,000022B -19-28MAR13-17/17

Remove and Install Base Cutter Lift Cylinders


(Track Harvester)

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before

X9811 —UN—23AUG88
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable CAUTION: Before removal of cylinder for
medical source. Such information is available repair, block up machine and relieve all
from Deere & Company Medical Department system pressure. Use cylinder safety stop
in Moline, Illinois, U.S.A. on cylinder not being removed.

IMPORTANT: Absolute cleanliness is essential 2. Lower base cutter.


when working on the hydraulic system.
Contamination can result in serious damage 3. Relieve hydraulic pressure.
or inadequate operation. Plug and cap all 4. Shut off engine and remove key.
open hoses and fittings.
5. Clean cylinder and surrounding area.
NOTE: Remove and install procedure is same for
left-hand and right-hand cylinder. 6. Engage cylinder safety stop on cylinder not being
removed and block up machine.
1. Park machine on level surface.
Continued on next page TB90758,000023A -19-02APR13-1/3

TM100419 (02APR13) 70-20-26 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=338
Hydraulic Cylinders

7. Disconnect upper hose (A).


8. Remove clamp (B).
9. Disconnect lower hose (C).

T8130000620 —UN—13FEB13
10. Cap and plug all openings and fittings.

A—Upper Hose C—Lower Hose


B—Clamp

T8130000621 —UN—13FEB13
TB90758,000023A -19-02APR13-2/3

CAUTION: Approximate weight of base cutter


lift cylinder is 34 kg (75 lb.).

11. Remove cap screw (B) and shim (C).

T8130000622 —UN—13FEB13
12. Remove lower cylinder end from ball pivot (A)
NOTE: Upper end of cylinder is located inside
engine compartment.

13. Remove cap screw and lock nut (E).


14. Remove washer (D) and pin (F).
15. Remove cylinder from machine.
16. Repair or replace cylinder as necessary. (See
Disassemble and Assemble Base Cutter Lift Cylinders
(Track Harvester) in Section 70, Group 20.)
T8130000623 —UN—13FEB13

17. Install in reverse order using the following special


instructions:
• Grease cylinder pins.
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)

A—Ball Pivot D—Washer


B—Cap Screw (2 used) E—Cap Screw and Lock Nut
C—Shim F— Pin

TB90758,000023A -19-02APR13-3/3

TM100419 (02APR13) 70-20-27 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=339
Hydraulic Cylinders

Disassemble and Assemble Base Cutter Lift Cylinders (Track Harvester)


Disassemble

2
3
4
5

1 6

8
9

10

11

12

T8130001053 —UN—27MAR13
13

1— Cylinder Rod 5— Backup Ring 9— Seal 13— Cylinder Barrel


2— Lock Nut 6— Piston 10— Cylinder Head
3— Thrust Washer 7— Piston Ring 11— Seals (2 used)
4— O-Ring 8— O-Ring 12— Cylinder Cap

CAUTION: Before removing cylinder for repair,


block up machine and relieve all system pressure. CAUTION: Do not use a flammable solvent to clean
cylinder parts. An explosion may occur inside
1. Remove cylinder from machine. (See Remove and the cylinder, at the moment of pressurization.
Install Base Cutter Lift Cylinders (Track Harvester) in
Section 70, Group 20.) IMPORTANT: Do not reuse seals.

2. Drain oil from cylinder. Plug and cap fittings and hoses. 8. Clean inside of barrel using solvent and blow dry using
compressed air.
3. Clean exterior with solvent and dry to prevent dirt and
debris from entering cylinder barrel. 9. Remove old seals and O-rings using soft metal tools
to avoid damaging sealing surfaces of cylinder cap
IMPORTANT: Clamping cylinder in a vise at middle and piston.
or end of barrel may damage barrel. Clamp
only at cylinder base end. 10. Clean cylinder parts thoroughly with solvent.
11. Clean rod assembly.
4. Place cylinder in vise and extend rod fully.
12. Light scratches, burrs, or dents may be repaired using
5. Using appropriate spanner wrench rotate cylinder cap
emery cloth. Repair or replace as necessary.
(12) counterclockwise and remove.
6. Pull rod assembly from cylinder barrel (13).
7. Remove lock nut (2), thrust washer (3), and piston (6)
from cylinder rod (1).
Continued on next page TB90758,0000297 -19-28MAR13-1/3

TM100419 (02APR13) 70-20-28 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=340
Hydraulic Cylinders

Assemble
A C
B
1. Ensure parts are thoroughly clean before assembly.
2. Check all seal widths, lengths, and diameters are
same as old ones.

T8130001058 —UN—26MAR13
3. Apply thin layer of clean oil to seals and rings before
installing.
4. Install wiper seal (H) into eye end of cylinder cap.
5. Install O-ring (B), seals (A), and wear ring (C) onto
piston.
IMPORTANT: Curved side of backup ring must Piston
be installed toward O-ring.
D E F G
6. Install O-ring (D), backup ring (E), seal (F), and wiper
seal (G) on cylinder head.

T8130001059 —UN—26MAR13
A—Seal (2used) E—Backup Ring
B—O-Ring F— Seal
C—Wear Ring G—Wiper Seal
D—O-Ring H—Wiper Seal

Cylinder Head

T8130001060 —UN—26MAR13
H

Cylinder Cap

Continued on next page TB90758,0000297 -19-28MAR13-2/3

TM100419 (02APR13) 70-20-29 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=341
Hydraulic Cylinders

7. Slide cap (A), cylinder head (B), and piston onto


cylinder rod.
8. Apply Thread Lock and Sealer (High Strength) to
external threads of cylinder rod (D).
9. Slide thrust washer (E) and lock nut (F) onto cylinder
rod (D).
10. Tighten lock nut to specification.

T8130001319 —UN—28MAR13
Specification
Piston Lock
Nut—Torque...................................................................... 691—718 N·m
(510—530 lb.-ft.)

11. Install rod assembly into barrel. Rod assembly must


be installed straight within barrel.
12. Apply anti-seize compound to cylinder barrel external
threads.
13. Tighten cylinder cap to specification.
Specification
Cylinder Cap—Torque....................................................... 711—779 N·m
(525—575 lb.-ft.)

T8130001320 —UN—28MAR13
A—Cap D—Cylinder Rod
B—Cylinder Head E—Thrust Washer
C—Piston F— Lock Nut

TB90758,0000297 -19-28MAR13-3/3

TM100419 (02APR13) 70-20-30 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=342
Hydraulic Cylinders

Remove and Install Knockdown Tilt Cylinder


(Optional)
1. Park machine on level surface.
2. Position topper cylinder (B) safety stop (A) in the
upward position.

X9811 —UN—23AUG88
3. Lower topper, relieve hydraulic pressure.
4. Shut off engine and remove key.
5. Clean knockdown cylinder and surrounding area.
6. Using an appropriate lifting device, support topper
assembly to remove weight from cylinder.

A—Safety Stop B—Topper Cylinder

T8130000705 —UN—13FEB13
Continued on next page TB90758,0000243 -19-28MAR13-1/2

TM100419 (02APR13) 70-20-31 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=343
Hydraulic Cylinders

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten

T8130000703 —UN—13FEB13
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.

T8130000704 —UN—13FEB13
7. Disconnect hoses (A). Cap and plug all openings and
fittings.

CAUTION: Approximate weight of knock down


cylinder is 9 kg (20 lb.).

8. Remove lock nuts (C), cap screws (B), and cylinder


pins (D). Remove cylinder.
9. Replace or repair cylinder as necessary. (See
Disassemble and Assemble Knockdown Tilt and Crop A—Hoses (2 used) C—Lock Nuts (2 used)
B—Cap Screws (2 used) D—Cylinder Pins (2 used)
Divider Tilt Cylinder (Optional) in Section 70, Group
20.)
10. Install in reverse order of removal using the following • Check hydraulic reservoir oil level and fill as
special instructions: necessary. (See Hydraulic Oil in Section 10, Group
15.)
• Grease cylinder pins.
TB90758,0000243 -19-28MAR13-2/2

TM100419 (02APR13) 70-20-32 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=344
Hydraulic Cylinders

Remove and Install Crop Divider Tilt


Cylinders (Optional)
1. Park machine on level surface.

CAUTION: Escaping fluid under pressure can

X9811 —UN—23AUG88
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available

T8130000624 —UN—13FEB13
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.

2. Relieve hydraulic pressure.


3. Turn off engine and remove key.
NOTE: Remove and install procedure is same for
left-hand and right-hand side cylinder.

4. Clean crop divider tilt cylinder (A) and surrounding


area.
5. Disconnect hose (B). Cap and plug all openings.

A—Crop Divider Tilt Cylinder B—Hose (2 used)

T8130000625 —UN—13FEB13
Continued on next page TB90758,0000244 -19-28MAR13-1/2

TM100419 (02APR13) 70-20-33 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=345
Hydraulic Cylinders

CAUTION: Approximate weight of crop divider


tilt cylinder is 9 kg (20 lb.).

6. Remove lock nut (A) and cap screw (B) from cylinder
base.
7. Remove cap screw (C).
8. Remove bracket (D).

T8130000701 —UN—13FEB13
9. Remove cylinder.
10. Replace or repair cylinder as necessary. (See
Disassemble and Assemble Knockdown Tilt and Crop
Divider Tilt Cylinder (Optional) in Section 70, Group
20.)
11. Install in reverse order using the following special
instructions:
• Grease cylinder pins.
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15.)

A—Lock Nut C—Cap Screw


B—Cap Screw D—Bracket

T8130000702 —UN—13FEB13
TB90758,0000244 -19-28MAR13-2/2

TM100419 (02APR13) 70-20-34 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=346
Hydraulic Cylinders

Disassemble and Assemble Knockdown Tilt and Crop Divider Tilt Cylinder (Optional)

CM073510072 —UN—26MAR08

1— Tube 7— Spherical Roller Bearing 12— Seal 18— O-Ring


2— Hydraulic Cylinder Rod 8— Lubrication Fitting 13— O-Ring 19— Backup Ring
3— Cylinder Head 9— Bushing 14— Backup Ring 20— O-Ring
4— Piston 10— Ring 15— O-Ring 21— Wear Ring
5— Nut 11— Seal 16— Wear Ring
6— Washer 17— Backup Ring
Continued on next page TB90758,0000245 -19-02APR13-1/9

TM100419 (02APR13) 70-20-35 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=347
Hydraulic Cylinders

1. Remove cylinder from machine and clean thoroughly. Extend rod to remove oil or air between rod
(See Remove and Install Knockdown Tilt Cylinder piston and rod guide. Excessive amounts
(Optional) or Remove and Install Crop Divider Tilt of trapped oil or air will expand seals and
Cylinders (Optional) in Section 70, Group 20.) make disassembly more difficult.
IMPORTANT: Clamping cylinder in a vise at the
middle or rod end of barrel may damage barrel. 2. Place cylinder in vise with fitting ports facing down
Clamp only at cylinder base end. and secure.
3. Open both ports and drain oil from cylinder.
TB90758,0000245 -19-02APR13-2/9

4. Extend rod (B) fully from cylinder barrel (A). B


5. Remove cylinder head set screw.
A
A—Cylinder Barrel B—Rod

T8130000763 —UN—26FEB13
TB90758,0000245 -19-02APR13-3/9

6. Using a spanner wrench, turn cylinder head (B)


counterclockwise until threads on head separates from B
internal threads in cylinder barrel (A).
7. Remove complete rod assembly (C) from barrel. A C

T8130000764 —UN—26FEB13
A—Cylinder Barrel C—Rod Assembly
B—Cylinder Head

TB90758,0000245 -19-02APR13-4/9

8. Remove locknut (A), washer (B, piston (C) and E


cylinder head (D) from rod (E).
9. Remove all seals and O-rings from piston and rod D
head.
T8130000765 —UN—26FEB13

C
10. Clean cylinder components thoroughly and inspect
piston, cylinder head, and barrel for damage. Repair B
or replace as necessary. A

A—Lock Nut D—Cylinder Head


B—Washer E—Rod
C—Piston

Continued on next page TB90758,0000245 -19-02APR13-5/9

TM100419 (02APR13) 70-20-36 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=348
Hydraulic Cylinders

11. Install wear ring (A), seal (B), O-ring (D), and O-ring
loader (C) on piston. Lightly coat new seals and rings A B
with clean filtered oil. Oil on seals eases assembly
and prevents seal damage. C

T8130001061 —UN—26MAR13
12. Install wear ring (E), O-rings (F and H), wiper seal (I),
rod seal (J), and backup ring (G) to cylinder head.
13. Lightly coat new seals and rings with clean filtered D
oil. Oil on seals eases assembly and prevents seal
damage.

A—Wear Ring F— O-Ring


B—Seal G—Backup Ring
C—O-Ring H—O-Ring Piston
D—O-Ring Loader I— Wiper Seal
E—Wear Ring J— Rod Seal F G H

T8130001062 —UN—26MAR13
I

E
J

TB90758,0000245 -19-02APR13-6/9

14. Lubricate interior seals of cylinder head (A) with


clean oil and install head onto rod (B) ensuring not B
to damage interior seals. A

A—Cylinder Head B—Rod

T8130000766 —UN—26FEB13
Continued on next page TB90758,0000245 -19-02APR13-7/9

TM100419 (02APR13) 70-20-37 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=349
Hydraulic Cylinders

15. Install piston (C) and washer (B) onto rod (E).
16. Apply Thread Lock and Sealer (High Strength) onto E
D
internal threads of lock nut (A) and install on rod.
Tighten nut to specification. C

T8130000922 —UN—21MAR13
Specification A
Lock Nut—Torque.............................................................. 393—420 N·m
(290—310 lb.-ft.)

17. Lubricate exterior seals on cylinder head (D), piston,


and barrel chamfer area with clean oil.
B
A—Lock Nut D—Cylinder Head
B—Washer E—Rod
C—Piston

TB90758,0000245 -19-02APR13-8/9

18. Insert complete rod assembly (A) into cylinder barrel


A
(B), ensuring not to damage seals. Light taps on rod
end may be necessary.
19. Using spanner wrench tighten cylinder head into barrel

T8130000767 —UN—26FEB13
to specification.
Specification
Cylinder Head—Torque..................................................... 338—406 N·m
(250—300 lb.-ft.)

20. Tighten set screw to specification. B


Specification
Set Screw—Torque............................................................. 3.3—3.9 N·m
(30—35 lb.-in.)
A—Rod Assembly B—Cylinder Barrel
21. Test repaired cylinder for leaks and install on machine.
TB90758,0000245 -19-02APR13-9/9

TM100419 (02APR13) 70-20-38 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=350
Hydraulic Cylinders

Remove and Install Elevator Lift Cylinders


1. Park machine on level surface.
2. Shut off engine and remove key.
3. Clean elevator lift cylinder and surrounding area.

X9811 —UN—23AUG88
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department

T8130000442 —UN—05FEB13
in Moline, Illinois, U.S.A.

CAUTION: Always support outer section of


elevator, even if only one lift cylinder is removed.

NOTE: Procedure for left-hand cylinder (A) shown,


procedure for right-hand cylinder (D) is similar.

4. Using an appropriate lifting device, support outer A—Left-Hand Lift Cylinder C—Hoses (2 used)
section of elevator from lifting points (B) outward. B—Lifting Points (2 used) D—Right-Hand Lift Cylinder
5. Tag and disconnect hoses (C).
6. Cap and plug hoses and fittings.
Continued on next page TB90758,000022D -19-28MAR13-1/2

TM100419 (02APR13) 70-20-39 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=351
Hydraulic Cylinders

CAUTION: Approximate weight of elevator


lift cylinder is 17 kg (37 lb.).

7. Remove cap screw and washer (A).


8. Remove pin (B).
9. Remove spring pin (D), pin (C), and remove cylinder.

T8130000443 —UN—05FEB13
10. Replace or repair lift cylinder as necessary. (See
Disassemble and Assemble Elevator Lift Cylinders
in Section 70, Group 20.)
11. Install in reverse order of removal using the following
special instructions:
• Grease lift cylinder pins.
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)

A—Cap Screw and Washer C—Pin


B—Pin D—Spring Pin

T8130000444 —UN—05FEB13
TB90758,000022D -19-28MAR13-2/2

TM100419 (02APR13) 70-20-40 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=352
Hydraulic Cylinders

Disassemble and Assemble Elevator Lift Cylinders

CM11472724A4 —UN—14FEB07

1— Cylinder Tube 5— Expander Ring 10— Buffer Seal 14— Locking Collar
2— Lock Nut 6— Piston 11— Head 15— Cylinder Rod
3— Nylon Wear Ring 7— O-Ring 12— U-Cup Seal
4— Seal 8— Set Screw 13— Wiper Seal
9— O-Ring
Continued on next page TB90758,0000226 -19-28MAR13-1/8

TM100419 (02APR13) 70-20-41 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=353
Hydraulic Cylinders

Disassemble

CAUTION: Secure elevator and swing table


before removal of cylinder. A

1. Remove cylinder from machine. (See Remove and B


Install Elevator Lift Cylinders in Section 70, Group 20.)
2. Drain oil from cylinder and extend rod fully. Plug and
cap fittings and hoses.
3. Clean exterior with solvent and dry to prevent dirt and
debris from entering cylinder barrel.
4. Place cylinder in vise and tighten securely.

T8130000576 —UN—06FEB13
IMPORTANT: Avoid cylinder damage. Set screw C
must me removed before rod assembly can
be removed from barrel (C).

5. Remove set screw (A).


6. Remove locking collar (B).
7. Remove caps or plugs on cylinder barrel ports.
A—Set Screw C—Barrel
B—Locking Collar

TB90758,0000226 -19-28MAR13-2/8

8. Remove rod (D) and internal parts from cylinder barrel.


9. Remove lock nut (A) that retains piston (B).
A
10. Remove piston and cylinder head (C) from rod with
B
gentle blows from a dead- blow hammer.

T8130000577 —UN—06FEB13
C
11. Remove old seals. Use soft metal tools to avoid
damaging sealing surfaces of cylinder head or piston.
D
IMPORTANT: All parts must be thoroughly cleaned
and dried prior to reuse.

12. Clean all cylinder parts thoroughly with solvent, before


repacking and reassembly. Inspect barrel and seal
grooves for scratches or extreme wear. If necessary
remove nicks, burrs, or rust using emery cloth. A—Lock Nut C—Cylinder Head
B—Piston D—Rod

Continued on next page TB90758,0000226 -19-28MAR13-3/8

TM100419 (02APR13) 70-20-42 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=354
Hydraulic Cylinders

Piston Seal Installation


NOTE: The piston (A) has two nylon wear rings (B) and a
A
bronze filled TEFLON piston ring (C) with O-ring (D).

1. Install O-ring into center groove.

T8130000578 —UN—06FEB13
2. Install piston ring onto first groove of piston.
3. Install nylon wear rings.

A—Piston C—Piston Ring


B—Nylon Wear Ring D—O-Ring D
B C B

TB90758,0000226 -19-28MAR13-4/8

Assemble A

1. Place rod eye into vise and support rod horizontally. B


Lubricate rod lead on chamfer, as well as cylinder
head (C) inner diameter. Install locking collar (D) on
rod (B), then align the cylinder head on rod and bump C

T8130000579 —UN—06FEB13
it onto rod with a dead blow hammer. D

2. Locate piston (A) on the rod.


3. Apply Thread Lock and Sealer (High Strength) to
turndown threads. Thread lock nut onto rod threads
until resistance is felt. Tighten lock nut to specification.
Specification
Piston Lock
nut—Torque....................................................................... 339—373 N·m
A—Piston C—Cylinder Head
(250—275 lb.-ft.) B—Rod D—Locking Collar

TB90758,0000226 -19-28MAR13-5/8

T8130000580 —UN—06FEB13

B D E
A C A

A—Nylon Wear Ring B—Seal D—Seal


C—Expander Ring E—Expander Ring

4. Place clean cylinder barrel into vise. Generously apply ring (A), seal (B), expander ring (C), seal (D), buffer
system oil to barrel inner diameter, especially lead seal (E), and outer diameter of cylinder head.
chamfer. Apply oil to piston outer diameter, nylon wear
Continued on next page TB90758,0000226 -19-28MAR13-6/8

TM100419 (02APR13) 70-20-43 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=355
Hydraulic Cylinders

T8130000916 —UN—28FEB13
C

A—Barrel B—Rod C—Rod Eye

5. Clamp barrel (A) vertically or horizontally in vise. Align strike end of rod eye (C) to drive rod (B) into barrel,
rod center line with barrel center line and carefully at least 305 mm (12 in.).
Continued on next page TB90758,0000226 -19-28MAR13-7/8

TM100419 (02APR13) 70-20-44 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=356
Hydraulic Cylinders

A
C

T8130000921 —UN—28FEB13
D

A—Barrel C—Locking Collar D—Cylinder Head


B—Set Screw

6. Tap cylinder head into place, taking care not to cut


9. Apply Thread Lock and Sealer (Medium Strength) to
O-ring or backup ring.
set screw (B) and tighten to specification.
7. Brush anti-seize onto barrel threads . Turn locking Specification
collar (C) onto barrel threads, until snug. Use spanner Set Screw—Torque............................................................... 20—33 N·m
wrench to tighten locking collar against cylinder head (15—25 lb.-ft.)
(D).
8. Tighten locking collar to specification.
Specification
Locking Collar—Torque..................................................... 203—271 N·m
(150—200 lb.-ft.)
TB90758,0000226 -19-28MAR13-8/8

TM100419 (02APR13) 70-20-45 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=357
Hydraulic Cylinders

Remove and Install Elevator Discharge Flap


Cylinder
1. Park machine on level surface.
2. Shut off engine and remove key.

X9811 —UN—23AUG88
3. Clean elevator discharge flap cylinder and surrounding
area.

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.

T8120002358 —UN—03JAN13
4. Tag and disconnect hoses (B and C).
5. Cap and plug hoses and fittings.
6. Remove cotter pin and lower pin (D).
7. Remove cotter pin, upper pin (A), and discharge flap
cylinder (E).
8. Replace or repair cylinder as necessary. (See
Disassemble and Assemble Elevator Discharge Flap A—Upper Pin D—Lower Pin
Cylinder in Section 70, Group 20.) B—Hose E—Discharge Flap Cylinder
C—Hose
9. Install in reverse order of removal using the following
special instructions:
• Grease cylinder pins.
• Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)
TB90758,0000246 -19-28MAR13-1/1

TM100419 (02APR13) 70-20-46 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=358
Hydraulic Cylinders

Disassemble and Assemble Elevator Discharge Flap Cylinder


Disassemble

6
7

9
10

11
12

13

T8130000585 —UN—08FEB13
2

3
4

1— Cylinder Barrel 5— Piston 9— Wiper Seal 12— O-Ring


2— Nut 6— O-Ring 10— Rod Guide 13— Cylinder Rod
3— Piston Ring 7— Lock Ring 11— Wiper Seal
4— O-Ring 8— Backup Ring
Continued on next page TB90758,000023B -19-01APR13-1/9

TM100419 (02APR13) 70-20-47 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=359
Hydraulic Cylinders

IMPORTANT: Clamping cylinder in a vise at the


middle or rod end of barrel may damage barrel.
Clamp only at cylinder base end.
Extend rod to remove oil or air between rod
piston and rod guide. Excessive amounts
of trapped oil or air will expand seals and
make disassembly more difficult.

1. Clean outside surface of cylinder with solvent and dry


to prevent dirt and debris from entering cylinder barrel.
2. Open both ports and drain all oil from cylinder.
3. Extend rod fully.
NOTE: Spray penetrating oil in access slot to

T8130001361 —UN—01APR13
ease in disassembly.

4. Lift lock ring (A) out of slot using screwdriver.


5. Rotate end of rod guide (B) in same direction end of
lock ring is pointing, rotating lock ring out of slot, while
pulling on lock ring.

A—Lock Ring B—Rod Guide

TB90758,000023B -19-01APR13-2/9

NOTE: Scribe a line on rod guide and cylinder


barrel to aid in assembly.

6. Remove rod (A) from cylinder barrel (B).

A—Rod B—Cylinder Barrel

T8130001362 —UN—01APR13
Continued on next page TB90758,000023B -19-01APR13-3/9

TM100419 (02APR13) 70-20-48 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=360
Hydraulic Cylinders

NOTE: Install rod end in soft-jawed vise in order


to remove nut.

7. Remove nut (A), piston (B), and rod guide (D) from
rod (C).
IMPORTANT: When removing seals from piston and
rod guide, do not damage, mark, or score
any surfaces that contact seals.

T8130001363 —UN—01APR13
8. Remove all seals and O-rings from piston and rod
guide.

A—Nut C—Rod
B—Piston D—Rod Guide

TB90758,000023B -19-01APR13-4/9

9. Inspect groove in cylinder barrel. If necessary, clean


groove and remove nicks, burrs, or rust from inside of
barrel using emery cloth.
10. Clean inside of barrel using solvent and blow dry using
compressed air.

HCD1084 —UN—19NOV01
Continued on next page TB90758,000023B -19-01APR13-5/9

TM100419 (02APR13) 70-20-49 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=361
Hydraulic Cylinders

Assemble A

IMPORTANT: All parts must be thoroughly cleaned


and dried prior to reuse. Any contamination can
lead to leakage problems and part damage.

T8130001063 —UN—26MAR13
1. Install seal (A) to piston.
IMPORTANT: When installing rod seal ensure flat side
of seal is towards bottom end of cylinder.

2. Install O-rings (B and D), backup ring (C), rod seal (F),
and wiper seal (E) on rod guide.
3. Apply light film of clean oil on all seals and rings. Piston
D
B C
A—Seal D—O-Ring
B—O-Ring E—Wiper Seal
C—Backup Ring F— Rod Seal

T8130001064 —UN—26MAR13
E
F

Rod Guide

TB90758,000023B -19-01APR13-6/9

NOTE: Install rod end in soft-jawed vise or pin rod


end in order to tighten nut.

4. Install rod guide (C), piston (B), and nut (C) on rod (D).
5. Apply light coat of Thread Lock and Sealer (Medium
Strength) and tighten to specification in table.
NUT TORQUE SPECIFICATIONS

T8130001364 —UN—01APR13
Thread Size Torque
5/8-18 UNF-2A 130 N·m (96 lb.-ft.)
3/4-16 UNF-2A 215 N·m (159 lb.-ft.)

A—Nut C—Rod Guide


B—Piston D—Rod

Continued on next page TB90758,000023B -19-01APR13-7/9

TM100419 (02APR13) 70-20-50 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=362
Hydraulic Cylinders

6. Apply light film of clean hydraulic oil on all seals and


chamfer (B) of barrel.
7. Install rod guide (C) into cylinder barrel (A).

A—Cylinder Barrel C—Rod Guide


B—Chamfer

T8130001365 —UN—01APR13
TB90758,000023B -19-01APR13-8/9

8. Rotate rod guide (D) until lock ring hole (B) can be
seen in access slot (A)
9. Place straight end of lock ring (C) in hole and rotate
rod guide in direction shown until lock ring is seated
in access slot.

T8130001366 —UN—01APR13
A—Access Slot C—Lock Ring
B—Lock Ring Hole D—Rod Guide

T8130001367 —UN—01APR13

TB90758,000023B -19-01APR13-9/9

TM100419 (02APR13) 70-20-51 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=363
Hydraulic Cylinders

TM100419 (02APR13) 70-20-52 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=364
Group 25
Hydraulic Motors
Other Material
Number Name Use
PM38654 (U.S.) Thread Lock and Sealer (High Used to seal and lock threads.
271 (LOCTITE®) Strength)

0841306708 (U.S.) Araldite Cartridge Used to retain and lock threads.

(0841306707 Araldite Applicator


and 0841306709 Araldite Applicator
Nozzle are required to dispense
Araldite cartridge.)

PM38655 (U.S.) Flexible Form-In-Place Gasket Used to seal parts from fluid leakage.
TY9484 (Canadian)
515 (LOCTITE®)

PM37477 (U.S.) Thread Lock and Sealer (Medium Used to lock and seal threads.
TY9473 (Canadian) Strength)
242 (LOCTITE®)

Loctite is a trademark of Henkel Corporation


PW66162,000099E -19-22FEB13-1/1

Specifications
Item Measurement Specification

Gathering Disk-to-Motor Nut Torque 373 N·m


(275 lb.-ft.)
Valve Housing Cap Screw Torque 50 N·m
(37 lb.-ft.)
Case Drain Plug with Torque 6 N·m
O-Ring-to-Valve Housing (53 lb.-in.)
Chopper Motor Drive Gear Torque 275 N·m
Cap Screw (200 lb.-ft.)
Chopper Motor Flange Cap Screws Torque 271 N·m
(200 lb.-ft.)
Topper Severing Disk (Whole Torque 272 N·m
Topper) and Secondary Extractor (200 lb.-ft.)
Fan Motor End Cover Cap Screws
Secondary Extractor Rotate Motor Torque 32 N·m
End Cover Cap Screws (24 lb.-ft.)
PW66162,00009A3 -19-26FEB13-1/1

TM100419 (02APR13) 70-25-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=365
Hydraulic Motors

Remove and Install Topper Gathering Disk


Motor (Whole Topper)
NOTE: Procedure for right-hand and left-hand gathering
disk motors are the same.

T8120001594 —UN—25SEP12
1. Park machine on level surface.
2. Lower crop divider.
3. Lower topper completely.
4. Shut off engine and remove key.
5. Clean topper.
6. Remove shaft cover (A).
7. Remove cotter pin (D), nut (C), and gathering disk (B).
8. Tag and disconnect hoses (E and G).
9. Cap and plug hoses and fittings.
10. Remove cap screws (F), nuts, and gathering disk
motor.
11. Replace or repair motor as necessary. (See
Disassemble and Assemble Topper Gathering Disk,
Scroll, Side Knife, Butt-Lifter, Feed Roller, and Elevator
Motors in Section 70, Group 25.)

T8120002628 —UN—17JAN13
12. Install in reverse order of removal using the following
special instructions:
• Apply Thread Lock and Sealer (High Strength) to
threads of motor shaft.
NOTE: If necessary, tighten motor nut to next slot in nut.
Do NOT loosen nut to install cotter pin.

• Tighten gathering disk-to-motor nut to specification.


Specification
Gathering Disk-to-Motor
Nut—Torque................................................................................373 N·m

T8120001593 —UN—17JAN13
(275 lb.-ft.)

• Check hydraulic reservoir oil level and fill as


necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)

A—Shaft Cover E—Hose


B—Gathering Disk F— Cap Screw (4 used)
C—Nut G—Hose
D—Cotter Pin

PW66162,00009E3 -19-02APR13-1/1

TM100419 (02APR13) 70-25-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=366
Hydraulic Motors

Disassemble and Assemble Topper


Gathering Disk, Scroll, Side Knife, Butt-Lifter,
Feed Roller, and Elevator Motors
NOTE: For clarity, pictures do not show motor in a vise.
Follow clamping instructions as indicated.
Some motors are configured with a spline shaft and
top valve housing fitting ports. Repair procedure
is similar. Side ports and keyed shaft shown.

1. Drain oil from motor.


2. Clean external housing of motor.
3. Place motor in a vise with protective jaws, clamping

N87636 —UN—05FEB10
on mounting flange with output shaft facing downward
as shown.
4. Using a scribe or paint stick, mark lines across all
sections of motor to aid in assembly.

PW66162,0000922 -19-26FEB13-1/12

5. Remove four cap screws (A).

A—Cap Screw (4 used)

N87637 —UN—05FEB10
Continued on next page PW66162,0000922 -19-26FEB13-2/12

TM100419 (02APR13) 70-25-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=367
Hydraulic Motors

NOTE: Springs and pins (B) retained by valve housing A


can move when valve housing is removed. Be
prepared to catch components.

6. Lift valve housing (A) straight up.

A—Valve Housing B—Pin (2 used)

N87638 —UN—05FEB10
PW66162,0000922 -19-26FEB13-3/12

7. Remove seal (B) from valve housing (A).


A
8. Remove case drain plug (D) and O-ring (C).
B
A—Valve Housing C—O-Ring
B—Seal D—Case Drain Plug

N87639 —UN—05FEB10
C
D

Continued on next page PW66162,0000922 -19-26FEB13-4/12

TM100419 (02APR13) 70-25-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=368
Hydraulic Motors

9. Remove pins (C) and springs (D). B C D

10. Remove balance ring assembly (E). A

11. Remove valve (A).


12. Remove inner and outer face seals (B) from balance D
ring. C

N87640 —UN—05FEB10
E
13. Remove valve plate (H), valve drive (G), and seal (F).
14. Remove geroler (K) and retain rollers in outer ring.
15. Remove main drive (J).
16. Remove seal (I).

A—Valve G—Valve Drive


B—Inner and Outer Face Seals H—Valve Plate F G
C—Pins (2 used) I— Seal
D—Springs (2 used) J— Main Drive
E—Balance Ring K—Geroler
F— Seal

N87641 —UN—05FEB10
H

J
I

N88230 —UN—24MAR10
K

Continued on next page PW66162,0000922 -19-26FEB13-5/12

TM100419 (02APR13) 70-25-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=369
Hydraulic Motors

NOTE: Removal of shaft and bearing assembly can


require use of a press.
B C
Shaft and bearing assembly cannot be repaired.
A
A worn or damaged shaft and bearing assembly
must be replaced as a unit.

N87643 —UN—08FEB10
NOTE: Do not scratch seal cavity outer diameter.
Scratches in seal cavity can cause leaks.
D
17. Remove wear plate (D).
18. Remove shaft face seal (C) from wear plate.
19. Remove seal (B) from bearing housing (A).
20. Remove shaft and bearing assembly (E) from bearing
housing.
A
21. Using an appropriate seal remover, remove exclusion
seal (F), backup ring (G), and shaft pressure seal (H)
from bearing housing.

N87644 —UN—08FEB10
IMPORTANT: Do not dry parts using paper towels or
cloth as lint can damage hydraulic system. E

Do not spin roller bearings of shaft and


bearing assembly with compressed air,
as damage can occur.

22. Clean metal parts using a safe solvent and dry using A
compressed air.
23. Inspect all mating surfaces and parts for wear or
damage, replace as necessary.
F
A—Bearing Housing E—Shaft and Bearing H

N87645 —UN—08FEB10
B—Seal Assembly G
C—Shaft Face Seal F— Exclusion Seal
D—Wear Plate G—Backup Ring
H—Shaft Pressure Seal

Continued on next page PW66162,0000922 -19-26FEB13-6/12

TM100419 (02APR13) 70-25-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=370
Hydraulic Motors

IMPORTANT: Always install new seals and lubricate


them with petroleum jelly before installation.
Coat all internal metal parts with clean
hydraulic oil during assembly.

NOTE: Wrap splines of shaft and bearing assembly


using tape to avoid damaging seals. F

A
24. Install exclusion seal (E) as shown using a press and
appropriate seal driver.
25. Install backup ring and shaft pressure seal (F) using
an appropriate seal driver. B

26. Wrap splines of shaft and bearing assembly (D) using


tape.
E
27. Lubricate inner diameter of shaft pressure seal and
exclusion seal using petroleum jelly.
C
28. Install shaft and bearing assembly using a press.
Inspect shaft pressure seal for damage and replace as
necessary.

N87646 —UN—08FEB10
29. Place motor in a vise with protective jaws clamping on
mounting flange and output shaft facing downward. D
30. Install seal (C).
31. Install seal (A) in wear plate (B) as shown.
32. Install wear plate.
A—Seal D—Shaft and Bearing
B—Wear Plate Assembly
C—Seal E—Exclusion Seal
F— Backup Ring and Shaft
Pressure Seal

PW66162,0000922 -19-26FEB13-7/12

33. Install seal (A) and main drive (B).


B
A—Seal B—Main Drive A

N87896 —UN—10FEB10

Continued on next page PW66162,0000922 -19-26FEB13-8/12

TM100419 (02APR13) 70-25-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=371
Hydraulic Motors

34. Locate largest open pocket alignment guide (F) in


geroler (B) and mark location on outside edge.
35. Install seal in valve plate (D). B
C

36. Install geroler on main drive (A).


37. Install valve drive (C) in geroler.

N87647 —UN—08FEB10
E
A
38. Align notch on geroler with corresponding notch on
valve plate and install valve plate on valve drive. D
39. Locate any one of six openings in side of valve (E).
Align selected opening in valve with largest open F
pocket in geroler and install valve, rotating clockwise
to engage spline teeth. Do not rotate more than 1/2
spline tooth.
A—Main Drive D—Valve Plate
B—Geroler E—Valve
C—Valve Drive F— Largest Open Pocket
Alignment Guide

PW66162,0000922 -19-26FEB13-9/12

40. Install seal (A).


D
41. Install springs (C) and pins (B) in holes located in bore
of valve housing (D).
A C
A—Seal C—Springs (2 used) B
B—Pins (2 used) D—Valve Housing

N87648 —UN—08FEB10
C
B

Continued on next page PW66162,0000922 -19-26FEB13-10/12

TM100419 (02APR13) 70-25-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=372
Hydraulic Motors

NOTE: Do not bend or force inner and outer face seals.


B C
Failure to install inner face seal and outer face seal A D
as shown can cause the motor to operate improperly.

42. Install inner face seal (B) and outer face seal (A) in
balance ring (D) as shown.
43. Align pin notches (C) in balance ring with pins in valve
housing (E) bore and install balance ring.
44. Retain balance ring in position by inserting a finger
in valve housing and apply pressure to balance ring.
Maintain pressure on balance ring as valve housing
is installed on geroler (F).
45. Check valve housing alignment by pushing down on
valve housing. A slight spring action is attained from
proper assembly. Repeat steps 43—45 if no spring
action is observed.

A—Outer Face Seal D—Balance Ring


B—Inner Face Seal E—Valve Housing E
C—Pin Notch F— Geroler D

N87649 —UN—08FEB10
F

Continued on next page PW66162,0000922 -19-26FEB13-11/12

TM100419 (02APR13) 70-25-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=373
Hydraulic Motors

46. Install four caps screws (A) and tighten to specification


in an alternating pattern.
Specification
Valve Housing Cap
Screw—Torque..............................................................................50 N·m
(37 lb.-ft.)

N87651 —UN—05FEB10
47. Install case drain plug (C) with O-ring (B). Tighten to
A
specification.
Specification B
Case Drain Plug C
with O-Ring-to-Valve
Housing—Torque.............................................................................6 N·m
(53 lb.-in.)
A—Cap Screw (4 used) C—Case Drain Plug
48. Remove tape from output shaft splines. B—O-Ring

PW66162,0000922 -19-26FEB13-12/12

TM100419 (02APR13) 70-25-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=374
Hydraulic Motors

Remove and Install Chopper Motor


SPECIAL TOOLS NEEDED:
• Araldite Applicator
Used to dispense Araldite.

T8130000589 —UN—06FEB13
Tool Number—0841306707
• Araldite Applicator Nozzle
Used to dispense Araldite.
Tool Number—0841306709
• Araldite Cartridge
Used to retain and lock threads.
Tool Number—0841306708
Remove
1. Park machine on level surface. Shut off engine and
remove key.
2. Clean chopper motor and surrounding area.

T8130000590 —UN—06FEB13
3. Unlatch and open flywheel shield (A).
4. Remove cap screws (B and C) and flywheel shield.
5. Tag and disconnect hoses (E and F).
6. Cap and plug hoses and fittings.
NOTE: Approximate capacity of chopper gear case
is 11.01 L (2.9 gal.).

7. Using an appropriate container, remove drain plug (D)


and drain chopper case oil.
8. Install plug.

CAUTION: Approximate weight of chopper


motor is 102 kg (224 lb.).

NOTE: Motor shown supported in removed position.

T8130000593 —UN—06FEB13
9. Attach an appropriate lifting device (I) to chopper
motor (H).
NOTE: Three of the five flange cap screws are short
in length. Observe location of short flange cap
screws to aid in assembly.

10. Remove flange cap screws (G) and chopper motor.


11. Remove and discard motor flange O-ring.
A—Flywheel Shield F— Hoses (2 used)
B—Cap Screw G—Flange Cap Screw (5 used)
C—Cap Screw H—Chopper Motor
D—Drain Plug I— Lifting Device
E—Hose

Continued on next page PW66162,00009DE -19-02APR13-1/4

TM100419 (02APR13) 70-25-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=375
Hydraulic Motors

NOTE: Apply heat to motor drive gear cap screw


to aid in removal. Heat softens 0841306708
Araldite1 used to retain cap screw.

12. If necessary remove cap screw (A) and motor drive

T8130000592 —UN—06FEB13
gear (B). Replace motor drive gear as necessary.
13. Replace or repair motor as necessary. (See
Disassemble and Assemble Chopper Motor in Section
70, Group 25.)

A—Cap Screw B—Drive Gear

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page PW66162,00009DE -19-02APR13-2/4

TM100419 (02APR13) 70-25-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=376
Hydraulic Motors

Install
NOTE: Some drive gears are marked with an “X”. If used,
mount gear with “X” mark away from motor.
Apply 0841306708 Araldite1 to motor drive gear

T8130000592 —UN—06FEB13
cap screw. 0841306707 Araldite Applicator1
and 0841306709 Araldite Applicator Nozzle1 are
required to apply 0841306708 Araldite1.

1. If removed, install drive gear (B) and cap screw (A) to


chopper motor shaft. Tighten motor drive gear cap
screw to specification.
Specification
Chopper Motor
Drive Gear Cap
Screw—Torque............................................................................275 N·m
(200 lb.-ft.)

2. Install new motor flange O-ring.


NOTE: Use threaded rods of approximately 63.5
mm (2.5 in.) in length.

3. Install appropriate sized threaded rods (C) into


opposite holes as shown to aid in assembly.

T8130000591 —UN—06FEB13
4. Apply Thread Lock and Sealer (High Strength) to
threads of flange cap screws.
NOTE: Install three short flange cap screws in location
observed at disassembly. Short flange cap
screws are positioned to avoid contact with
gears in chopper gear case.

5. Install flange cap screws into holes without threaded


rods. A—Cap Screw C—Threaded Rods (2 used)
B—Drive Gear
6. Remove threaded rods and install remaining flange
cap screws. Tighten flange cap screws to specification.
Specification
7. Remove caps and plugs. Install hydraulic hoses.
Chopper Motor Flange
Cap Screws—Torque..................................................................271 N·m
(200 lb.-ft.)
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page PW66162,00009DE -19-02APR13-3/4

TM100419 (02APR13) 70-25-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=377
Hydraulic Motors

NOTE: Be sure that drain plug (D) is installed.

8. Fill chopper gear case with oil. (See Pump Drive,


Base Cutter, and Chopper Gear Case Oil in Section
10, Group 15 for recommended oil.)

T8130000589 —UN—06FEB13
9. Install flywheel shield (A) and cap screws (B and C).
10. Check hydraulic reservoir oil level and fill as
necessary. (See Hydraulic Oil in Section 10, Group
15 for recommended oil.)

A—Flywheel Shield C—Cap Screw


B—Cap Screw D—Drain Plug

PW66162,00009DE -19-02APR13-4/4

TM100419 (02APR13) 70-25-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=378
Hydraulic Motors

Disassemble and Assemble Chopper Motor

CM073510410 —UN—17SEP07

Continued on next page PW66162,000094B -19-26FEB13-1/31

TM100419 (02APR13) 70-25-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=379
Hydraulic Motors

1— Steel Ring 11— O-ring 19— Cap Screw 28— Ring


2— Ring 12— Shaft Seal 20— O-ring 29— Seal
3— O-ring 13— Shaft 21— O-ring 30— O-ring
4— Seal 14— Retaining Clip 22— O-ring 31— Rotary Valve Sleeve
5— Cover 15— Bearing 23— Seal 32— Shaft Key
6— O-ring 16— Locating Pin 24— Dowel Pin
7— Cylinder (5 used) 17— Drive Pin 25— Disk
8— Piston 18— Cap Screw (5 used) 26— Bushing
9— Housing 27— Distributor Cover
10— Plastic Slipper Seal
PW66162,000094B -19-26FEB13-2/31

Disassemble and Assemble Tools

CM073510411 —UN—17SEP07
1— Jacking Plate 2— Extractor Jacks 3— Lever
A—Bolt Circle

Disassemble with fault diagnosis, mark the position of motor cover with
respect to the motor body. Observe position of each of the
NOTE: During assembly at the factory, one of the cylinders with respect to motor housing.
distributor cap screws is lead sealed. The number on
the seal is a factory reference number and must not 1. Drain casing oil.
be removed. Warranty, where applicable, on motors
returned for repairs is only valid if this seal is intact.

To aid in assembly, mark alignment of distributor ports


with respect to the drain line holes the distributor. To aid
Continued on next page PW66162,000094B -19-26FEB13-3/31

TM100419 (02APR13) 70-25-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=380
Hydraulic Motors

2. Remove cap screws (18), lead tag, distributor cover


(27), and rotary valve sleeve (31).

18— Cap Screw (5 used) 31— Rotary Valve Sleeve


27— Distributor Cover

CM073510412 —UN—19MAR08
CM073510413 —UN—19MAR08
PW66162,000094B -19-26FEB13-4/31

3. Remove drive pin (17) and centering bushing (26).

17— Drive Pin 26— Centering Bushing

CM073510414 —UN—19MAR08
CM073510415 —UN—19MAR08

Continued on next page PW66162,000094B -19-26FEB13-5/31

TM100419 (02APR13) 70-25-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=381
Hydraulic Motors

4. Remove cap screws (19).


NOTE: Threaded rod of puller is inserted through
drive pin hole as shown.

CM073510416 —UN—19MAR08
5. Attach an appropriate puller using distributor cap
screw holes as shown.
6. Remove cover (5), O-rings (20), and locating pins (16).

5— Cover 19— Cap Screw


16— Locating Pin 20— O-Ring

CM073510417 —UN—19MAR08
PW66162,000094B -19-26FEB13-6/31

7. Using appropriate snap ring pliers, remove retaining


clip (14).

14— Retaining Clip

CM073510418 —UN—19MAR08
Continued on next page PW66162,000094B -19-26FEB13-7/31

TM100419 (02APR13) 70-25-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=382
Hydraulic Motors

8. Rotate shaft so that piston (8) of the cylinder (7) to be


removed is fully extended.
NOTE: If necessary, tap cylinder trunnion with a
rubber-headed hammer to loosen piston from shaft.

CM073510419 —UN—19MAR08
9. Lift upward and remove cylinder and piston assembly
by hand.
10. If necessary, remove piston from cylinder and inspect
surfaces for wear or damage. Replace as needed.
11. If necessary, replace rings (1 and 2), O-ring (3), seal
(4), plastic slipper seal (10), and O-ring (11).

1— Steel Ring 7— Cylinder (5 used)


2— Ring 8— Piston
3— O-Ring 10— Plastic Slipper Seal
4— Seal 11— O-Ring

PW66162,000094B -19-26FEB13-8/31

12. Using a rubber-headed hammer, tap and remove shaft


(13).
NOTE: Only remove shaft bearings if replacement
is required.

CM073510420 —UN—19MAR08
13. Remove and discard shaft seal.

13— Shaft

CM073510421 —UN—19MAR08

Continued on next page PW66162,000094B -19-26FEB13-9/31

TM100419 (02APR13) 70-25-19 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=383
Hydraulic Motors

14. If necessary, use an appropriate puller and remove


shaft bearings (15).

CM073510422 —UN—19MAR08
PW66162,000094B -19-26FEB13-10/31

Assemble 1. Wrap spline area on motor shaft with transparent tape.


NOTE: Transparent tape applied to shaft splines prevents
damage to lip of seal during installation.

CM073510423 —UN—19MAR08
9— Housing 12— Shaft Seal

2. Lubricate and install new shaft seal (12) in housing (9).


PW66162,000094B -19-26FEB13-11/31

IMPORTANT:
• Roller Bearings — Avoid bearing damage.
Outer bearing race must be installed into
motor housing or cover and the inner race CM073510424 —UN—19MAR08
must be assembled onto shaft.
• Ball bearings — Must be installed into
motor housing or cover and NOT
assembled onto shaft.

NOTE: Heating and cooling bearing parts as


described aids in installation.

3. Heat bearing assemblies installed onto shaft to


approximately 80 °C (176 °F).
4. Using a freezer, cool bearing assemblies installed into 5. Smooth edges that may have been damaged during
cover or housing. bearing removal.
6. If removed, install bearings.
Continued on next page PW66162,000094B -19-26FEB13-12/31

TM100419 (02APR13) 70-25-20 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=384
Hydraulic Motors

7. Replace the shaft retaining ring, spring, and C clip to


the rear side of the piston support ring.

CM073510425 —UN—19MAR08
PW66162,000094B -19-26FEB13-13/31

8. Dislodge C-clip from front side of the piston support


ring.

CM073510426 —UN—19MAR08
Continued on next page PW66162,000094B -19-26FEB13-14/31

TM100419 (02APR13) 70-25-21 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=385
Hydraulic Motors

NOTE: If necessary, lightly tap shaft with a rubber-headed


hammer to aid in shaft installation.

9. Install shaft (13) into bearing in motor cover (5).

CM073510427 —UN—19MAR08
CM073510428 —UN—19MAR08
PW66162,000094B -19-26FEB13-15/31

10. Insert O-ring (11) and plastic slipper seal (10) into the
cylinder (7). Insert O-ring (3), plastic ring seal (2),
steel ring (1) and shaped insert (4) into the cylinder
trunnions. Insert pistons (8) into cylinders.

CM073510429 —UN—19MAR08
CM073510419 —UN—19MAR08

Continued on next page PW66162,000094B -19-26FEB13-16/31

TM100419 (02APR13) 70-25-22 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=386
Hydraulic Motors

11. Place the long cylinder trunnion containing the seal


into the motor cover. Slide piston out onto the piston
support ring and place the lip of piston foot between
piston retaining ring and piston support ring.

CM073510430 —UN—19MAR08
NOTE: It may be necessary to lift cylinder and shaft
outward slightly to aid in installation.

12. Using an appropriate lever ensure that piston foot


comes into full contact with piston support ring.
13. Repeat necessary steps for remaining cylinders.

PW66162,000094B -19-26FEB13-17/31

14. Position front retaining ring and spring over piston feet
and insert C-clip.
15. Tap lightly with a rubber-headed hammer on cylinder
trunnions and shaft end to ensure that the shafts are

CM073510431 —UN—19MAR08
properly seated.

PW66162,000094B -19-26FEB13-18/31

CM073510432 —UN—19MAR08

5— Cover 9— Housing 20— O-Ring


6— O-Ring 16— Locating Pin

16. If removed, install locating pins (16). 17. Lubricate and install new O-rings (20 and 6).
Continued on next page PW66162,000094B -19-26FEB13-19/31

TM100419 (02APR13) 70-25-23 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=387
Hydraulic Motors

NOTE: Use care not to damage shaft seal.

18. Position housing (9) by aligning the trunnion seats with


cylinder trunnions and gently lower housing into place.

CM073510433 —UN—19MAR08
PW66162,000094B -19-26FEB13-20/31

IMPORTANT: Do not hammer the distributor surfaces


in the center of the motor cover. Using
an appropriate lever insert the distributor
drive pin slot, ensure that the shaft rotates
through 360 degrees without excessive

CM073510435 —UN—19MAR08
or variable resistance.

19. For motors with O-rings between the cover and body,
insert cap screws into the cover to ensure that the
O-rings are correctly positioned. Turn motor over so
that the shaft points downward.
20. Install and tighten cap screws (19).

CM073510434 —UN—19MAR08
Continued on next page PW66162,000094B -19-26FEB13-21/31

TM100419 (02APR13) 70-25-24 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=388
Hydraulic Motors

CM073510437 —UN—17SEP07
21. Install O-ring in rotary valve. 22. Install plastic slipper with concave side against O-ring.
PW66162,000094B -19-26FEB13-22/31

23. Install plastic seal with lug positioned correctly. For


motors with a steel ring, first install O-ring, then plastic
seal (without lug) and then steel ring.

CM073510438 —UN—19MAR08
PW66162,000094B -19-26FEB13-23/31

NOTE: Ensure that no objects fall into cover. Motor


disassembly is necessary to remove object.

24. Install distributor drive pin into the shaft through hole
in cover.

CM073510441 —UN—19MAR08

Continued on next page PW66162,000094B -19-26FEB13-24/31

TM100419 (02APR13) 70-25-25 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=389
Hydraulic Motors

25. Insert locating pins into their holes in cover.

CM073510442 —UN—19MAR08
PW66162,000094B -19-26FEB13-25/31

NOTE: Motors without the disk do not have the locating


pins. Disk must sit flush with cover.
Disk does not have to be pressed on. Five oil
feed holes must line up with holes in cover.

CM073510443 —UN—19MAR08
Once positioned, be sure that disk does not
rotate or move laterally.

26. Install disk onto cover and positioning it with locating


pins.

PW66162,000094B -19-26FEB13-26/31

27. Install centering bushing into disk.

CM073510444 —UN—19MAR08

Continued on next page PW66162,000094B -19-26FEB13-27/31

TM100419 (02APR13) 70-25-26 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=390
Hydraulic Motors

28. Position distributor rotary onto disk with side containing


seals on the top and with three radial holes to the left of
the reference cylinder and three axial holes to the right.

CM073510445 —UN—19MAR08
PW66162,000094B -19-26FEB13-28/31

29. Lubricate and install distributor cover O-ring into


groove as shown.

CM073510439 —UN—19MAR08
PW66162,000094B -19-26FEB13-29/31

CM073510440 —UN—19MAR08

30. For distributors with bronze disk, install O-ring and


plastic slipper with chamfer against O-ring.
Continued on next page PW66162,000094B -19-26FEB13-30/31

TM100419 (02APR13) 70-25-27 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=391
Hydraulic Motors

IMPORTANT: Avoid serious damage to motor.


Do not attempt to place distributor cover
pre-assembled with rotary valve and disk
directly onto motor cover. External components
of the distributor must be assembled separately

CM073510436 —UN—19MAR08
from the distributor cover.

31. Place distributor cover over the rotary, aligning cap


screw holes in distributor cover and motor cover.
32. Install distributor cap screws and tighten.

Incorrect

CM073510447 —UN—19MAR08
PW66162,000094B -19-26FEB13-31/31

TM100419 (02APR13) 70-25-28 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=392
Hydraulic Motors

Topper Severing Disk (Whole Topper) and Secondary Extractor Fan Motors Exploded View

1 9
3 11
6
7 10
8
2

7
5 6
4
5 11
3 4 10

1 16
19

17

16

18

15
14
13
17
12

22
13
21
17
14

11
12
9
14
13

15
17 20
T8120001841 —UN—15OCT12

11
13

14

Continued on next page PW66162,00009A5 -19-26FEB13-1/2

TM100419 (02APR13) 70-25-29 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=393
Hydraulic Motors

1— Snap Ring 9— Plug 14— End Seal (4 used) 19— Gear Housing
2— Shaft 10— Check Valve Assemblies (2 15— Thrust Plates (2 used) 20— End Cover
3— Bearing used) 16— Square Seals (2 used) 21— Washer (4 used)
4— Spacer 11— Bushings (4 used) 17— Dowel Pins (4 used) 22— Cap Screw (4 used)
5— Retaining Ring 12— Backup Seals (2 used) 18— Gear Set
6— Seal Retainer 13— Side Seals (4 used)
7— Seal
8— Shaft Housing
PW66162,00009A5 -19-26FEB13-2/2

Disassemble and Assemble Topper Severing


Disk (Whole Topper) and Secondary
Extractor Fan Motors
Disassemble

T8120001732 —UN—03OCT12
1. Clean motor (D) with solvent and blow dry with
compressed air.
IMPORTANT: Do not damage machined surfaces. Use
care when prying between motor sections.
Do not remove dowel pins between
motor sections.

NOTE: Motor shown is not mounted in a vice for clarity.


A—Cap Screw (4 used) C—Lines (2 used)
B—End Cover D—Motor
2. Place motor in a vise with drive shaft pointing
downward. Mark lines (C) across all three motor
sections as shown.
3. Remove cap screws (A), washers, and end cover (B).
Continued on next page PW66162,0000849 -19-17JAN13-1/20

TM100419 (02APR13) 70-25-30 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=394
Hydraulic Motors

IMPORTANT: Observe orientation of gears to install


in the same position at assembly. To prevent
damage, avoid tapping gear teeth together
or against other hard surfaces.

T8120001733 —UN—05OCT12
NOTE: Thrust plate and seals can stick to end
cover during disassembly.

4. Remove thrust plate (B) from gear housing or end


cover.
5. Remove and discard backup seal, side seals, and end
seals from thrust plate.
6. Carefully remove gears (C).
7. Remove and discard square seal (D).

A—Gear Housing C—Gears (2 used)


B—Thrust Plate D—Square Seal

T8120001734 —UN—03OCT12
PW66162,0000849 -19-17JAN13-2/20

IMPORTANT: Do not damage machined surfaces. Use


care when prying between motor sections.
Do not remove dowel pins between
motor sections.

NOTE: Thrust plate and seals can stick to shaft


housing during disassembly.

8. Remove gear housing (D) from shaft housing (A).


9. Remove and discard square seal (C).
T8120001735 —UN—04OCT12

10. Remove thrust plate (B) from gear housing or shaft


housing.
11. Remove and discard backup seal, side seals, and end
seals from thrust plate.

A—Shaft Housing C—Square Seal


B—Thrust Plate D—Gear Housing

Continued on next page PW66162,0000849 -19-17JAN13-3/20

TM100419 (02APR13) 70-25-31 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=395
Hydraulic Motors

12. Inspect bushings (B) for scoring or discoloration. If


necessary, use an appropriate bushing removal tool
and remove bushings.

A—Shaft Housing C—End Cover

T8120001736 —UN—03OCT12
B—Bushings (4 used)

T8120001737 —UN—03OCT12
PW66162,0000849 -19-17JAN13-4/20

13. Place shaft housing (C) in a vise with mounting face


upward.
14. Remove the snap ring (A).
15. Using an appropriate puller, remove shaft assembly

T8120001738 —UN—03OCT12
(B).

A—Snap Ring C—Shaft Housing


B—Shaft Assembly

Continued on next page PW66162,0000849 -19-17JAN13-5/20

TM100419 (02APR13) 70-25-32 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=396
Hydraulic Motors

16. Remove seal retainer (A) and seal (C) from shaft
housing (B). Discard seal.

A—Seal Retainer C—Seal


B—Shaft Housing

T8120001739 —UN—04OCT12
T8120001740 —UN—04OCT12
PW66162,0000849 -19-17JAN13-6/20

17. If necessary, remove check valves (B) from shaft


housing (A).

A—Shaft Housing B—Check Valves (2 used)

T8120001835 —UN—04OCT12
Continued on next page PW66162,0000849 -19-17JAN13-7/20

TM100419 (02APR13) 70-25-33 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=397
Hydraulic Motors

18. Remove retaining ring (D), spacer (C), and bearing (B)
from shaft (A).

A—Shaft C—Spacer
B—Bearing D—Retaining Ring

T8120001878 —UN—15OCT12
PW66162,0000849 -19-17JAN13-8/20

Clean and Inspect


1. Clean and inspect all parts for wear or damage.
Replace as necessary.
NOTE: Hydraulic oil pressure pushes gears against

T8120001831 —UN—04OCT12
gear housing on the low-pressure side. As the
hubs and bushings wear, the gear housing bore
also wears. Excessive wear in a short time period
indicates excessive oil pressure or contamination. If
relief valve settings are within specification, check
hydraulic system and reservoir for contamination.
Gears are a matched set and cannot be
replaced separately. Housing bushings must be
replaced if gears are replaced.

2. Place straight edge (A) across bore (B) as shown.


Using a feeler gauge (C), measure gap between gear
housing bore and straight edge. Replace gear housing
if gap exceeds 0.13 mm (0.005 in.).
3. Check gears (D) for nicks, scoring, or grooves on gear
T8120001832 —UN—04OCT12

hub and gear teeth surfaces. Replace as necessary.


4. Check all housing dowel pins and replace as
necessary.

A—Straight Edge C—Feeler Gauge


B—Bore D—Gears (2 used)

Continued on next page PW66162,0000849 -19-17JAN13-9/20

TM100419 (02APR13) 70-25-34 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=398
Hydraulic Motors

NOTE: Thrust plates “seal” gear sections at the sides


of gear. Worn thrust plates allow internal oil
leakage. Pitted thrust plates indicate cavitation
or oil aeration. Discolored thrust plates indicate
overheating, that is likely due to insufficient oil.

T8120001834 —UN—04OCT12
5. Check thrust plates (A) for wear. Maximum allowable
wear is 0.05 mm (0.002 inch).
6. Check center of thrust plates where the gears
mesh. Worn center area of thrust plates indicates oil
contamination.
7. Replace scored, pitted, or worn thrust plates.

A—Thrust Plate (2 used)

PW66162,0000849 -19-17JAN13-10/20

NOTE: Wear in the shaft seal contact area indicates


oil contamination.

8. Check seal contact area of shaft (A) The maximum


allowable wear is 0.05 mm (0.002 inch). Check shaft
splines for wear or damage. Replace as necessary.

A—Shaft

T8120001833 —UN—04OCT12
Continued on next page PW66162,0000849 -19-17JAN13-11/20

TM100419 (02APR13) 70-25-35 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=399
Hydraulic Motors

Assemble
1. Using medium grit emery cloth, clean housing
machined surfaces. Clean all motor parts and
housings with solvent and blow dry with compressed

T8120001736 —UN—03OCT12
air.
IMPORTANT: Use a press to install housing bushings.
Do not use a hammer to install bushings.

2. If removed, install bushings (B) into shaft housing (A)


and end cover (C).

A—Shaft Housing C—End Cover


B—Bushings (4 used)

T8120001737 —UN—03OCT12
PW66162,0000849 -19-17JAN13-12/20

NOTE: Check valves are “peened” in place to prevent


valves from loosening.

3. If removed, install check valves (B) into shaft housing


(A).

T8120001835 —UN—04OCT12
4. Using a small punch, peen edges around check valves
at both ends of screwdriver slot in valve.

A—Shaft Housing B—Check Valves (2 used)

Continued on next page PW66162,0000849 -19-17JAN13-13/20

TM100419 (02APR13) 70-25-36 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=400
Hydraulic Motors

5. Place shaft housing (B) in a vice with flange side


upward.
6. Apply Flexible Form-In-Place Gasket to the outer edge
of new seal (A) and seal bore.

T8120001836 —UN—04OCT12
7. Lubricate lip of seal.
NOTE: Make sure that seal is fully seated in seal bore.

8. Using an appropriate driver, install seal with the metal


side of seal upward. Wipe off excess sealant.
9. Install seal retainer (C) into shaft housing.

A—Seal C—Seal Retainer


B—Shaft Housing

T8120001837 —UN—04OCT12
PW66162,0000849 -19-17JAN13-14/20

10. Install bearing (B), spacer (C), and retaining ring (D)
onto shaft (A).

A—Shaft C—Spacer
B—Bearing D—Retaining Ring

T8120001878 —UN—15OCT12

Continued on next page PW66162,0000849 -19-17JAN13-15/20

TM100419 (02APR13) 70-25-37 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=401
Hydraulic Motors

11. Using an appropriate driver, install shaft assembly (B)


into shaft housing (C)
12. Install snap ring (A).

T8120001738 —UN—03OCT12
A—Snap Ring C—Shaft Housing
B—Shaft Assembly

PW66162,0000849 -19-17JAN13-16/20

13. Remove shaft housing from vice and position shaft


housing in vice with flange side downward.
NOTE: Position housings using lines marked
at disassembly.

T8120001838 —UN—04OCT12
Be sure that square seals remain in place
during assembly.

14. Grease new square seals (A) and install into grooves
in both sides of gear housing (B). Place gear housing
onto shaft housing and tap with a soft-headed hammer
until it contacts shaft housing.

A—Square Seals (2 used) B—Gear Housing

PW66162,0000849 -19-17JAN13-17/20

15. Lubricate and install seals (B—D) into grooves of


thrust plates (A) with flat side of seals facing away
from thrust plate.
NOTE: Install thrust plate with seals facing shaft housing.

16. Slide one thrust plate assembly through gear housing


(E) until it contacts shaft housing.

A—Thrust Plate (2 used) D—End Seal (4 used)


B—Side Seal (4 used) E—Gear Housing
C—Backup Seal (2 used)
T8120001839 —UN—05OCT12

Continued on next page PW66162,0000849 -19-17JAN13-18/20

TM100419 (02APR13) 70-25-38 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=402
Hydraulic Motors

NOTE: Install gear with spline onto spline of shaft.


Install thrust plate with flat side against gears.

17. Install gears (B) into gear housing (A).


18. With seals installed, install remaining thrust plate (D)
into gear housing.
19. Ensure that seal (C) is in gear housing groove.

A—Gear Housing C—Square Seal


B—Gears (2 used) D—Thrust Plate

T8120001840 —UN—05OCT12
T8120001880 —UN—18OCT12
Continued on next page PW66162,0000849 -19-17JAN13-19/20

TM100419 (02APR13) 70-25-39 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=403
Hydraulic Motors

NOTE: Marked lines (C) made at disassembly must be


positioned across all three motor sections as shown.

20. Position marked lines on end cover (B) and gear


housing and install end cover. Tap end cover lightly

T8120001732 —UN—03OCT12
with soft-headed hammer to contact end cap to gear
housing seal.
21. Install cap screws (A) and washers. Tighten cap
screws alternately to specification.
Specification
Topper Severing Disk
(Whole Topper) and
Secondary Extractor Fan
Motor End Cover Cap
Screws—Torque..........................................................................272 N·m A—Cap Screw (4 used) C—Lines (2 used)
B—End Cover D—Motor
(200 lb.-ft.)

22. Remove motor (D) from vice and rotate shaft with a
wrench to make certain there is no binding. 2. After motor installation, operate motor at least 2
minutes at no load and at low rpm (400 rpm minimum).
Start-up procedure During this break-in period, motor must run free and
1. Before connecting any hoses, fill all motor ports with not develop an excessive amount of heat.
clean hydraulic oil to provide initial lubrication.
PW66162,0000849 -19-17JAN13-20/20

TM100419 (02APR13) 70-25-40 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=404
Hydraulic Motors

Repair Base Cutter and Primary Extractor Motors

CM073510233 —UN—05SEP07

Continued on next page PW66162,0000859 -19-27FEB13-1/44

TM100419 (02APR13) 70-25-41 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=405
Hydraulic Motors

1— Drive Shaft Assembly 8— Seal Ring 17— Rear Bearing Cone 25— Sealing Flat Washer
2— End Cover 9— O-Ring 18— Rear Bearing Cup 26— Relief Valve (2 used)
3— Valve 10— Back-Up Ring 19— Rotary Group 27— Relief Valve Seal Set (2 used)
4— Housing 11— Fitting 20— Cap Screw
5— Cap Screw (2 used) 12— Bearing Cup 21— Shaft Seal
6— Cap Screw (6 used) 13— Gasket 22— Spacer
7— Cap Screws (4 used) 14— Pins (2 used) 23— Retaining Ring
15— Port Plate 24— Plug
16— Rear Bearing Shim (as
required)
PW66162,0000859 -19-27FEB13-2/44

CM073510234 —UN—05SEP07 CM073510235 —UN—05SEP07


Disassemble
NOTE: Thoroughly clean the exterior of the motor
before disassembly. Make sure that all
open ports are sealed.

1. Using a pair of retaining ring pliers, remove retaining


ring (23).
2. Use a punch and hammer to punch a hole in the shaft
seal.
PW66162,0000859 -19-27FEB13-3/44

CM073510236 —UN—05SEP07 CM073510237 —UN—05SEP07


3. Install a 3 inch sheet metal screw with the point blunted
into punched hole far enough to remove shaft seal.
4. Grasp sheet metal screw with pliers and pull outward
to remove seal.
5. Carefully, insert the blade of a flat screwdriver behind
the seal and pry out the seal taking care not to damage
the output drive shaft.

Continued on next page PW66162,0000859 -19-27FEB13-4/44

TM100419 (02APR13) 70-25-42 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=406
Hydraulic Motors

NOTE: Some motor configurations do not use


valve block assembly.

6. Position motor on mounting flange as shown.

CM073510239 —UN—19MAR08
7. Loosen, but do not remove, relief valves (26) and
plugs (24) from valve block (3).
8. Remove cap screws (7) and valve block.

3— Valve Block 24— Plugs (2 used)


7— Cap Screws (4 used) 26— Relief Valves (2 used)

CM073510240 —UN—19MAR08
PW66162,0000859 -19-27FEB13-5/44

9. Remove O-rings (9) and back-up rings (10) from the


mounting face of valve block (3).

3— Valve Block 10— Back-Up Rings (2 used)


9— O-Rings (2 used)

CM073510241 —UN—19MAR08
Continued on next page PW66162,0000859 -19-27FEB13-6/44

TM100419 (02APR13) 70-25-43 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=407
Hydraulic Motors

NOTE: The high pressure relief valves have two white


back-up rings and one O-ring in the lower groove.
The settings on these valves are preset at the factory.

10. Remove relief valves (26) from valve block (3).

CM073510242 —UN—19MAR08
11. Remove plugs (24) from valve block.

3— Valve Block 26— Relief Valves (2 used)


24— Plug (2 used)

CM073510243 —UN—19MAR08
PW66162,0000859 -19-27FEB13-7/44

CAUTION: Internal parts are spring loaded. To


avoid damage, remove cap screws leaving two
cap screws opposite each other tight. Gradually
and evenly remove the remaining cap screws.

CM073510244 —UN—19MAR08
Parts can be stuck to end cover. Be
careful not to drop parts.

12. Remove cap screws (5 and 6).


13. Remove end cover (2), gasket (13) and pins (14).
14. Remove any parts (port plate, bearing cup, or shims)
that may have stuck to end cover.

2— End Cover 13— Gasket


5— Cap Screw (2 used) 14— Pins (2 used)
6— Cap Screw (6 used)
CM073510245 —UN—19MAR08

Continued on next page PW66162,0000859 -19-27FEB13-8/44

TM100419 (02APR13) 70-25-44 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=408
Hydraulic Motors

NOTE: Rear bearing cup is “slip fit” into end cover.


Retained shims are used to adjust shaft
bearing end play.

CM073510246 —UN—19MAR08
15. Remove rear bearing cup (18) from end cover (2).
16. Remove and retain rear bearing shims (16) from end
cover.

2— End Cover 18— Rear Bearing Cup


16— Rear Bearing Shims

CM073510247 —UN—19MAR08
PW66162,0000859 -19-27FEB13-9/44

IMPORTANT: Handle bearing plate and valve plates


with extreme care. They are machined to
close tolerances for flatness.
If using a small screw driver to pry bearing plate

CM073510248 —UN—19MAR08
from housing, make sure that bearing plate and
barrel surfaces are not scratched or damaged.

17. Remove port plate (A), bearing plate (B), and pins
from housing C).

A—Port Plate C—Housing


B—Bearing Plate

Continued on next page PW66162,0000859 -19-27FEB13-10/44

TM100419 (02APR13) 70-25-45 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=409
Hydraulic Motors

NOTE: Low clearance bearing puller is recommended


for removal of end cover bearing. The bearing
puller pulls against bearing rollers, not against
inner cup. It is designed to prevent bearing cone
and cylinder barrel face from being damaged when

CM073510249 —UN—19MAR08
bearing is removed. Low clearance between the
end cover bearing and cylinder barrel makes it
difficult to use any other bearing puller.

18. Attach an appropriate bearing puller and remove


bearing from shaft.

PW66162,0000859 -19-27FEB13-11/44

19. Carefully reposition motor on its side. Using a 1/4 in.


hex bit socket, remove the two cap screws (20) and
washers (25) that hold the swash plate in the housing
(4).

CM073510250 —UN—19MAR08
PW66162,0000859 -19-27FEB13-12/44

20. Remove and discard sealing washer (25) from cap


screws (20). Replace with new sealing washers.

CM073510251 —UN—19MAR08

Continued on next page PW66162,0000859 -19-27FEB13-13/44

TM100419 (02APR13) 70-25-46 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=410
Hydraulic Motors

21. Push inward on shaft assembly (1) to dislodge the


swashplate (D) from its pocket in housing (4).

CM073510252 —UN—19MAR08
PW66162,0000859 -19-27FEB13-14/44

22. Carefully remove the output shaft/cylinder barrel


assembly from housing.

CM073510253 —UN—05SEP07
PW66162,0000859 -19-27FEB13-15/44

23. Position the shaft/cylinder barrel subassembly with


the shaft facing up. Carefully lift out the output drive
shaft subassembly.

CM073510254 —UN—05SEP07

Continued on next page PW66162,0000859 -19-27FEB13-16/44

TM100419 (02APR13) 70-25-47 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=411
Hydraulic Motors

IMPORTANT: When removing or installing bearing


cone, do not damage the shaft sealing area
(stepped area between the bearing journal
and output drive shaft splines). This area is
critical for sealing the shaft seal.

CM073510255 —UN—05SEP07
24. When the bearing must be replaced, use a press to
remove the bearing from the shaft assembly.
25. You must use special stop limit tool when installing a
new cone bearing.

PW66162,0000859 -19-27FEB13-17/44

26. If the bearing cup (12) needs replacing, carefully


remove the cup using a hammer and drift punch (E).

CM073510256 —UN—19MAR08
PW66162,0000859 -19-27FEB13-18/44

27. Reposition the cylinder barrel/swashplate with the


swashplate (D) on the bottom. Using a 1/4 in. hex
key, remove the cap screws (F) from the retaining
strap (G) on one side of the swashplate (D) . Loosen
the cap screw (F) on the other retainer strap (G) to

CM073510257 —UN—19MAR08
make it easier to remove cylinder barrel (C) from the
swashplate (D).

Continued on next page PW66162,0000859 -19-27FEB13-19/44

TM100419 (02APR13) 70-25-48 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=412
Hydraulic Motors

28. Carefully reposition the cylinder barrel/swashplate


(D) with the swashplate facing up. Remove the
swashplate by lifting slightly and sliding it over to
disengage from the retainer strap (G).

CM073510258 —UN—19MAR08
29. Remove cap screws, retaining strap, spacer, and
thrust plate from swashplate.
30. Disassemble cylinder barrel subassembly. Place it on
a clean protective surface for inspection and cleaning.

PW66162,0000859 -19-27FEB13-20/44

Assemble
IMPORTANT: Before reassembly, clean all parts and
assemblies in clean solvent and blow them
dry with compressed air. Inspect and replace

CM073510259 —UN—19MAR08
all scratched or damaged parts. Do not use
coarse grit paper, files, or grinders on any
finished surfaces. Replace all gaskets and
O-rings. Lubricate O-rings with petroleum jelly
for retention during reassembly. Freely lubricate
all bearings and finished part surfaces with
clean hydraulic fluid. This will provide required
start-up lubrication for moving parts.

1. Lubricate and install shoe retainer plate (H) and


piston shoes (I) in cylinder barrel (C) assembly. After height of retaining strap spacer with a micrometer or
installation, freely lubricate brass shoe faces with vernier caliper. There are two fixed spacer heights
clean hydraulic fluid. – one for the 33, 39, 46 units and one for the 54, 64
units. Spacers are critical to the unit design and may
2. Before assembling the motor any further, you must not be interchanged.
check the fixed clearance of motor. Measure the
PW66162,0000859 -19-27FEB13-21/44

3. Measure the combined thickness of the piston shoe


and shoe retainer plate. Subtract this measurement
from the spacer height to arrive at the fixed clearance
of unit.

CM073510260 —UN—19MAR08
NOTE: An alternative method of checking fixed clearance
is with the use of a feeler gauge. If using this
method, make sure that gauge is inserted between
retaining strap and shoe retainer plate only. Piston
shoe faces could be damaged if gauge is inserted
between piston shoe and thrust plate.

4. Fixed clearance must not exceed 0.008 inches


(.20 mm). If fixed clearance exceeds 0.009 inches
(.22 mm), replace worn parts, (i.e. piston shoe
subassemblies, thrust plate, retaining strap and/or 1— Spacer 5— Shoe Retainer Plate
retainer plate). 2— Retaining Strap 6— Piston Shoes
3— Cap Screw 7— Thrust Plate
4— Piston 8— Swashplate

Continued on next page PW66162,0000859 -19-27FEB13-22/44

TM100419 (02APR13) 70-25-49 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=413
Hydraulic Motors

5. Apply one or two drops of Loctite 271 in the first


or second thread, in each of the four holes in the
swashplate.

CM073510261 —UN—19MAR08
PW66162,0000859 -19-27FEB13-23/44

6. Lightly lubricate and install thrust plate (7), aligning the


cap screw holes. Install spacers (1), retaining straps
(2) and cap screws (3) on one side of the swashplate.
DO NOT tighten cap screws at this time.

CM073510262 —UN—19MAR08
PW66162,0000859 -19-27FEB13-24/44

CAUTION: Loctite parts must contact only those


surfaces intended for assembly. Wipe excess
Loctite from swashplate with non-petroleum
base solvent applied to a cloth. Do not apply
Loctite to threads more than 15 minutes before

CM073510263 —UN—19MAR08
installing cap screws. If Loctite stands for
more than 15 minutes, repeat the application.
If repeating the application, it is not necessary
to remove previously applied Loctite.

7. Place the cylinder barrel (C) subassembly on a clean,


flat surface with the piston shoes facing up. Carefully
install the swashplate onto the barrel by slightly
lifting the side without the retaining strap. Slide the
swashplate over to engage installed strap around
piston retainer.
Continued on next page PW66162,0000859 -19-27FEB13-25/44

TM100419 (02APR13) 70-25-50 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=414
Hydraulic Motors

8. Carefully reposition cylinder barrel/swashplate with


the swashplate down. Install the remaining spacer,
retaining strap, and cap screw. Tighten all four cap
screws 22—26 N·m (16—19 lb.-ft.).

CM073510264 —UN—05SEP07
PW66162,0000859 -19-27FEB13-26/44

CM073510265 —UN—05SEP07
9. Carefully reposition cylinder barrel/swashplate with
cylinder barrel face on a clean flat surface. Lubricate
and install the output drive shaft subassembly into the
cylinder barrel subassembly.

PW66162,0000859 -19-27FEB13-27/44

10. Install two headless 5/16 inch cap screws, five to six
inches long into the swashplate to use as guides.
Aligning the pin in the housing with the notch in the
swashplate, carefully slide the housing over the output
drive shaft/swashplate/cylinder barrel subassembly.

CM073510266 —UN—05SEP07
Continued on next page PW66162,0000859 -19-27FEB13-28/44

TM100419 (02APR13) 70-25-51 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=415
Hydraulic Motors

11. Holding the cylinder barrel subassembly carefully in


position in the housing, reposition the motor on its
side. Remove the headless cap screws that were
used as guides.

CM073510267 —UN—05SEP07
PW66162,0000859 -19-27FEB13-29/44

12. Install new sealing washers on the two swashplate cap


screws. Install the cap screws into the swashplate.
Tighten to 27—33 N·m (20—24 lb.-ft.).

CM073510268 —UN—05SEP07
PW66162,0000859 -19-27FEB13-30/44

13. Carefully reposition and support the motor on its


mounting flange. Support the output shaft in a slightly
raised position. Using a press or bearing cone driver
(Z), install the end cover bearing cone (17) onto the
output shaft (1). The bearing cone must seat against

CM073510269 —UN—19MAR08
the shoulder of the output shaft.

Continued on next page PW66162,0000859 -19-27FEB13-31/44

TM100419 (02APR13) 70-25-52 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=416
Hydraulic Motors

14. Install two dowel pins (14) and gasket (13) on end
cover (2).

CM073510270 —UN—19MAR08
PW66162,0000859 -19-27FEB13-32/44

15. Lubricate and install bearing shims (16) and bearing


cup (18) into end cover (2).

CM073510271 —UN—19MAR08
PW66162,0000859 -19-27FEB13-33/44

16. You must check the end play of the output drive
shaft subassembly. Install the end cover (2) without
installing either valve (3) or bearing plates (15). This
eliminates spring tension against the output shaft.
17. Install cap screws into the end cover (2), slowly and

CM073510272 —UN—05SEP07
evenly tighten them. On models 33 / 39 / 46 torque
the cap screws to 53 N·m (39 lb.-ft.) on models 54 / 64
torque to 85 N·m (63 lb-ft).

Continued on next page PW66162,0000859 -19-27FEB13-34/44

TM100419 (02APR13) 70-25-53 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=417
Hydraulic Motors

18. Place and support the motor assembly on the end


cover (2). Gently tap the output shaft (1) inward with a
hammer. Install a magnetic base indicator (A) on the
mounting flange with the gauge on the output shaft
end. Using a pair of pliers to grip the output shaft as

CM073510273 —UN—05SEP07
low as possible, pry upward to determine the shaft end
play. The indicator must read 0.002—0.007 inches
(.05 to 0.17 mm) shaft end play. If the end play is
incorrect, adjust by adding or removing shims under
the bearing cup (18) located in the end cover (2).

PW66162,0000859 -19-27FEB13-35/44

NOTE: There are two types of shaft seals. Depending


on the date of manufacture, either type seal may
have been used. A unit MUST be serviced with
the same type of seal as was originally installed.
The seals are not interchangeable.

CM073510274 —UN—05SEP07
19. After adjusting the end play, reposition the motor on
its mounting flange and remove the end cover (2).
Install two dowel pins into the face of the cylinder
barrel subassembly. Freely lubricate the bearing plate
with dowel pins and install it on to the cylinder barrel
subassembly.

PW66162,0000859 -19-27FEB13-36/44

20. Lubricate the O-ring seal of the stationary seal


subassembly, and then install the seal.

CM073510275 —UN—19MAR08

Continued on next page PW66162,0000859 -19-27FEB13-37/44

TM100419 (02APR13) 70-25-54 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=418
Hydraulic Motors

21. Install spacer (22) into housing (4), then using snap
ring pliers, install retainer ring (23).

CM073510276 —UN—19MAR08
PW66162,0000859 -19-27FEB13-38/44

22. Install valve plate dowel pin in the face of the end
cover. Using petroleum jelly, lightly coat the side of
the valve plate (15) that will be facing the end cover
(2). Jelly assists in holding the valve plate during
assembly. Install valve plate (15) over bearing cup

CM073510277 —UN—19MAR08
(18), aligning it with the dowel pins.

PW66162,0000859 -19-27FEB13-39/44

23. Holding the valve plate (15) firmly in position, install


the end cover (2) on housing (4).
24. Install the cap screws (5) and (6) into end cover (2).
Tighten them slowly and evenly. Torque the cap screws
CM073510278 —UN—19MAR08

in a star pattern. Model 33 /39 /46 should be torqued


to 53 N·m (39 lb.-ft.). Models 54 /64 should be torqued
to 85 N·m (63 lb.-ft.). Torque each cap screw a second
time to compensate for gasket compression set.

Continued on next page PW66162,0000859 -19-27FEB13-40/44

TM100419 (02APR13) 70-25-55 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=419
Hydraulic Motors

25. Install O-rings and back-up rings on valve block (3).

CM073510279 —UN—19MAR08
PW66162,0000859 -19-27FEB13-41/44

NOTE: Be careful not to damage the O-rings and back-up


rings. Use petroleum jelly to hold O-rings and
back-up rings in place during block installation.

26. The high-pressure ports require an O-ring (A) and

CM073510280 —UN—19MAR08
back-up ring (B) . The O-ring (A) comes on first, then
the back-up ring (B). The curved side of the ring goes
towards the O-ring.

PW66162,0000859 -19-27FEB13-42/44

27. Position the valve block (3) on end cover (2). Install
four hex bolts (7). Torque bolts to 38 N·m (28 lb.-ft.).

CM073510281 —UN—19MAR08

Continued on next page PW66162,0000859 -19-27FEB13-43/44

TM100419 (02APR13) 70-25-56 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=420
Hydraulic Motors

28. Install the gauge port plugs (24) and torque to 22 N·m
(16 lb.-ft.). Install the two high pressure relief valves
and torque to 34 N·m (25 lb.-ft.).

CM073510282 —UN—19MAR08
PW66162,0000859 -19-27FEB13-44/44

TM100419 (02APR13) 70-25-57 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=421
Hydraulic Motors

Cooling Package Motor

CM073510333 —UN—11SEP07

Continued on next page PW66162,000085A -19-26FEB13-1/16

TM100419 (02APR13) 70-25-58 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=422
Hydraulic Motors

1— Front Cover 6— Key 11— Seal (4 used) 17— Check Valve (2 used)
2— End Cover 7— Pin (2 used) 12— Seal (4 used) 18— Washer (4 used)
3— Housing 8— Thrust Plate (2 used 13— Seal 19— Washer
4— Gear Assembly 9— Snap Ring 14— Seal (2 used) 20— Nut
5— Cap Screw (4 used) 10— Seal (2 used) 15— Spacer
16— Spacer
PW66162,000085A -19-26FEB13-2/16

Disassemble
1. Place the motor in a vise with drive shaft pointing
downward.
NOTE: Marked lines aid in assembly.

CM073510334 —UN—11SEP07
2. Mark a line across all motor sections.
3. Remove cap screws (5) and washers (18) from end
cover (2).

2— End Cover 18— Washers (4 used)


5— Cap Screws (4 used)

CM073510335 —UN—19MAR08
PW66162,000085A -19-26FEB13-3/16

NOTE: If necessary, pry cover to remove. Be careful


not to damage the machined surfaces. Pins (7),
if used, can remain in either end cover (2) or
housing (3). Do not remove pins.

CM073510336 —UN—19MAR08
4. Remove end cover (2).

2— Cover 7— Pins (2 used)


3— Housing

Continued on next page PW66162,000085A -19-26FEB13-4/16

TM100419 (02APR13) 70-25-59 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=423
Hydraulic Motors

5. Remove thrust plate (8), housing (3), gear assembly


(4), and remaining thrust plate from front cover (1).

1— Front Cover 4— Gear Assembly


3— Housing 8— Trust Plate (2 used)

CM073510337 —UN—19MAR08
PW66162,000085A -19-26FEB13-5/16

6. Place front cover (1) in a vise with mounting flange


upward.
7. Remove snap ring (9) using a pair of snap ring pliers.

CM073510338 —UN—19MAR08
1— Front Cover 9— Snap Ring

Continued on next page PW66162,000085A -19-26FEB13-6/16

TM100419 (02APR13) 70-25-60 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=424
Hydraulic Motors

8. Remove spacers (16 and 15) and seal (13) from front
cover (1).
9. Clean and inspect all parts for wear or damage,
replace if necessary.

CM073510339 —UN—19MAR08
10. Replace thrust plates (8) if they are scored, eroded,
or pitted.
11. Check center of the thrust plates where gears mesh.
Erosion here indicates oil contamination. Pitted thrust
plates indicate cavitation or oil aeration. Discolored
thrust plates indicate overheating from insufficient oil.
12. Pins (7) must be replaced if either the pin or pin hole
is damaged. If damage is observed, both pin and
housing must be replaced. 1— Front Cover 15— Spacer
13— Seal 16— Spacer

PW66162,000085A -19-26FEB13-7/16

Assemble
1. Place front cover (1) in a vise with mounting flange
upward.
NOTE: Replacement is necessary only if parts

CM073510340 —UN—19MAR08
are damaged.
Peen check valves in place at both ends of
screwdriver slot and around edges.

2. Examine check valves (17). Ensure that check valves


are firmly installed. If necessary, remove with a
screwdriver.

1— Front Cover 17— Check Valves (2 used)

PW66162,000085A -19-26FEB13-8/16

NOTE: Coat outer edge of seal and its bore with


non-hardening gasket sealant. Lubricate seal
lip with petroleum jelly.
Install seal with metal side upward.

3. Using an appropriate driver, install seal (13) into front CM073510341 —UN—19MAR08

cover (1).
4. Wipe off excess sealant.

1— Front Cover 13— Seal

Continued on next page PW66162,000085A -19-26FEB13-9/16

TM100419 (02APR13) 70-25-61 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=425
Hydraulic Motors

5. Install spacers (15 and 16) into front cover (1).


6. Using snap ring pliers, install snap ring (9).

1— Front Cover 15— Spacer

CM073510342 —UN—19MAR08
9— Snap Ring 16— Spacer

PW66162,000085A -19-26FEB13-10/16

CM073510343 —UN—19MAR08
7. Lubricate and install new seals (14) into grooves in 8. Place housing onto front cover (1) and tap with a
each side of housing (3). soft-headed hammer until it rests tightly against front
cover.
NOTE: Be sure that seals (4) remain in place
during installation.
PW66162,000085A -19-26FEB13-11/16

9. Lubricate and install seals (10), (11), and (12) into the
grooves located in thrust plates (8).

8— Trust Plate (2 used) 11— Seal (4 used)


10— Seal (2 used) 12— Seal (4 used)

CM073510344 —UN—19MAR08

Continued on next page PW66162,000085A -19-26FEB13-12/16

TM100419 (02APR13) 70-25-62 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=426
Hydraulic Motors

NOTE: Housing shown removed from front cover for clarity.

10. Carefully install one thrust plate (8) through housing


(3) and into place onto front cover (1).

CM073510345 —UN—19MAR08
1— Front Cover 8— Trust Plate
3— Housing

PW66162,000085A -19-26FEB13-13/16

11. Lightly lubricate drive shaft from gear assembly (4).


NOTE: Avoid damaging seal (13).

12. Install drive shaft through front cover (1) Rotate and

CM073510347 —UN—19MAR08
position shaft until integral gear rests against thrust
plate.
13. Install remaining gear from gear assembly.
14. Install remaining thrust plate assembly (8) over
journals of gear assembly (4).

1— Front Cover 4— Gear Assembly


3— Housing 8— Thrust Plate Assembly

PW66162,000085A -19-26FEB13-14/16

NOTE: Ensure that housing seals remain in position.

15. Install end cover (2). Align pins with the holes in
housing (3).

CM073510348 —UN—19MAR08
16. Tap end cover lightly in the center to engage pins.

2— End Cover 3— Housing

Continued on next page PW66162,000085A -19-26FEB13-15/16

TM100419 (02APR13) 70-25-63 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=427
Hydraulic Motors

17. Install new washers (18) and cap screws (5). Torque
to specification.

1— Front Cover 5— Cap Screw (4 used)


2— End Cover 18— Washer (4 used)

CM073510349 —UN—19MAR08
3— Housing

PW66162,000085A -19-26FEB13-16/16

TM100419 (02APR13) 70-25-64 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=428
Hydraulic Motors

Disassemble and Assemble Secondary Extractor Rotate Motor

CM073510283 —UN—12SEP07

1— Cap Screw 6— Commutator Plate 11— Key 16— Seal


2— Cover 7— Manifold 12— Shaft 17— Washer
3— Seal 8— Rotor 13— Bearing 18— Housing
4— Seal Ring 9— Plate 14— Thrust Washer 19— Bearing
5— Commutator Ring 10— Link 15— Bearing 20— Seal

Continued on next page PW66162,000085F -19-26FEB13-1/42

TM100419 (02APR13) 70-25-65 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=429
Hydraulic Motors

Suggested Tools • Torque Wrench — lb.-ft. (N·m)


• Sockets: 1/2 or 9/16 in. thin wall
• Clean, petroleum-based solvent • Allen Sockets: 3/16 and 3/8 in.
• Emery paper • Adjustable Crescent Wrench
• Vise with soft jaw • SAE 10W40 SE or SF oil
• Air pressure source • Special Bearing Mandrel
• Arbor Press • Feeler Gauge 0.005 in. (.13 mm)
• Screw Driver • Blind Hole Bearing Puller
• Masking Tape • Corrosion Resistant Grease
• Breaker Bar
PW66162,000085F -19-26FEB13-2/42

Disassemble
1. Clamp motor housing mounting flange in a soft jaw
vise, with shaft pointing downward. Mark a line on the
housing as shown to aid in assembly.

CM073510284 —UN—26MAR08
PW66162,000085F -19-26FEB13-3/42

2. Remove cap screws (1).

CM073510285 —UN—26MAR08
Continued on next page PW66162,000085F -19-26FEB13-4/42

TM100419 (02APR13) 70-25-66 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=430
Hydraulic Motors

3. Inspect cap screws for damaged threads, or sealing


rings under cap screw head. Replace damaged cap
screws.

CM073510286 —UN—26MAR08
PW66162,000085F -19-26FEB13-5/42

4. Remove end cover (2) and O-ring seal (4). Discard


O-ring.

CM073510287 —UN—12SEP07
PW66162,000085F -19-26FEB13-6/42

5. Clean end cover (2) with solvent and blow dry with
compressed air. Inspect end cover for cracks and cap
screw head recess for good sealing surfaces. Replace
end cover as necessary.

CM073510288 —UN—26MAR08

Continued on next page PW66162,000085F -19-26FEB13-7/42

TM100419 (02APR13) 70-25-67 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=431
Hydraulic Motors

NOTE: A polished pattern (not scratches) on the


cover from rotation of commutator ring (5) is
normal. Discoloration would indicate excess fluid
temperature, thermal shock, or excess speed.

CM073510289 —UN—26MAR08
6. Remove commutator plate (6). Inspect the plate for
cracks or burrs.

PW66162,000085F -19-26FEB13-8/42

7. Remove commutator ring (5) and seal ring (3).


Remove the seal ring from the commutator ring, using
an air hose to blow air into the ring groove until the
seal ring is lifted out. Once the seal ring is removed,
discard it. Inspect the commutator ring for cracks,

CM073510290 —UN—26MAR08
burrs, wear, or scoring. If any of these conditions exist,
replace the commutator plate (6) and commutator ring
(5) as a matched set.

CM073510291 —UN—26MAR08
Continued on next page PW66162,000085F -19-26FEB13-9/42

TM100419 (02APR13) 70-25-68 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=432
Hydraulic Motors

NOTE: The manifold is constructed of plates bonded


together to form an integral component not subject
to further disassembly for service. Compare
configuration of both sides of the manifold
to ensure that same surface is reassembled

CM073510292 —UN—26MAR08
against the rotor set.

8. Remove manifold (7) and inspect for cracks and


surface scoring. Replace the manifold if any of these
conditions exist. A polished pattern on the ground
surface from commutator ring or rotor rotation is
normal. Remove and discard the sealing rings (4) that
are on both sides of the manifold.

PW66162,000085F -19-26FEB13-10/42

9. Remove rotor (8) and wear plate (9) together to retain


the rotor set in its assembled form, maintaining the
same rotor vane to stator contact surfaces.

CM073510293 —UN—26MAR08
PW66162,000085F -19-26FEB13-11/42

NOTE: Rotor set (8) components can become


disassembled during service procedures.
Marking the surface of rotor and stator that is
facing upward, before removal for the motor
ensures correct assembly.

CM073510294 —UN—26MAR08
10. Drive link (10) can come away from coupling shaft (12)
with the rotor set and wear plate. If necessary, shift the
rotor set on wear plate to remove drive link from rotor
and wear plate. Inspect rotor set in its assembled form
for nicks and scoring on any surface. Check for broken
or worn splines. If rotor set requires replacement, the
complete rotor set must be replaced as a set. Inspect
the wear plate for cracks and scoring. Discard seal
ring (4) that is between the rotor set and wear plate.
Continued on next page PW66162,000085F -19-26FEB13-12/42

TM100419 (02APR13) 70-25-69 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=433
Hydraulic Motors

11. Place rotor set (8) and wear plate (9) on a flat surface
and center rotor in the stator so that two rotor lobes
(180 degrees apart) and a roller vane centerline are on
the same stator centerline. Check rotor lobe-to-roller
vane clearance with a feeler gage at this common

CM073510295 —UN—26MAR08
centerline. If there is more than 0.005 inches (0.13
mm) of clearance, replace the rotor set.

PW66162,000085F -19-26FEB13-13/42

12. Remove drive link (10) from coupling shaft (12) if it


was not removed with the rotor set and wear plate.
13. Inspect the drive link for cracks, worn or damaged
splines. No end play should be observed between

CM073510296 —UN—26MAR08
mating spline parts.
14. Remove and discard seal ring (4) from housing (18).

PW66162,000085F -19-26FEB13-14/42

15. Check exposed portion of coupling shaft (12) to ensure


that all rust and corrosion have been removed. Clean
with emery cloth if necessary.
16. Remove key (11).

CM073510297 —UN—26MAR08

Continued on next page PW66162,000085F -19-26FEB13-15/42

TM100419 (02APR13) 70-25-70 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=434
Hydraulic Motors

NOTE: Minor shaft wear in the seal area is permissible.


If wear exceeds 0.020 inches (0.51 mm)
diametrically, replace coupling shaft.

NOTE: A slight “polish” is permissible in the shaft

CM073510298 —UN—26MAR08
bearing area. Anything more would require
coupling shaft replacement.

17. Remove coupling shaft (12), by pushing on the output


end of the shaft. Inspect coupling shaft bearing
and seal surface for nicks, grooves, severe wear,
corrosion, and discoloration.
18. Inspect for damaged or worn internal and external
splines or keyway. Replace the coupling shaft if
necessary.
19. Remove and discard seal (4) from housing (18).

CM073510299 —UN—26MAR08
PW66162,000085F -19-26FEB13-16/42

20. Remove thrust bearing (15) and thrust washer (14).


21. Inspect for wear and corrosion. Be sure that all rollers
are in place in the thrust bearing.

CM073510300 —UN—26MAR08
Continued on next page PW66162,000085F -19-26FEB13-17/42

TM100419 (02APR13) 70-25-71 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=435
Hydraulic Motors

22. Remove and discard seal (16) and back up washer


(17) from housing (18).

CM073510301 —UN—26MAR08
PW66162,000085F -19-26FEB13-18/42

23. Remove housing (18) from the vise, invert it and


remove and discard seal (20). A blind hole bearing
or seal puller is required.

CM073510302 —UN—26MAR08
PW66162,000085F -19-26FEB13-19/42

24. Inspect housing (18) assembly for cracks, the


machined surfaces for nicks, burrs, and corrosion.
Remove burrs that can be removed without changing
dimensional characteristics. Inspect tapped holes for
thread damage. If the housing is defective in these

CM073510303 —UN—26MAR08
areas, discard the housing assembly.

Continued on next page PW66162,000085F -19-26FEB13-20/42

TM100419 (02APR13) 70-25-72 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=436
Hydraulic Motors

NOTE: Position of bearings/bushing (13) in relation to


the housing wear plate surface and the depth or
location of bearing/bushing (19) in relation to the
beginning of bearings/bushing counter bore must be
measured and noted before removal. This aids in

CM073510304 —UN—26MAR08
the correct assembly of new bearings/bushings.

25. Inspect bearing/bushings (19) and (13) and if they are


captured in the housing cavity the thrust washer (14)
and thrust bearing (15). The bearing rollers must be
firmly retained in the bearing cages, but must rotate
and orbit freely. All rollers and thrust washers must
be free of corrosion.

PW66162,000085F -19-26FEB13-21/42

26. If the bearings, bushing or thrust washers must


be replaced use a suitable size bearing puller to
remove bearing/bushing (19) and (13) from housing
(18) without damaging the housing. Remove thrust
washers (14) and thrust bearing (15) if they were

CM073510306 —UN—26MAR08
previously retained in the housing by bearing (13).

CM073510307 —UN—26MAR08
Continued on next page PW66162,000085F -19-26FEB13-22/42

TM100419 (02APR13) 70-25-73 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=437
Hydraulic Motors

Assemble
Replace all seals and seal rings with new ones each
time you reassemble the motor. Lubricate all seals and
seal rings with clean hydraulic oil before assembly.

CM073510308 —UN—26MAR08
Clean all parts in solvent and blow dry with compressed
air. Remove any paint from mating surfaces, ports, and
sealing areas of end cover, commutator set, manifold set,
and wear plate housing.
NOTE: Bearing mandrel must be pressed against the
lettering end of the bearing shell. Take care that
the housing bore is square with the press base and
the bearing/bushing is not cocked when pressing
a bearing/bushing into the housing.
If the bearing mandrel specified is not available
and alternate methods are used to press in
bearing/bushing (13) and (19), the bearing/bushing

CM073510309 —UN—26MAR08
depth specified must be achieved to insure
adequate bearing support and correct relationship
to adjacent components when assembled.

IMPORTANT: Bearing/bushings (13) and (19) must


be discarded if removed.

1. If housing (18) bearings were removed, thoroughly


coat and pack a new outer bearing/bushing (19) with
clean corrosion resistant grease recommended. Using
the appropriate sized bearing mandrel, install new 0.151—0.161 inches (3.84—4.09 mm) from the end
bearing/bushing into counter bore at mounting flange of bearing counter bore.
end of the housing. Install bearing/bushing to a depth
PW66162,000085F -19-26FEB13-23/42

2. The inner housing bearing/bushing (13) can now


be pressed into its counter bore in housing (18)
flush to 0.03 inch (.76 mm) below the housing wear
plate contact face. Use the opposite end of the
bearing mandrel that was used to press in the outer

CM073510310 —UN—26MAR08
bearing/bushing (19).

Continued on next page PW66162,000085F -19-26FEB13-24/42

TM100419 (02APR13) 70-25-74 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=438
Hydraulic Motors

3. Lubricate and install seal (20) into housing (18) outer


bearing counter bore. Seal (20) must be pressed in
until its flange is flush against the housing.

CM073510311 —UN—26MAR08
CM073510312 —UN—26MAR08
PW66162,000085F -19-26FEB13-25/42

4. Clamp housing mounting flange into a soft-jawed vise


with coupling shaft bore downward.

CM073510313 —UN—26MAR08
Continued on next page PW66162,000085F -19-26FEB13-26/42

TM100419 (02APR13) 70-25-75 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=439
Hydraulic Motors

5. Assemble a new back up washer (17) and new seal


(16) with the seal lip facing toward the inside motor.
Now, install them into their respective counter bores
in housing (18).

CM073510314 —UN—26MAR08
CM073510315 —UN—11SEP07
Continued on next page PW66162,000085F -19-26FEB13-27/42

TM100419 (02APR13) 70-25-76 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=440
Hydraulic Motors

6. Assemble thrust washer (14) then thrust bearing (15).

CM073510316 —UN—26MAR08
CM073510317 —UN—11SEP07
PW66162,000085F -19-26FEB13-28/42

7. Apply masking tape around the splines or keyway


shaft (12) to prevent damage to the seal.
CM073510318 —UN—26MAR08

Continued on next page PW66162,000085F -19-26FEB13-29/42

TM100419 (02APR13) 70-25-77 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=441
Hydraulic Motors

IMPORTANT: Outer bearing (19) is NOT lubricated


by hydraulic system oil. Be sure that
bearing is thoroughly lubricated with
recommended grease.

CM073510319 —UN—26MAR08
NOTE: A 102 tube is included in each seal kit.
The coupling shaft (12) is flush or just below the
housing wear plate surface when properly installed.

8. Be sure that a generous amount of clean corrosion


resistant grease has been applied to the lower (outer)
housing bearing/bushing (19). Install the coupling
shaft (12) into housing (18) seating against the thrust
bearing (15) in the housing.
PW66162,000085F -19-26FEB13-30/42

NOTE: Two alignment studs installed finger tight into


housing (18) cap screw holes, approximately
180 degrees apart, aids in assembly and
alignment of components.

CM073510320 —UN—26MAR08
9. Apply a small amount of grease to a new seal ring (4)
and insert it into the housing (18) seal ring groove.

PW66162,000085F -19-26FEB13-31/42

NOTE: Use lines marked on coupling shaft and drive


link at disassembly to assemble drive link splines
into position into coupling shaft spline.

10. Install drive link (10) with the long splined end

CM073510321 —UN—26MAR08
downward into coupling shaft (12). Engage drive link
splines with coupling shaft splines.

Continued on next page PW66162,000085F -19-26FEB13-32/42

TM100419 (02APR13) 70-25-78 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=442
Hydraulic Motors

11. Assemble wear plate (9) over the drive link (10) and
alignment stubs onto the housing (18).

CM073510322 —UN—26MAR08
PW66162,000085F -19-26FEB13-33/42

12. Lubricate and install a new seal ring (4) into groove on
wear plate side of rotor set.

CM073510323 —UN—26MAR08
PW66162,000085F -19-26FEB13-34/42

NOTE: If necessary, remove one alignment stud out of


the housing (18) temporarily to assemble rotor
set (8) or manifold (7) over drive link.

NOTE: Rotor set counter bore side must be down against

CM073510324 —UN—26MAR08
wear plate for drive link clearance and to maintain
the original rotor – drive link spline contact. A rotor
set without a counter bore and that was not etched
before assembly can be reinstalled using the drive
link spline pattern on the rotor splines if apparent, to
determine which side was down. The rotor set seal
ring groove faces toward the wear plate (9).

13. Install rotor set (8) onto wear plate (9) with rotor
counter bore and seal ring downward. Engage the
splines of rotor with drive link splines.
Continued on next page PW66162,000085F -19-26FEB13-35/42

TM100419 (02APR13) 70-25-79 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=443
Hydraulic Motors

NOTE: The manifold (7) is made up of several plates


bonded together permanently to form an integral
component. The manifold surface that must contact
the rotor set has its series of irregular shaped
cavities on the largest circumference or circle around

CM073510325 —UN—26MAR08
the inside diameter. The polished impression left on
the manifold by the rotor set is another indication
of which surface must contact the rotor set.

14. Lubricate and install new seal ring (4) into the groove
in rotor set that contacts side of manifold (7).

PW66162,000085F -19-26FEB13-36/42

NOTE: Be sure that the correct manifold surface


is against the rotor set.

15. Install manifold (7) over alignment studs, drive link


(10), and onto rotor set.

CM073510326 —UN—26MAR08
PW66162,000085F -19-26FEB13-37/42

16. Lubricate and install a new seal ring (4) into groove
exposed on manifold.

CM073510327 —UN—26MAR08

Continued on next page PW66162,000085F -19-26FEB13-38/42

TM100419 (02APR13) 70-25-80 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=444
Hydraulic Motors

17. Install commutator plate (6) over alignment studs onto


the manifold.

CM073510328 —UN—26MAR08
PW66162,000085F -19-26FEB13-39/42

18. with flat side upward, lubricate and install a new seal
ring (3) into commutator ring (5).
19. Install commutator ring over the end of drive link (10)
and onto manifold (7) with seal ring side upward.

CQ280284 —UN—19MAR08
CM073510329 —UN—26MAR08
Continued on next page PW66162,000085F -19-26FEB13-40/42

TM100419 (02APR13) 70-25-81 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=445
Hydraulic Motors

20. Lubricate and install a new seal ring (4) into end cover
(2).
21. Install end cover over alignment studs and onto the
commutator set.

CQ280283 —UN—19MAR08
CM073510330 —UN—26MAR08
Continued on next page PW66162,000085F -19-26FEB13-41/42

TM100419 (02APR13) 70-25-82 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=446
Hydraulic Motors

22. Install cap screws (1) into open holes in end cover.
23. Remove alignment studs and install remaining end
cover cap screws.
24. Using an alternating pattern, tighten end cover cap
screws to specification.

CQ280285 —UN—20MAR08
Specification
Secondary Extractor
Rotate Motor End Cover
Cap Screws—Torque....................................................................32 N·m
(24 lb.-ft.)

CM073510331 —UN—26MAR08
CQ280282 —UN—19MAR08
CM073510332 —UN—26MAR08

PW66162,000085F -19-26FEB13-42/42

TM100419 (02APR13) 70-25-83 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=447
Hydraulic Motors

Repair Fixed Displacement Ground Drive


Motor (Track Harvester)
Service instructions familiarize you with position of each
part, methods for disassembly and assembly, and the
care and use of this motor.
To facilitate the repair of this motor, and before any work is
done, we suggest that you first read all of the repair steps.
The first requirement for good maintenance of any
hydraulic equipment is cleanliness. Make sure that you
perform all repair work in a clean area. It is important to
air blast all parts and wipe them with a clean, lintless cloth
before assembly.

CM053510252 —UN—24MAR08
Use caution in gripping all parts before installation, to
be certain they were not damaged in shipment. Change
all seals, O-rings, and gaskets whenever the motor is
repaired. Close all parts of the hydraulic components with
cap and plugs, when a repair is being done.
Fill up hydraulic components with clean system oil before
start-up.
Seal Replacement
1. Tape the shaft splines and remove the circlip and pry
off the cover.
2. Inspect the cover, shaft seal located in the cover and
the drive shaft.
3. Remove the old shaft seal from the cover.
4. Press in the shaft seal ring, to the correct position,
with a suitable sleeve.
5. If the shaft is deeply grooved, insert a shim behind the
seal to reposition the seal on the shaft.

CM053510253 —UN—24MAR08
6. Lubricate and install a new O-ring. Ensure that it is a
snug fit. Grease the shaft seal and install the cover.
7. Install the circlip using a punch.
8. Using a punch, make sure that the circlip is well seated
by tapping on one end of the circlip.
9. Mark the position of the cover plate. Remove the bolts
that retain the cover plate assembly.
A—Seal C—Grooves
B—Shim

Continued on next page PW66162,0000860 -19-28FEB13-1/2

TM100419 (02APR13) 70-25-84 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=448
Hydraulic Motors

10. Twist the port plate on the locating pin and lift off the
cover plate assembly. Note the position of the locating
pin to the valve plate.
11. Inspect the O-ring groove and the valve plate. Lightly
grease a new O-ring and install into valve plate groove.

CM053510254 —UN—16AUG05
12. Remove the motor flushing valve bolts from the cover
plate assembly and remove the valve.
13. Remove O-rings and install new lightly greased
O-rings.
14. Install the motor flushing valve onto the cover plate
assembly. Install the bolts and torque to 10 N·m (7.4
lb.-ft.).
15. Install the cover plate to its original position. Install the 5. If pistons are changed, they should only be replaced
bolts and torque to 86 N·m (63.4 lb.-ft.). as a complete set. When changing other components,
recalibration is required.
Disassemble
6. The cylinder block and control plate must be replaced
1. Tape the splines on shaft and mark position of the as a set.
cover plate assembly.
Assemble
2. Remove bolts from the cover plate. Remove cover
plate and control plate. 1. Insert the center pin with retaining ring. Correctly fit
the retaining plate.
3. Carefully remove the cylinder. Do not damage it in
any way. 2. Apply Thread Lock and Sealer (Medium Strength)
sparingly to bolt only.
4. Remove the circlip and front cover.
3. Heavily grease and install the spring pad and Belleville
5. Remove the shims. washers as shown. Make sure that all parts are
6. Using a puller, remove the rotary group as a complete installed in their correct position.
unit. 4. Install the pistons in their bores.
7. Remove rotary group retaining plate. The bolts are 5. Press the pistons firmly into the cups while holding the
held by Loctite. cylinder block in a central position. Swivel the cylinder
Clean and Inspect block to maximize the angle.

1. Inspect the drive shaft for corrosion or erosion. 6. Make sure that a new shaft seal has been installed.
Check for damage to the splines and traces of wear 7. Heat the housing to 80 °C (176 °F) and install it over
scratches. Make sure that bearing cups are free from the rotating group, until the housing stops.
2. Inspect the piston, center pin, and retaining plate for 8. Turn the motor over and install the shims.
scratches, wear and pitting.
9. If the shaft is deeply grooved, insert a shim behind
3. Inspect the cylinder bores for scratches and wear. the seal.
Check the cylinder block and control plate for cracks,
scratches, and unevenness. It should have a minimum 10. Install a new O-ring, ensure that it is a snug fit. Grease
hardness of 700 HV10. the O-ring and lips of the shaft seal and install the
cover.
4. Check for damage or wear where the bearings fit into
the housing. 11. Install the circlip using a punch and make sure that it
is well seated.
PW66162,0000860 -19-28FEB13-2/2

TM100419 (02APR13) 70-25-85 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=449
Hydraulic Motors

Variable Displacement Ground Drive Motor Exploded View (Optional)

CM002500259 —UN—12JUL00

Continued on next page PW66162,000098D -19-27FEB13-1/2

TM100419 (02APR13) 70-25-86 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=450
Hydraulic Motors

1— Ring-Distance 18— Bearing 38— Bolt 59— O-ring


2— Ring Kit-Piston 19— Pin 39— Plug 60— Ring
3— Shaft Assembly 20— Plate-Bearing 40— O-ring 61— Plug
4— O-ring 21— Valve-Segment 41— Bolt 62— Bolt
5— O-ring 22— Gasket-End Cap 42— O-ring 63— Filter-Screen
6— Housing-Bearing 23— Pin 43— Cover-Piston 64— O-ring
7— Ring-Retaining 24— Housing 44— Bolt 65— Orifice
8— O-ring 25— Ring-Seal 45— Plug 66— Nut-Seal
9— Seal-Lip 26— Lever-Feedback 46— O-ring 67— Cap
10— Carrier-Seal 27— Bolt 47— O-ring 68— Plug
11— Bolt 28— Bolt 48— Plug 69— O-ring
12— O-ring 29— Piston-Servo 49— O-ring 70— Bolt
13— Housing-Motor 30— Nut-Seal Lock 50— Spring 71— Plug
14— Shaft-Synch 31— Bolt 51— Guide-Spring 72— Orifice
15— Roller 32— O-ring 52— Piston 73— Spool
16— Pin-Support 33— Bolt 53— Guide-Spring 74— Plug
17— Block-Cylinder 34— Nut 54— Spring 75— Relief-Charge
35— O-ring 55— Seat-Spring 76— Spring
36— O-ring 56— Spring 77— Poppet
37— Bolt 57— Seat-Spring
58— Bushing Assy
PW66162,000098D -19-27FEB13-2/2

TM100419 (02APR13) 70-25-87 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=451
Hydraulic Motors

Repair Variable Displacement Ground Drive


Motor (Wheel Harvester)
Replace Shaft Seal

CM073510350 —UN—19MAR08
CM002500263 —UN—12JUL00
CM073510351 —UN—19MAR08

CM073510352 —UN—19MAR08
6— Bearing Housing 7— Retaining Ring 8— O-Ring
10— Seal Carrier

IMPORTANT: Absolute cleanliness is essential of shaft seal requires removal of the motor
when working with hydraulic components. from final drive.
Contamination can result in serious damage
or inadequate operation. Clean all parts with 1. Remove and discard outer O-ring (12) from bearing
solvent and blow dry with compressed air. housing (6).
Avoid damage to machined surfaces when 2. Remove retaining ring (7) from bearing housing.
clamping parts in a vise.
NOTE: Do not damage bearing housing bore or shaft
Replace all seals, O-rings, and gaskets during seal carrier removal.
whenever motor is repaired. Cap and plug
all open hoses and fittings. 3. Carefully remove seal carrier (10) from bearing
housing.
NOTE: Lip seals can be replaced without major
disassembly of motor. However, replacement 4. Remove O-ring (8) from bearing housing.
Continued on next page PW66162,0000862 -19-26FEB13-1/23

TM100419 (02APR13) 70-25-88 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=452
Hydraulic Motors

5. Remove and discard seal (9) from seal carrier (10).


6. Inspect seal carrier for damage or nicks.
7. Inspect seal contact area on shaft for rust, wear, or
contamination.

CM073510353 —UN—19MAR08
9— Seal 10— Seal Carrier

CM073510354 —UN—12SEP07
Continued on next page PW66162,0000862 -19-26FEB13-2/23

TM100419 (02APR13) 70-25-89 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=453
Hydraulic Motors

8. Lubricate and install new O-ring (8) into the groove of


bearing housing (6).
NOTE: Apply a sealant to outside surface of the seal
prior to installation into seal carrier. This prevents

CM073510355 —UN—19MAR08
leaks caused by damage during installation.

9. Install seal (9) into seal carrier (10).


NOTE: Wrapping shaft splines protects seal from damage.

10. Using transparent tape, wrap splines of shaft (3).


NOTE: Prior to assembly, lubricate the interior surface
of seal with petroleum jelly.

11. Install carrier assembly onto shaft and into bore of


bearing housing.
12. Install retainer ring (7) and outer O-ring (12).

CM073510356 —UN—19MAR08
3— Shaft 9— Seal
6— Bearing Housing 10— Seal Carrier
7— Retaining Ring 12— Outer O-Ring
8— O-Ring

CM073510357 —UN—19MAR08
Continued on next page PW66162,0000862 -19-26FEB13-3/23

TM100419 (02APR13) 70-25-90 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=454
Hydraulic Motors

Disassemble Cartridge

CM073510358 —UN—12SEP07

1— Distance Spacer Ring 4— O-ring 7— Retaining Ring


3— Shaft Assembly 5— O-ring 11— Cap Screw
6— Bearing Housing 13— Motor Housing
Continued on next page PW66162,0000862 -19-26FEB13-4/23

TM100419 (02APR13) 70-25-91 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=455
Hydraulic Motors

1. Remove and discard O-ring (12).


2. Remove retaining ring (7)..
3. Remove seal carrier (10), seal (9), and O-ring (8) from
shaft assembly (3).

CM073510359 —UN—19MAR08
3— Shaft Assembly 9— Seal
6— Bearing Housing 10— Seal Carrier
7— Retaining Ring 12— O-Ring
8— O-Ring

PW66162,0000862 -19-26FEB13-5/23

4. Remove cap screws (11).


5. Separate bearing housing (6) from motor housing (13).

6— Bearing Housing 13— Motor Housing

CM073510360 —UN—19MAR08
11— Cap Screw

CM073510361 —UN—19MAR08
Continued on next page PW66162,0000862 -19-26FEB13-6/23

TM100419 (02APR13) 70-25-92 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=456
Hydraulic Motors

6. Remove O-rings (4 and 5) from bearing housing (6).


7. Remove spacer ring (1).

1— Spacer Ring 5— O-Ring

CM073510362 —UN—19MAR08
4— O-Ring 6— Bearing Housing

CM073510363 —UN—19MAR08
PW66162,0000862 -19-26FEB13-7/23

8. Press shaft assembly (3) out of bearing housing (6),


taking care not to damage the shaft, piston sockets,
and speed sensor ring (if installed).

CM073510364 —UN—19MAR08
Continued on next page PW66162,0000862 -19-26FEB13-8/23

TM100419 (02APR13) 70-25-93 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=457
Hydraulic Motors

9. Remove inner ring (7) from bearing housing (6).

CM073510365 —UN—19MAR08
PW66162,0000862 -19-26FEB13-9/23

Disassemble and Assemble Housing Assembly

CM073510366 —UN—19MAR08
24— End Cover Housing 26— Feed Back Lever 28— Lock Screw 61— Plug
25— Seal Ring 27— Pointed Set Screw 29— Servo Piston
Continued on next page PW66162,0000862 -19-26FEB13-10/23

TM100419 (02APR13) 70-25-94 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=458
Hydraulic Motors

1. Remove plug (61) from end cap (24).


2. Remove lock screw (28) and pointed set screw (27).
3. Remove feedback lever (26) through the port in end
cap.

CM073510367 —UN—19MAR08
24— End cap 28— Lock Screw
26— Feedback Lever 61— Plug
27— Pointed Set Screw

CM073510368 —UN—19MAR08
CM073510369 —UN—19MAR08
Continued on next page PW66162,0000862 -19-26FEB13-11/23

TM100419 (02APR13) 70-25-95 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=459
Hydraulic Motors

CM073510370 —UN—19MAR08
24— End cap 25— Seal
29— Servo Piston

4. Remove servo piston (29) from end cap (24).


7. Replace servo piston and end cap if necessary.
5. Remove and discard seal (25) from servo piston.
6. Inspect servo piston bore in end cap for damage or
wear.
Continued on next page PW66162,0000862 -19-26FEB13-12/23

TM100419 (02APR13) 70-25-96 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=460
Hydraulic Motors

1. Lubricate and install seal (25) onto servo piston (29).


NOTE: End of servo piston with seal is located
opposite the multifunction block/control mounting
surface of the end cap.

CM073510371 —UN—19MAR08
2. Lubricate and install servo piston into end cap (24).

24— End cap 29— Servo Piston


25— Seal

CM073510372 —UN—19MAR08
Continued on next page PW66162,0000862 -19-26FEB13-13/23

TM100419 (02APR13) 70-25-97 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=461
Hydraulic Motors

CM073510374 —UN—19MAR08
NOTE: Off set of feedback lever must be located away
from the multifunction block control of end cap.

3. Install feedback lever (26) into the servo piston (29)


through the port in end cap housing (24).

CM073510373 —UN—19MAR08
4. Install pointed set screw (27) so that point of screw
enters groove (A) in feedback lever. Do not tighten
the set screw at this time.

A—Groove 29— Servo Piston


24— End Cap 27— Pointed Set Screw
26— Feedback Lever

Continued on next page PW66162,0000862 -19-26FEB13-14/23

TM100419 (02APR13) 70-25-98 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=462
Hydraulic Motors

CM073510375 —UN—19MAR08
5. Install plug (61) into end cap.
NOTE: A 1.06” (26.9 mm) diameter rod with the
end machined perpendicular to its axis may
be inserted through the valve sleeve bore in

CM073510367 —UN—19MAR08
the end cap housing to align the fork while
tightening the cone point set screw.

6. Tighten pointed set screw (27) to specification.


Specification
Ground Drive
Motor (Wheel
Harvester) Pointed Set
Screw—Torque................................................................................5 N·m
(44 lb.-in.)

7. Install and tighten lock screw (28) to specification.


Specification
Ground Drive Motor
(Wheel Harvester) Lock
Screw—Torque.............................................................................6.2 N·m
(55 lb.-in.)
Continued on next page PW66162,0000862 -19-26FEB13-15/23

TM100419 (02APR13) 70-25-99 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=463
Hydraulic Motors

Reconditioning and Replacement of Shaft Assembly

CM053510150 —UN—21JUL05
A—Speed Sensor Ring C—Synchronizing Shaft Insert E—Bearing H—Spring Seat
B—Piston Assemblies D—Bearing F— Bearing Retaining Nut
G—Seal Area

There is an optional magnetic speed sensor ring (A) that is NOTE: If the bearing adjustments for used bearings are
pressed into a machined surface of the output shaft flange. incorrect or if used bearings must be replaced, a
NOTE: Do not damage the magnetic speed sensor ring. complete shaft assembly including pistons and
new bearings must be installed.
Check the seal area of the shaft (G) and the output splines
for damage or wear. Inspect the synchronizing shaft Check the piston assemblies (B) for damage and wear. It
insert (C) and the spring seat (H) for wear. The internal is normal for the piston balls to be tight in their sockets.
spring must not be damaged. These parts are retained The piston sockets are retained in the output shaft by an
by three hardened steel pins pressed into blind holes in interference press fit.
the synchronizing shaft insert (C), and are not individually NOTE: If a piston(s) must be replaced, this entire
serviceable. assembly, including pistons and new bearings,
Inspect shaft bearings (D and E) for wear and roughness. must be installed.
Check that the bearing retaining nut (F) is firmly staked
to the output shaft, and that no noticeable looseness is The replacement output shaft assembly includes pistons
present in the bearings (D and E). and bearings.
Continued on next page PW66162,0000862 -19-26FEB13-16/23

TM100419 (02APR13) 70-25-100 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=464
Hydraulic Motors

Reconditioning and Replacement of Bearing Plate,


Valve Segment, and Cylinder Block

CM073510376 —UN—12SEP07
17— Cylinder Block 20— Bearing Plate 21— Valve Segment
PW66162,0000862 -19-26FEB13-17/23

CM073510377 —UN—12SEP07
1. Inspect the running (bronze) surface of the bearing
plate (20) for damage and excessive wear. The
sealing surfaces must be free from scratches and
nicks. The locating pinholes must not be worn.

Continued on next page PW66162,0000862 -19-26FEB13-18/23

TM100419 (02APR13) 70-25-101 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=465
Hydraulic Motors

2. Inspect the valve segment (21) for damage or wear on


the sealing surfaces. Inspect the spindle (B) for wear.

CM073510378 —UN—12SEP07
PW66162,0000862 -19-26FEB13-19/23

3. Check the spindle in the valve segment (21) by


measuring distance (A). If the dimension is not within
1.28” (32.6 mm) to 1.29” (32.8 mm), it indicates that
the spindle has moved in the valve segment and the
assembly must be replaced.

CM073510379 —UN—12SEP07
PW66162,0000862 -19-26FEB13-20/23

4. Inspect the cylinder block assembly (17) for wear or


damage. The bearing plate (20) must be free from
scratches or nicks and the holes for the bearing plate
locating pins must not be worn. The races for the
synchronizing shaft rollers must not be worn. If the

CM073510380 —UN—12SEP07
cylinder block (17) requires replacement, remove the
bearing using a suitable puller.

Continued on next page PW66162,0000862 -19-26FEB13-21/23

TM100419 (02APR13) 70-25-102 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=466
Hydraulic Motors

5. Press the new bearing (D) into the cylinder block using
a suitable press pin. Press the bearing (D) into the
cylinder block until it is located the proper distance
below the plate surface. Distance (B) should be 1.101”
(27.97 mm) and distance (C) should be 0.45” + 0.01”

CM073510381 —UN—12SEP07
(11.75 + 0.25 mm).

PW66162,0000862 -19-26FEB13-22/23

Piston Ring Reconditioning and Replacement

CM053510151 —UN—21JUL05
A—Radial identification mark B—The spherical surface of the
located on this side of piston piston ring must conform to
ring. the spherical shape of the
piston.

A small pair of retaining ring pliers may facilitate the A radial identification mark provided on the outer side of
removal of the piston rings from the pistons. the piston rings must NOT overlap each other.
Install new piston rings onto the pistons.
IMPORTANT: Fill motor with clean hydraulic
NOTE: When installing new spherical piston rings, oil before start up.
make sure that the spherical surface conforms
to the shape of the piston.
PW66162,0000862 -19-26FEB13-23/23

TM100419 (02APR13) 70-25-103 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=467
Hydraulic Motors

TM100419 (02APR13) 70-25-104 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=468
Group 30
Accumulators
Special Tools
For more information, or to order tools referenced in this
group, see the SERVICEGARD™ online tool catalog or
your John Deere dealer.
SERVICEGARD is a trademark of Deere & Company
PW66162,00009CA -19-19MAR13-1/1

Specifications
Item Measurement Specification

Base Cutter Accumulator Charge Pressure 2 758 kPa


(27.6 bar)
(400 psi)
Crop Divider Accumulator Charge Pressure 1 379 kPa
(13.8 bar)
(200 psi)
Accumulator Internal Hex Plug Torque 20 N·m
(15 lb.-ft.)
Topper Accumulator Charge Pressure 6 550 kPa
(65.5 bar)
(950 psi)
Elevator Accumulator Charge Pressure 8 274 kPa
(82.7 bar)
(1200 psi)
PW66162,0000991 -19-15FEB13-1/1

TM100419 (02APR13) 70-30-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=469
Accumulators

Charge Crop Divider and Base Cutter


Accumulators
SPECIAL TOOL NEEDED:
• Nitrogen Accumulator Service Kit
Used to service nitrogen accumulators.

TS281 —UN—23AUG88
Tool Number—JDG11007

CAUTION: Escaping fluid or gas from systems


with pressurized accumulators that are used
in air conditioning, hydraulic, and air brake
systems can cause serious injury. Extreme
heat can cause the accumulator to burst, and
pressurized lines can be accidentally cut. Do
not weld or use a torch near a pressurized
accumulator or pressurized line.
Relieve pressure from the pressurized system

T8130000586 —UN—05FEB13
before removing accumulator.
Relieve pressure from the hydraulic system
before removing accumulator. Never attempt
to relieve hydraulic system or accumulator
pressure by loosening a fitting. To relieve
hydraulic pressure; completely lower crop
dividers and base cutter. Repeat the “lower
command” two or three times to ensure crop
dividers and base cutter is fully lowered.
Accumulators cannot be repaired.

NOTE: Right-hand base cutter accumulator shown.


Procedure for left-hand base cutter and crop

T8130000588 —UN—05FEB13
divider accumulators are similar.

1. Park machine on level surface.


2. Lower topper, base cutter, elevator, and crop dividers.
3. Shut off engine and remove key.
4. Clean accumulator and surrounding area.

CAUTION: Pressure MUST be relieved in floating A—Cap B—Internal Hex Plug


crop divider valve before servicing crop divider
accumulator. (See Remove and Install Floating
Crop Divider Valves in Section 70, Group 15 hex plug can allow pressurized nitrogen to escape
for pressure release procedure.) and eject internal hex plug from accumulator
causing serious injury to you or others.
5. For floating crop divider valve accumulators, relieve
pressure. IMPORTANT: Before connecting JDG11007 Nitrogen
Accumulator Service Kit to accumulator,
6. Remove cap (A). slightly loosen accumulator internal hex plug
to avoid damage to service kit.
CAUTION: Internal hex plug is under high
pressure. Fully loosening or removal of internal 7. Loosen accumulator internal hex plug.
Continued on next page PW66162,0000845 -19-28FEB13-1/2

TM100419 (02APR13) 70-30-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=470
Accumulators

IMPORTANT: Use only dry nitrogen to charge


accumulator. Oxygen or other combustible
gases can damage oil piston seal and
accumulator.
Be sure that all service kit valves are closed
before installation. If checking pressure only,
DO NOT install nitrogen charge hose. This could
give false reading on pressure gauge.

8. For checking accumulator (D), install JDG11007


Nitrogen Accumulator Service Kit1 to accumulator.

T8130000587 —UN—05FEB13
9. Use ratchet (A) to open accumulator valve (E).
Accumulator charging pressure is indicated by
pressure gauge (C). If charging pressure is too low,
the accumulator must be charged with nitrogen.
10. The accumulator may be charged by opening the gas
cocks (B). If the accumulator is not connected to an
external nitrogen source under pressure, pressure is
reduced by opening knurled screw (F).
NOTE: When charging an accumulator that has no A—Ratchet D—Accumulator
B—Gas Cocks (2 used) E—Accumulator Valve
initial gas charge, allow 20—30 minutes for the C—Pressure Gauge F— Knurled Screw
gas temperature to stabilize. When charging an
accumulator that has an existing gas charge, allow
5—10 minutes for gas temperature to stabilize.
Then, check charging pressure. 12. Close gas cocks and accumulator valve.
13. Remove service kit and tighten accumulator hex plug
11. Adjust accumulator charge pressure to specification. to specification.
Specification
Specification
Base Cutter Accumulator
Accumulator Internal Hex
Charge—Pressure.................................................................... 2 758 kPa
Plug—Torque.................................................................................20 N·m
(27.6 bar)
(15 lb.-ft.)
(400 psi)
Crop Divider Accumulator 14. Install cap.
Charge—Pressure.................................................................... 1 379 kPa
(13.8 bar)
(200 psi)
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,0000845 -19-28FEB13-2/2

TM100419 (02APR13) 70-30-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=471
Accumulators

Charge Topper and Elevator Accumulators


SPECIAL TOOLS NEEDED:
• Regulator
Used to connect dry nitrogen bottle to JDG10976
Nitrogen Accumulator Service Kit.

TS281 —UN—23AUG88
Tool Number—JT05711
• Nitrogen Accumulator Service Kit
Used to service nitrogen accumulators.
Tool Number—JDG10976

CAUTION: Escaping fluid or gas from systems


with pressurized accumulators that are used
in air conditioning, hydraulic, and air brake
systems can cause serious injury. Extreme
heat can cause the accumulator to burst, and
pressurized lines can be accidentally cut. Do
not weld or use a torch near a pressurized

T8130000598 —UN—11FEB13
accumulator or pressurized line.
Relieve pressure from the pressurized system
before removing accumulator.
Relieve pressure from the hydraulic system
before removing accumulator. Never attempt
to relieve hydraulic system or accumulator
pressure by loosening a fitting.
Accumulators cannot be repaired.
A—Cap Screws (2 used) C—Accumulator
Use only dry nitrogen to charge accumulator. B—Cap D—Hose
Never fill accumulator with oxygen. An
explosion could result, if oil and oxygen mix
under pressure. Never charge accumulator
6. Remove nuts, cap screws (A), and accumulator.
over recommended pressure.
7. Remove cap (B).
IMPORTANT: Be sure that all service kit valves
are closed before installation.
Make sure that valve on dry nitrogen bottle is
closed before connecting JT05711 Regulator.

NOTE: Elevator accumulator shown. Procedure for


topper accumulator is similar.

1. Park machine on level surface.


2. Lower topper, base cutter, crop dividers, and elevator.
3. Shut off engine and remove key.
4. Clean accumulator (C) and surrounding area.
5. Disconnect and plug hose (D). Cap accumulator hose
fitting.
Continued on next page PW66162,0000949 -19-15FEB13-1/2

TM100419 (02APR13) 70-30-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=472
Accumulators

8. Connect JT05711 Regulator (C) to dry nitrogen tank


(D).
9. Connect JDG10976 Nitrogen Accumulator Service Kit1
to JT05711 Regulator and to accumulator charging
port using the appropriate adapters.
10. Close regulator output valve (A).
11. Turn gas cock valve (F) attached to accumulator (E)
clockwise.
NOTE: If the accumulator is not connected to an external
nitrogen source under pressure, pressure is
reduced by opening gas cock valve.

T8130000685 —UN—15FEB13
When charging an accumulator that has no initial
gas charge, allow 20—30 minutes for the gas
temperature to stabilize. When charging an
accumulator that has an existing gas charge, allow
5—10 minutes for gas temperature to stabilize.
Then, check charging pressure.

12. Open regulator output valve and read pressure on


output gauge of regulator. Check that pressure is to
specification. A—Regulator Output Valve D—Dry Nitrogen Tank
Specification B—Valve E—Accumulator
C—Regulator F— Gas Cock Valve
Topper Accumulator
Charge—Pressure.................................................................... 6 550 kPa
(65.5 bar)
(950 psi) 17. Charge accumulator until output gauge reads
Elevator Accumulator specification with dry nitrogen tank valve closed.
Charge—Pressure.................................................................... 8 274 kPa
18. Close valve on dry nitrogen tank and regulator output
(82.7 bar)
valve.
(1 200 psi)
19. Turn gas cock valve attached to accumulator
13. If pressure is not to specification, close regulator
counterclockwise.
output valve.
20. Remove all adapters from accumulator.
14. Open valve (B) on dry nitrogen tank.
21. Remove service kit and install cap.
15. Adjust JT05711 Regulator until gauge reads correct
pressure specification. 22. Install accumulator to harvester in reverse order of
removal.
16. Open regulator output valve.
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,0000949 -19-15FEB13-2/2

TM100419 (02APR13) 70-30-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=473
Accumulators

TM100419 (02APR13) 70-30-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=474
Section 80
Miscellaneous
Contents

Page

Group 05—Rails and Platform


Remove and Install Left-Hand
Ladder ....................................................... 80-05-1

TM100419 (02APR13) 80-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 80-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Rails and Platform
Remove and Install Left-Hand Ladder
1. Park machine on level surface, shut off engine, and
remove key.
2. Remove cap screws (A) and U-bolts (B).
3. Remove cap screws (C) from ladder platform (D).
4. Open engine compartment door (F).
5. Remove cap screws (E) and ladder (G).
6. Install in reverse order of removal.

T8130000599 —UN—12FEB13
A—Cap Screw (2 used) E—Cap Screw (2 used)
B—U-Bolts (2 used) F— Engine Compartment Door
C—Cap Screw (5 used) G—Ladder
D—Ladder Platform

T8130000600 —UN—12FEB13
T8130000680 —UN—12FEB13

PW66162,0000981 -19-12FEB13-1/1

TM100419 (02APR13) 80-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=477
Rails and Platform

TM100419 (02APR13) 80-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=478
Section 90
Operator's Station
Contents

Page
Page
Group 05—Air Conditioning System
Other Material................................................ 90-05-1 Cab Door Latch Striker ................................ 90-20-13
Special Tools ................................................. 90-05-1 Cab Tilt Procedure....................................... 90-20-14
Specifications ................................................ 90-05-2 Remove and Install Cab .............................. 90-20-15
Service Parts Kits .......................................... 90-05-2
Service Information........................................ 90-05-3
Hose and Tubing O-Ring
Connection Torques................................... 90-05-3
Proper Refrigerant Handling.......................... 90-05-4
R-134a Refrigerant Precautions .................... 90-05-4
Leak Test With Dye........................................ 90-05-5
Flush Air Conditioning System ...................... 90-05-6
Purge Air Conditioning System...................... 90-05-8
Evacuate Air Conditioning
System....................................................... 90-05-9
Charge Air Conditioning System ................. 90-05-10
Check Refrigerant Oil Charge ..................... 90-05-10
Compressor Oil Information......................... 90-05-11
Determine Correct Oil Charge ..................... 90-05-12
Replace Compressor Relief Valve................ 90-05-13
Remove and Install Compressor ................. 90-05-14
Repair Compressor ..................................... 90-05-15
Repair Compressor Clutch .......................... 90-05-19
Check Clutch Hub Clearance ...................... 90-05-20
Replace Compressor Manifold .................... 90-05-20
Test Shaft Seal Leakage.............................. 90-05-21
Test Volumetric Efficiency............................ 90-05-22
Discharge and Recover Air
Conditioning System................................ 90-05-24

Group 10—System Components


Specifications ................................................ 90-10-1
Replace Receiver Dryer ................................ 90-10-1
Remove and Install Condenser ..................... 90-10-1
Repair Condenser ......................................... 90-10-1
Replace High Pressure Switch ...................... 90-10-2

Group 15—Seats
Remove and Install Instructional
Seat ........................................................... 90-15-1

Group 20—Cab
Specifications ................................................ 90-20-1
Remove and Install Cab
Windshield—Style B .................................. 90-20-1
Remove and Install Cab Outer
Roof—Style B ............................................ 90-20-6
Remove and Install Cab Inner
Roof—Style B ............................................ 90-20-6
Remove and Install Cab
Headliner—Style B .................................. 90-20-10
Remove and Install Cab Door ..................... 90-20-10
Disassemble and Assemble Cab
Door......................................................... 90-20-12

TM100419 (02APR13) 90-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 90-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Air Conditioning System
Other Material
Number Name Use
TY25601 (U.S.) ACC-U-FLUSH II Air Conditioning Used to flush air conditioning system.
System Flush

TY27506 (U.S.) R-134a Refrigerant/PAG Oil Dye Used to locate air conditioning
system leaks.

TY27013 (U.S.) Fluorescent Dye Cleaner Used to remove dye from components.

TY15951 (30 lb.) (U.S.) R-134a Refrigerant Used to service air conditioning
system.

TY22101 (U.S.) PAG Refrigeration Oil Used to lubricate air conditioning


system components.

PW66162,00008E0 -19-11FEB13-1/1

Special Tools
For more information, or to order tools referenced in this
group, see the SERVICEGARD™ online tool catalog or
your John Deere dealer.
SERVICEGARD is a trademark of Deere & Company

PW66162,00009CB -19-19MAR13-1/1

TM100419 (02APR13) 90-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=481
Air Conditioning System

Specifications
Item Measurement Specification

Evacuate System Required Vacuum At Sea Level 98 kPa


(980 mbar)
(29 in. Hg)
Refrigerant Charge 2.27 kg
(5 lb.)
Compressor Oil Charge 230 mL
(7.7 fl. oz.)
Compressor Oil Level 30—45 mL
(1.0 to 1.5 fl. oz.)
Relief Valve Torque 12—16 N·m
(106—142 lb.-in.)
Relief Valve Opening Pressure 3450—4140 kPa
(34.5—41.4 bar)
(500—600 psi)
Discharge Line-to-Air Conditioning Torque 32—40 N·m
Compressor (24—29 lb.-ft.)
Suction Line-to-Air Conditioning Torque 34—42 N·m
Compressor (25—31 lb.-ft.)
Front Housing Bolt Torque 26 N·m
(19 lb.-ft.)
Hub-to-Pulley Clearance 0.35—0.65 mm
(0.014—0.026 in.)
Clutch Shaft Cap Screw Torque 14 N·m
(120 lb.-in.)
Air Conditioning Compressor Torque 26 N·m
Manifold Attaching Cap Screws (19 lb.-ft.)
PW66162,00008E2 -19-09JAN13-1/1

Service Parts Kits • Compressor Clutch Hub And Pulley Kit


The following kits are available through your parts catalog:
• Compressor Clutch Coil Kit
• Compressor Hardware Kit
• Compressor Shaft Seal Kit
PW66162,00008E3 -19-09JAN13-1/1

TM100419 (02APR13) 90-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=482
Air Conditioning System

Service Information IMPORTANT: Prevent refrigerant oil from becoming


FLUSHING: too diluted and shortening compressor
life. Always use a recommended final
Flushing the system or a component is a cleaning process flushing solvent after using a parts cleaning
using a liquid solvent to remove oil and debris. solvent for the primary flush.
When to flush the air conditioning system: Failure to purge the system properly
dilutes flushing solvent.
• The compressor has an internal failure.
• No oil remains in used compressor. Use 0.47 L (1 pt.) of clean solvent for flushing a
• Oil drained from compressor appears or smells serviceable compressor that will be reinstalled on a
overheated. machine.
• System was contaminated with a mixture of refrigerant
oils. PURGING:
• System was left open to the atmosphere long enough Purging the system or a component is a cleaning process
for dirt, moisture, or debris to enter the tubing or
components. using a gas to force liquid from the system. Purging alone
cannot completely remove refrigerant oil from the system.
• System has an internal blockage.
The R-134a system requires a two-step process as follows: When to purge an air conditioning system:

PRIMARY FLUSH: • After flushing system with solvent, to prevent oil dilution.
• System was contaminated with nitrogen or two
IMPORTANT: Use only fresh solvent for the refrigerants.
primary flush. • System was left open to atmosphere and flushing could
not be performed.
Automotive parts cleaning solvent used according to • Installation of new lines, condenser, or evaporator was
applicable guidelines can be utilized for a system primary required.
flush.
EVACUATING:
IMPORTANT: Do Not Use diesel fuel, gasoline, fuel oil,
water, alcohol or any cleaning fluids formulated Evacuating the system is a process to remove air and
for dissolving oil, grease and antifreeze. moisture from the system, by creating a vacuum.
SOLVENTS
FINAL FLUSH:
ACC-U-FLUSH II® Air Conditioning System Flush is
• Use 1.9 L (1/2 gal.) ACC-U-FLUSH II® Air Conditioning the solvent is recommended for flushing air conditioning
System Flush.
systems.
• Review applicable MSDS data for hazard identification
rating. NOTE: New solvent used from a parts cleaning
• Separate the air conditioning system into two circuits tank can be used, providing a final flush with
and follow the flushing procedure listed in this group. ACC-U-FLUSH II® Air Conditioning System
• Recover all used solvents with appropriate flushing Flush is performed. Parts tank solvents do not
equipment. evaporate at temperatures below 60 °C (140
• Purge the air conditioning system with compressed air °F). ACC-U-FLUSH II® Air Conditioning System
for the recommended amount of time specified in the Flush is necessary for the final flush because it
flushing procedure. evaporates quickly and is easily removed.
PW66162,00008E4 -19-09JAN13-1/1

Hose and Tubing O-Ring Connection Torques


Metal Tube Outside Diameter Thread and Fitting Size Torque
N·m (lb.-ft.)
1/4 7/16 14—20 (10—15)
3/8 5/8 14—20 (10—15)
1/2 3/4 33—39 (24—29)
5/8 7/8 35—42 (26—31)
3/4 1-1/16 41—47 (30—35)

PW66162,00008E5 -19-11FEB13-1/1

TM100419 (02APR13) 90-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=483
Air Conditioning System

Proper Refrigerant Handling


The U.S. Environment Protection Agency prohibits Systems containing R-12 refrigerant use different oil than
discharge of any refrigerant into the atmosphere and systems using R-134a. Certain seals are not compatible
requires that refrigerant be recovered using the approved with refrigerant.
recovery equipment.
The difference in the refrigerant oils is that R-12 systems
IMPORTANT: Use correct refrigerant recovery, use a MINERAL BASED OIL. R-134a systems use a
recycling, and charging stations. DO NOT SYNTHETIC OIL called PAG (polyakyleneglycol). These
mix refrigerant, hoses, fittings, components, two oils are NOT COMPATIBLE and MUST NOT be
or refrigerant oils. interchanged.

The recovery, recycle, and charging stations for R-12


and R-134a refrigerants MUST NOT be interchanged.
PW66162,00008E6 -19-09JAN13-1/1

R-134a Refrigerant Precautions

CAUTION: DO NOT allow liquid refrigerant to DO NOT heat refrigerant over 52 °C (125 °F) in a
contact eyes or skin. Liquid refrigerant can closed container. Heated refrigerant will develop
freeze eyes or skin on contact. Wear goggles, high pressure which can burst the container.
gloves, and protective clothing.
Keep refrigerant containers away from heat
If liquid refrigerant contacts eyes or skin, DO sources. Store refrigerant in a cool place.
NOT rub the area. Splash large amounts of
DO NOT handle damp refrigerant container
COOL water on affected area. Go to a physician
with your bare hands. Skin can freeze to
or hospital immediately for treatment.
container. Wear gloves.
DO NOT allow refrigerant to contact open
If skin freezes to container, pour COOL water
flames or very hot surfaces such as electric
over container to free skin. Go to a physician
welding arc, electric heating element, and
or hospital immediately for treatment.
lighted smoking materials.
PW66162,00008E7 -19-09JAN13-1/1

TM100419 (02APR13) 90-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=484
Air Conditioning System

Leak Test With Dye JT02178-5 R-134a Dye Injector.1 Install low-side hose
to outlet of JT02178-5 R-134a Dye Injector.
SPECIAL TOOLS NEEDED:
4. Purge air from low-side hose and dye injector to
• Enhancer Glasses remove air and impurities.
Used to enhance testing dye.
Tool Number—JT02178-4 5. Close both valves on JT02178-5 R-134a Dye
• Ultra Violet Lamp Injector and carefully remove cap. Add R-134a
Used to detect testing dye. Refrigerant/PAG Oil Dye into injector and close cap
Tool Number—JT02178-1 tightly.
• Recovery, Recycling, and Recharging Unit
6. Open dye injector outlet side valve first and then open
Used to service air conditioning system.
Tool Number—JDG10555 inlet valve. Recharging air conditioning system carries
• R-134a Dye Injector dye into system.
Used to inject testing dye. 7. Run harvester with air conditioning on for 15 minutes
Tool Number—JT02178-5 to circulate refrigerant and dye.

CAUTION: Always wear safety glasses when Check For Leaks in System
working with refrigerants. Contact with
refrigerant can cause serious injury. 1. Perform an operational check to be sure that air
conditioning system is functioning properly to circulate
IMPORTANT: Use only approved dye in John Deere dye.
systems, other dyes may not have compatible
oil for R-134a systems. DO NOT allow dye to CAUTION: Light is made for intermittent use
come into contact with vehicle painted surfaces. ONLY. DO NOT hold light switch on for more
Wipe off IMMEDIATELY in case of spillage. than 5 minutes at one time. DO NOT touch lens
end of light when hot. NEVER look directly into
Check for presence of dye in system: light or expose skin. DO NOT operate light with
cracked lens or broken housing. Always wear
If dye has been installed in the system, the receiver dryer JT02178-4 Enhancer Glasses when using light.
should be tagged with a decal.
Turn off sugar cane harvester before
If necessary, add dye to system. testing components.
Add Dye To System
NOTE: Park harvester out of direct sunlight for best results.
IMPORTANT: A minimum of 0.23 kg (0.5 lb.) of
refrigerant must pass through JT02178-5 R-134a 2. Shut off engine and remove key.
Dye Injector when injecting dye. 3. Put on JT02178-4 Enhancer Glasses1 before using
If system is at full charge or unknown, recover light.
a minimum of 0.23 kg (0.5 lb.) of refrigerant 4. Shine JT02178-1 Ultra Violet Lamp1 on components
before attempting to inject dye. to test for leaks. Leaks are indicated by a yellow tint
on components where dye has left system.
1. Perform an operational check on system before trying
to inject dye. 5. Clean area of leak using Fluorescent Dye Cleaner and
recheck to confirm leak is still present.
2. Recover refrigerant as necessary. (See Discharge
and Recover Air Conditioning System in Section 90, 6. Repair air conditioning system as necessary.
Group 05.)
7. Clean area of leak dye.
3. Remove low pressure (Blue) hose from JDG10555
Recovery, Recycling, and Recharging Unit1 and install
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008E8 -19-09JAN13-1/1

TM100419 (02APR13) 90-05-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=485
Air Conditioning System

Flush Air Conditioning System


SPECIAL TOOLS NEEDED: f. Let compressor sit inverted for 3—5 minutes.
• Air Conditioning Flusher g. Repeat previous two steps at least three times.
Used to flush air conditioning system.
Tool Number—JT02075 4. Remove and discard receiver dryer.
• Fitting
5. Flushing can be performed on harvester. Divide
Used to connect caps.
Tool Number—JT02099 system into two circuits:
• Fitting • Condenser, including inlet and outlet hoses. (Steps
Used to connect caps. 6 through 13)
Tool Number—JT02100 • Evaporator, including inlet and outlet hoses. (Steps
• Cap 14 through 30)
Used to cap opening.
Tool Number—JT03194 Flush/Purge Condenser:
• Adapter
IMPORTANT: DO NOT attempt to flush through
Used to connect flusher.
Tool Number—JT02102 compressor or receiver dryer. Flushing through
expansion valve or orifice tube is acceptable if
• Adapter
refrigerant oil has a normal odor and appearance.
Used to connect flusher.
Tool Number—JT03197
6. Connect flusher outlet hose to inlet connection of
• Adapter
compressor discharge line using JT02102 Adapter1
Used to connect flusher.
Tool Number—JT02101 to flush condenser.
• Adapter 7. Attach a return hose and aerator nozzle to receiver
Used to connect flusher. dryer inlet line using JT03197 Adapter1. Put nozzle in
Tool Number—JT03188 container to collect flushing solvent.
1. Discharge system. (See Discharge and Recover Air NOTE: New solvent used from a parts cleaning
Conditioning System in Section 90, Group 05.) tank can be used, providing a final flush with
NOTE: Add flushing solvent to system with JT02075 ACC-U-FLUSH II® Air Conditioning System
Air Conditioning Flusher1. Flush is performed. Parts tank solvents do not
evaporate at temperatures below 60 °C (140
If compressor is being replaced, go to step 4. °F). ACC-U-FLUSH II® Air Conditioning System
Flush is necessary for the final flush because it
2. Remove compressor and measure oil drained from evaporates quickly and is easily removed.
both manifold ports.
8. Fill flusher tank with 4 L (1 gal.) of solvent and fasten
3. Clean compressor as follows: all connections.
IMPORTANT: Keep fluid loss at a minimum. NOTE: Air pressure must be at least 620 kPa (6.2 bar)
ACC-U-FLUSH II® Air Conditioning System (90 psi) for flushing and purging.
Flush evaporates at 85 °F. Keep container lids
on at all times when not in use. 9. Connect a supply line of moisture-free compressed air
or dry nitrogen to flusher air valve.
a. Pour 240 mL (8 fl oz.) of ACC-U-FLUSH II® Air
Conditioning System Flush into suction port and 10. Open air valve to force flushing solvent into condenser
120 mL (4 fl oz.) into discharge port. Plug both circuit. Flusher tank is empty when hose pulsing stops.
ports in compressor manifold, using JT020991 and Additional flushing cycles are required if system is
JT021001 with JT031941 Caps. heavily contaminated with burned oil or metal particles.
b. Turn compressor end for end and roll compressor 11. Continue forcing air through system to purge out
side to side. solvent. Purging the condenser circuit takes 10—12
minutes to thoroughly remove solvent.
c. Remove both plugs from manifold ports and drain
solvent from compressor. 12. Disconnect hose from aeration nozzle to check circuit
for solvent. Hold hose close to a piece of cardboard;
d. Connect battery power to compressor clutch coil. continue purging until cardboard is dry.
Rotate pulley at least five revolutions to move
solvent out of cylinders. 13. Solvent from condenser that is not contaminated
with burnt oil or metal particles can be used to flush
e. Invert compressor, roll to all sides, and drain evaporator. Used solvent can be placed into a shop
thoroughly. parts cleaner.
Continued on next page PW66162,00008E9 -19-09JAN13-1/2

TM100419 (02APR13) 90-05-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=486
Air Conditioning System

Flush/Purge Evaporator: d. After flushing the circuits with ACC-U-FLUSH II®


Air Conditioning System Flush, continue to purge
14. Flush evaporator through expansion valve if oil with shop air through the flushing equipment.
appears normal.
e. Disconnect hose from aeration nozzle to check
15. Connect flusher outlet hose to compressor suction line circuit for solvent. Hold hose close to a piece of
using JT02101 Adapter1. cardboard and continue purging until cardboard is
16. Attach a hose and aerator nozzle to receiver dryer dry.
outlet line using JT03188 Adapter1. Put nozzle in f. After flushing both circuits, put used ACC-U-FLUSH
container to collect flushing solvent. II® Air Conditioning System Flush in a separate,
17. Repeat Steps 8, 9, and 10 to flush evaporator. clean container and cap immediately.

18. Purging the evaporator circuit takes 12—15 minutes NOTE: Identify the container as ACC-U-FLUSH II® Air
to thoroughly remove solvent. Conditioning System Flush). This solvent can
be used to flush additional machines. Dispose
19. If system is contaminated with burned refrigerant oil or of solvent that has an excessive amount of
debris, remove expansion valve to flush evaporator. dilution from parts solvent used for primary
flush. Dispose of solvent in compliance with
20. Disconnect hose from aeration nozzle to check circuit
local and state regulations.
for solvent. Hold hose close to a piece of cardboard;
continue purging until cardboard is dry.
g. Cap system hoses or lines immediately after
21. Reinstall expansion valve. removal of test equipment to prevent moisture from
entering the system.
Final Flush
23. Fasten connections and mounting brackets.
22. Final flush uses the same procedure as primary flush
for condenser and evaporator, except for solvent used. 24. Install a new receiver dryer compatible with R-134a
refrigerant. (See Replace Receiver Dryer in Section
a. Add 1.9 L (0.5 gal.) of ACC-U-FLUSH II® Air 90, Group 10.)
Conditioning System Flush to the flusher tank.
25. Add required oil. (See Determine Correct Oil Charge
b. Connect a supply line of moisture-free air or dry in Section 90, Group 05.)
nitrogen to the flusher valve.
26. Install compressor and connect refrigerant lines to
NOTE: Air pressure must be at least 490 kPa (4.9 bar) manifold.
(70 psi) but not more than 620 kPa (6.2 bar) (90
psi) maximum for final flushing and purging. 27. Connect clutch coil wire and install drive belt.
28. Purge system. (See Purge Air Conditioning System
c. Open the air valve to force flushing solvent into the in Section 90, Group 05.)
condenser or evaporator circuit. Flusher is empty
when hose pulsing stops. Reuse the same solvent
to do both circuits.
NOTE: Only one final flushing cycle is necessary, providing
that another solvent was used prior to the Final Flush.
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008E9 -19-09JAN13-2/2

TM100419 (02APR13) 90-05-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=487
Air Conditioning System

Purge Air Conditioning System 2. Connect Manifold with Gauges suction hose to
SPECIAL TOOL NEEDED: compressor suction port and open valves.

• Manifold with Gauges 3. Connect Manifold with Gauges discharge hose


Used to service air conditioning system. to compressor discharge port and open valve.
Tool Number—JT02051 Disconnect discharge hose from Manifold with Gauges
to allow purging nitrogen to atmosphere.
IMPORTANT: Air compressors used for purging
systems require a water separator. Purging 4. Open nitrogen tank valve and adjust regulator to 275
without a separator adds moisture, creating kPa (2.75 bar) (40 psi). Purge system for 2 minutes.
hydrofluoric acid when combined with Disconnect nitrogen supply.
refrigerant oil. Acid is corrosive to metal tubing. 5. Evacuate system. (See Evacuate Air Conditioning
System in Section 90, Group 05.)
1. Connect dry nitrogen hose to JT02051 Manifold with
Gauges1 center hose.
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008EA -19-09JAN13-1/1

TM100419 (02APR13) 90-05-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=488
Air Conditioning System

Evacuate Air Conditioning System


SPECIAL TOOL NEEDED:
• Recovery, Recycling, and Recharging Unit
Used to service air conditioning system using R-134a
refrigerant.
Tool Number—JDG10555
1. Park machine on level surface. Shut off engine and
remove key.
2. Open engine compartment door and remove protective

T8120002619 —UN—09JAN13
caps to access air conditioning fittings.
IMPORTANT: To prevent compressor damage, DO
NOT mix R-134a equipment, refrigerant, and
refrigerant oils with R-12 systems. Use only
R-134a Refrigerant Recovery, Recycling,
and Recharging Units.
Use only John Deere approved refrigerants,
lubricants, and flush, or their equivalents.
Substitute refrigerants could contain flammable A—Low-Side Hose (blue) B—High-Side Hose (red)
hydrocarbons. Mixing substitutes with approved
John Deere products can cause contamination
to air conditioning service equipment,
components, and refrigerant supplies. If 98 kPa (980 mbar) (29 in. Hg.) vacuum cannot be
obtained in 15 minutes, test system for leaks. (See
3. Connect JDG10555 Refrigerant, Recovery, and Leak Test With Dye in Section 90, Group 05.) Repair
Recycling Unit1 to machine using the following leaks as necessary.
instructions:
7. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close
• Connect low-side hose (blue) (A) from charging unit low-side and high-side valves.
to low pressure (suction) test port.
8. Turn vacuum pump off.
• Connect high-side hose (red) (B) to high pressure
(discharge) test port. 9. If vacuum decreases more than 3.4 kPa (34 mbar)
(1 in. Hg) in 5 minutes, there is a leak in the system.
IMPORTANT: DO NOT run compressor while
Repair as necessary.
evacuating the system.
10. Start the evacuating process.
4. Follow Recovery, Recycling, and Recharging Unit
manufacturer's instructions for discharging system. • Open low and high-side valves.
• Evacuate system for 30 minutes after 98 kPa (980
5. Open low-side and high-side valves on unit. mbar) (29 in. Hg) vacuum is reached.
NOTE: The vacuum specifications listed are for sea level • Close low and high-side valves.
conditions. Subtract 3.4 kPa (34 mbar) (29 in. Hg.) • Stop evacuation.
for each 300 m (1000 ft.) elevation above sea level. 11. Charge system. (See Charge Air Conditioning System
in Section 90, Group 05.)
6. Evacuate system until low-side gauge registers 98
kPa (980 mbar) (29 in. Hg.) vacuum.
Specification
Evacuate
System—Required
Vacuum At Sea Level.................................................................... 98 kPa
(980 mbar)
(29 in. Hg)
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008EB -19-09JAN13-1/1

TM100419 (02APR13) 90-05-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=489
Air Conditioning System

Charge Air Conditioning System


SPECIAL TOOL NEEDED:
• Recovery, Recycling, and Recharging Unit
Used to service air conditioning system.
Tool Number—JDG10555
1. Park machine on level surface. Shut off engine and
remove key.
2. Open engine compartment door and remove protective
caps to access air conditioning fittings.

T8120002619 —UN—09JAN13
IMPORTANT: To prevent compressor damage,
DO NOT mix R-134a equipment, refrigerant,
and compressor oils with R-12 systems.
Use only R-134a Refrigerant Recovery,
Recycling, and Charging units.
Use only John Deere approved refrigerants,
lubricants, and flush, or their equivalents.
Substitute refrigerants can contain flammable
hydrocarbons. Mixing substitutes with approved A—Low-Side Hose (blue) B—High-Side Hose (red)
John Deere products can cause contamination
to air conditioning service equipment,
components, and refrigerant supplies.
5. Evacuate system. (See Evacuate Air Conditioning
3. Connect JDG10555 Recovery, Recycling, and System in Section 90, Group 05.)
Recharging Unit1.
6. Charge air conditioning system. Add R-134a
Connect low-side hose (blue) (A) from charging unit refrigerant until system is charged to specification.
to low pressure (suction) test port. Specification
Connect high-side hose (red) (B) to high pressure Refrigerant—Charge.................................................................... 2.27 kg
(discharge) test port. (5 lb.)

4. Follow Recovery, Recycling, and Recharging Unit


manufacturer's instructions for discharging system.
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008EC -19-11FEB13-1/1

Check Refrigerant Oil Charge


3. Flush complete system with ACC-U-FLUSH II® Air
Remove compressor if a refrigerant leak was detected Conditioning System Flush.
and repaired. (See Remove and Install Compressor in
Section 90, Group 05.) 4. Perform a volumetric efficiency test on compressor to
determine serviceable condition. (See Test Volumetric
NOTE: Refrigerant oil drained from a new compressor Efficiency in Section 90, Group 05.) If compressor is
can be reused. serviceable, pour flushing solvent in manifold ports
and internally wash out old oil.
Drain oil from compressor into an appropriate container
and record amount. 5. Install a new receiver dryer.

If oil drained from a compressor is very black or amount of 6. Install 260 mL (8.8 fl oz.) of PAG Refrigeration Oil in
oil is less than 6 mL (0.2 fl oz.), perform the following: compressor.

1. Remove and discard receiver dryer. 7. Connect all components, evacuate, and charge
system. (See Evacuate Air Conditioning System and
2. Remove, clean, and bench test expansion valve, but Charge Air Conditioning System in Section 90, Group
do not disassemble valve. 05.)
PW66162,00008ED -19-09JAN13-1/1

TM100419 (02APR13) 90-05-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=490
Air Conditioning System

Compressor Oil Information

CAUTION: To avoid possible injury, wear


safety goggles while slowly discharging the
compressor. All new compressors are charged
with a mixture of nitrogen, R-134a refrigerant,

TS266 —UN—23AUG88
and PAG Refrigeration Oil.

IMPORTANT: Use only John Deere approved


refrigerants, lubricants, and flush, or their
equivalents. Substitute refrigerants can
contain flammable hydrocarbons. Mixing
substitutes with approved John Deere
products can cause contamination to air
conditioning service equipment, components,
and refrigerant supplies. Specification
Compressor—Oil
New service part compressors contain 230 mL (7.7 fl. oz.) Charge.......................................................................................... 230 mL
of oil. The amount of oil that cannot be drained is 81 mL (7.7 fl. oz.)
(2.7 fl. oz.). Approximately 60 mL (2.0 fl. oz.) will have
seeped into the cylinders during shipping and storage. The normal operating oil level of a compressor removed
from operation is 30—45 mL (1.0 to 1.5 fl. oz.).
Typically 21 mL (0.7 fl. oz.) of oil covers internal surfaces Specification
of the compressor exposed to refrigerant gas and cannot Compressor—Oil Level...........................................................30—45 mL
be drained. (1.0 to 1.5 fl. oz.)
When 230 mL (7.7 fl. oz.) is installed in a dry compressor,
the oil level will be above the drive shaft.
PW66162,00008EE -19-09JAN13-1/1

TM100419 (02APR13) 90-05-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=491
Air Conditioning System

Determine Correct Oil Charge


SPECIAL TOOL NEEDED:
• Air Conditioning Oil Injector
Used to inject oil into air conditioning system.
Tool Number—JT02129

TS266 —UN—23AUG88
CAUTION: To prevent the risk of injury, always
wear protective goggles and gloves when
working on the air conditioning system.

IMPORTANT: Use care adding refrigerant oil. Too


much oil in the system reduces maximum
cooling capacity. Too little oil results in
poor lubrication of the compressor, leading Evaporator .................................................... 40 mL (1.4 fl. oz.)
to early compressor failure. Condenser .................................................... 40 mL (1.4 fl. oz.)

DO NOT leave air conditioning system Receiver Dryer ............................................ 10 mL (0.35 fl. oz.)
or refrigerant oil containers open. Oil Compressor .................................................. 50 mL (1.7 fl. oz.)
easily absorbs moisture. Hoses ......................................................... 20 mL (0.7 fl. oz.)

DO NOT spill refrigerant oil on acrylic or ABS Compressor:


plastic. Oil deteriorates these materials rapidly.
NOTE: Determine amount of system refrigerant oil charge
Identify refrigerant oil containers and measures prior to installation of compressor.
to eliminate accidental mixing of different oils.
Remove compressor to determine correct refrigerant oil
System: charge if any of the following components listed have
NOTE: If the complete system was purged with all been removed, drained, and flushed.
components in place, the amount of refrigerant If a new compressor is installed, fill with 50 mL (1.7 fl.
oil lost is negligible. oz.) PAG Refrigeration Oil.
If the entire system is disassembled and all lines and Hoses:
components have been discharged and cleaned, add
160 mL (5.4 fl. oz.) PAG Refrigeration Oil to the system NOTE: Equation for figuring amount of oil needed for
after assembly. hose length is 3 mL of oil per 30 cm of hose (0.1
fl. oz. of oil per 1 ft. of hose).
During start-up, add 60 mL (2 fl. oz.) of refrigerant oil to
the low-pressure line to lubricate compressor and bring If any section of hose is removed and flushed, or is
total system to full capacity of 220 mL (7.4 fl. oz.). replaced with a new hose, measure hose length and use
the formula to determine the correct amount of oil to add
Add refrigerant oil charge using JT02129 Air Conditioning to the system.
Oil Injector1.
Components:
Use the following chart as a guide for adding PAG
Refrigeration Oil:
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008EF -19-11FEB13-1/1

TM100419 (02APR13) 90-05-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=492
Air Conditioning System

Replace Compressor Relief Valve

CAUTION: High pressure can exist at discharge


fitting. If pressure is released too rapidly, there
can be considerable discharge of refrigerant
and oil. Wear goggles to protect eyes when

TS266 —UN—23AUG88
replacing compressor relief valve.

1. Discharge system. (See Discharge and Recover Air


Conditioning System in Section 90, Group 05.)
2. Slowly remove relief valve (A) and discard.
NOTE: Relief valve is not serviceable.

3. Install new relief valve and tighten relief valve to


specification.
Specification
Relief Valve—Torque............................................................. 12—16 N·m
(106—142 lb.-in.)

4. Evacuate air conditioning. (See Evacuate Air


Conditioning System in Section 90, Group 05.)
5. Charge system. (See Charge Air Conditioning System
in Section 90, Group 05.)
Specification

T8120002620 —UN—09JAN13
Relief Valve—Opening
Pressure........................................................................ 3450—4140 kPa
(34.5—41.4 bar)
(500—600 psi)

A—Relief Valve

PW66162,00008F0 -19-09JAN13-1/1

TM100419 (02APR13) 90-05-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=493
Air Conditioning System

Remove and Install Compressor


1. Park machine on level surface. Shut off engine and
remove key.
2. Open engine compartment door.
3. Recover refrigerant from system. (See Discharge
and Recover Air Conditioning System in Section 90,
Group 05.)
4. Remove belt (E) from compressor.
5. Disconnect electrical connector (C).
6. Disconnect suction hose (B) and discharge hose (A).

T8120002621 —UN—09JAN13
Cap and plug hoses and fittings.
7. Remove cap screws (D) and compressor.
8. Repair or replace compressor as necessary. (See
Repair Compressor in Section 90, Group 05.)
9. Flush entire air conditioning system. (See Flush Air
Conditioning System in Section 90, Group 05.)
10. Replace receiver dryer. (See Replace Receiver Dryer
in Section 90, Group 10.) A—Discharge Hose D—Cap Screws (3 used)
B—Suction Hose E—Belt
11. Determine correct oil charge of compressor. (See C—Connector
Determine Correct Oil Charge in Section 90, Group 05.)
12. Install compressor in reverse order of removal using • Evacuate and charge system. (See Evacuate Air
the following special instructions: Conditioning System and Charge Air Conditioning
• Tighten discharge and suction hoses to specification. System in Section 90, Group 05.)
Specification IMPORTANT: If a new clutch was installed on
Discharge Line-to-Air compressor, cycle compressor on and off with
Conditioning engine running. Cycle in 1 second intervals for
Compressor—Torque............................................................ 32—40 N·m 5 seconds. Burnish clutch and hub surfaces
(24—29 lb.-ft.) by cycling clutch five times in 5 seconds.
Suction Line-to-Air
Conditioning
Compressor—Torque............................................................ 34—42 N·m
(25—31 lb.-ft.)
PW66162,00009E4 -19-02APR13-1/1

TM100419 (02APR13) 90-05-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=494
Air Conditioning System

Repair Compressor Tool Number—DFRW20


SPECIAL TOOLS NEEDED:
• Lip Seal Protector
Used to protect lip seal during installation.
• Compressor Holding Fixture Tool Number—JDG746
Used to hold compressor.

H63259 —UN—07APR00
A—Rear Pins G—Rear O-Ring L— Front Gasket R—Felt
B—Rear Housing H—Front O-Ring M—Snap Ring S—Front Housing
C—Rear Gasket I— Front Suction Reed Valve N—Lip Seal T— Front Pins (2 used)
D—Rear Discharge Reed Valve J— Front Valve Plate O—Washer (4 used)
E—Rear Valve Plate K—Front Discharge Reed Valve P—Through Bolt (4 used)
F— Rear Suction Reed Valve Q—Felt Seal

1. 4. Inspect valves for an even wear pattern and cylinders


for scoring or excessive wear. Replace compressor if
Clean compressor using solvent PRIOR to necessary.
disassembly.
NOTE: Some cylinder scuffing (light scratches) is normal.
2. Mount compressor on holding fixture and remove
clutch. See Repair Compressor Clutch in Section 90, 5. Remove snap ring (M).
Group 05.)
6. Turn housing over and remove felt seal (Q) and felt
IMPORTANT: Be careful NOT to damage sealing (R) from front housing (S).
surfaces when removing front and rear housings.
7. Remove lip seal (N) from housing using a 5/8 in. OD
3. Disassemble compressor. Discard O-rings, gaskets, driver.
lip seal, snap ring, and through bolts. Replace with
parts from service kits. 8. Wash parts in clean solvent and dry using
moisture-free compressed air.
NOTE: Valve plates, reed valves, cylinders, and
housing are NOT serviceable. Replace complete
compressor if one of these parts fail.
Continued on next page PW66162,00008F2 -19-11FEB13-1/5

TM100419 (02APR13) 90-05-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=495
Air Conditioning System

N42194KP —UN—08FEB99
RW21162 —UN—24JUN92

A—Bushing

IMPORTANT: Only use PAG Refrigeration Oil for


R-134a to lubricate O-rings, gaskets, and lip 11. Install a new snap ring, flat side down.
seals. Other oils could damage the compressor. IMPORTANT: Bushing must be in position before
assembling compressor.
9. Apply PAG Refrigeration Oil to bore of front housing.
10. Install a new lip seal in front housing until it bottoms in 12. Insert bushing (A) into position as shown.
bore.
PW66162,00008F2 -19-11FEB13-2/5

13. Install pins (A) and O-ring (B) in rear housing (C).

A—Pins C—Rear Housing


B—O-ring

N42194FR —UN—26JAN99

Continued on next page PW66162,00008F2 -19-11FEB13-3/5

TM100419 (02APR13) 90-05-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=496
Air Conditioning System

NOTE: The rear valve plate is marked with a “R”


and installed with face upward.

14. Install parts (A—C) over rear cylinder pins.

A—Front Suction Reed Valve C—Front Discharge Reed Valve


B—Front Valve Plate

N42194GP —UN—26JAN99
Continued on next page PW66162,00008F2 -19-11FEB13-4/5

TM100419 (02APR13) 90-05-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=497
Air Conditioning System

H63259 —UN—07APR00
A—Rear Pins G—Rear O-Ring L— Front Gasket R—Felt
B—Rear Housing H—Front O-Ring M—Snap Ring S—Front Housing
C—Rear Gasket I— Front Suction Reed Valve N—Lip Seal T— Front Cylinder Pins (2 used)
D—Rear Discharge Reed Valve J— Front Valve Plate O—Washer (4 used)
E—Rear Valve Plate K—Front Discharge Reed Valve P—Through Bolt (4 used)
F— Rear Suction Reed Valve Q—Felt Seal

15. Install a new rear gasket (C), flat side down, and 21. Remove lip seal protector.
housing (B) on rear cylinder.
22. Install bolts (P) and new washers (O). Uniformly
16. Install front cylinder pins (T) and a new front O-ring tighten bolts, then final tighten to specification.
(H) in front cylinder.
Specification
NOTE: Front valve plate (J) is marked with an "F" Front Housing
and installed with face upward. Bolt—Torque..................................................................................26 N·m
(19 lb.-ft.)
17. Install parts (I—K) over front cylinder pins.
18. Install a new front gasket (L) with flat side downward.
23. Install felt (R) and felt seal (Q) using clutch hub.
19. Place JDG746 Lip Seal Protector1 on shaft and
lubricate with PAG Refrigeration Oil. 24. Install pulley-clutch hub and check clearance. (See
Check Clutch Hub Clearance in Section 90, Group 05.)
20. Install front housing (S) on cylinder.
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008F2 -19-11FEB13-5/5

TM100419 (02APR13) 90-05-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=498
Air Conditioning System

Repair Compressor Clutch


SPECIAL TOOLS NEEDED:
• Compressor Holding Fixture
Used to hold compressor.
Tool Number—DFRW20
• Clutch Spanner Wrench
Used to hold clutch hub stationary.
Tool Number—JDG747
• Puller
Used to remove compressor pulley.
Tool Number—D05277ST
• Pulley Adapter
Used with Puller D05277ST
Tool Number—JDG220

RW21157 —UN—24JUN92
• Jaws
Used with Puller D05277ST
Tool Number—JDG748
• Hub Protector
Used to protect hub during removal.
Tool Number—JDG771
1. Mount compressor on DFRW20 Compressor Holding Clutch Hub
Fixture using two 6 x 1/4 in. eyebolts with nuts. (See
DFRW20—Compressor Holding Fixture in Section
199, Group 05 for fixture instructions.)
F
2. Remove dust cover.
D
3. Hold clutch hub using JDG747 Clutch Spanner
Wrench1 (A).

H65447 —UN—04JAN01
H
4. Remove clutch shaft cap screw (B).
G
5. Remove clutch hub (C).
B E
6. Remove and save shims (H) from hub. C
7. Remove and discard pulley snap ring (D).
8. Remove pulley (E) using either a plastic hammer or
D05277ST Puller1, JDG220 Pulley Adapter1, JDG748 A—JDG747 Compressor E—Pulley
Clutch Spanner F— Clutch Coil Snap Ring
Jaws1, and JDG771 Hub Protector1. B—Clutch Shaft Cap Screw G—Clutch Coil
C—Clutch Hub H—Shim
9. Disconnect clutch coil lead wire. D—Pulley Snap Ring
10. Remove and discard clutch coil snap ring (F).
11. Remove clutch coil (G).
15. Tighten clutch shaft cap screw (B) to specification.
NOTE: Pulley bearing is NOT serviceable.
Specification
Clutch Shaft Cap
12. Check pulley bearing operation. Replace pulley as
Screw—Torque..............................................................................14 N·m
required.
(120 lb.-in.)
13. Install new snap rings (F and D).
14. Apply multipurpose grease to shims (H) and install
in hub (C).
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008F3 -19-11FEB13-1/1

TM100419 (02APR13) 90-05-19 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=499
Air Conditioning System

Check Clutch Hub Clearance


NOTE: Clutch coil is NOT polarity sensitive.

1. Check pulley-to-clutch hub clearance using a dial


indicator. Mount gauge to the pulley as illustrated and
connect a set of jumper wires from compressor leads
to a 12 V battery.
2. Rotate pulley and check clearance in three equally
spaced locations around the clutch hub. Add or
remove shims as required.
Specification
Hub-to-Pulley—Clear-
ance..................................................................................0.35—0.65 mm
(0.014—0.026 in.)

3. Tighten clutch shaft cap screw to specification after


correct clearance is obtained.
Specification
Clutch Shaft Cap
Screw—Torque..............................................................................14 N·m

RW21159 —UN—24JUN92
(120 lb.-in.)

PW66162,00008F4 -19-09JAN13-1/1

Replace Compressor Manifold


When installing manifold (B), lubricate new gasket (C)
with PAG Refrigerant Oil.
Tighten manifold cap screws (A) to specification.
Specification
Air Conditioning
Compressor Manifold
Attaching Cap
Screws—Torque............................................................................26 N·m
(19 lb.-ft.)

A—Hex Head Cap Screw (4 C—Manifold Gasket


used) RW21160 —UN—24JUN92

B—Manifold

PW66162,00008F5 -19-11FEB13-1/1

TM100419 (02APR13) 90-05-20 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=500
Air Conditioning System

Test Shaft Seal Leakage


SPECIAL TOOLS NEEDED:
• Manifold with Gauges
Used to service air conditioning system.
Tool Number—JT02051
• Leak Detector
Used to detect leaks in air conditioning systems.
Tool Number—TIFZX-1
1. Remove front plate from compressor pulley.
2. Remove clutch hub and screw. (See Repair
Compressor Clutch in Section 90, Group 05.)
IMPORTANT: Do not lose inner clutch hub shims.

RW41334A —UN—19DEC97
3. Cap all open fittings on compressor except suction
port (A).
4. Connect Manifold with Gauges1 and container of
TY15951 (30 lb.) Refrigerant1 to suction port of
compressor as shown.
5. Open valves to pressurize compressor.
IMPORTANT: Do not exceed range of low
pressure gauge. A—Suction Port

6. Check the following for leaks using TIFZX-1 Leak


Detector1 or 50-50 mixture of soap and water: • Suction coupler Schrader valve
• Shaft seal If a leak is detected, repair compressor as necessary
• Manifold seal and repeat test.
• Housing seals at front, rear, and midsection of 7. Assemble compressor and add required oil. (See
compressor body Determine Correct Oil Charge in Section 90, Group 05.)
• Relief valve
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008F6 -19-11FEB13-1/1

TM100419 (02APR13) 90-05-21 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=501
Air Conditioning System

Test Volumetric Efficiency


SPECIAL TOOL NEEDED:
• Manifold with Gauges
Used to service air conditioning system.
Tool Number—JT02051
1. Drain oil from compressor and record amount.
2. Remove front cover from compressor pulley.
3. Using a speed wrench and appropriate socket, rotate
drive shaft a minimum of 30 revolutions.
4. Drain remaining oil from compressor and record
amount.
NOTE: If no oil was removed, add 2 oz. of PAG
Refrigeration Oil in suction port. Slowly roll
compressor in each direction at least two
times. Repeat Steps 1—3.

5. Secure compressor in a vise with ports upward.

RW40028A —UN—20AUG98
6. Cap all open fittings on compressor except suction
test port (A).
7. Connect suction hose coupler of JT02051 Manifold
with Gauges1 to suction test port on manifold as shown.
8. Close gauge set suction side valve and open valve
on suction hose coupler.
9. Rotate compressor drive shaft with speed wrench to A—Suction Test Port
obtain peak vacuum on low side gauge. Check for even
suction (no pulsing) while turning wrench at a slow
rate to maintain peak vacuum (25 in. Ha. minimum). seconds, inspect compressor valve plates and cylinder
10. Stop rotating shaft and check “leak down” time. walls for damage.
Compressor should hold peak vacuum for a minimum 11. Open suction port of compressor to atmosphere.
of 3 seconds. If compressor does not hold for 3
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page PW66162,00008F7 -19-09JAN13-1/2

TM100419 (02APR13) 90-05-22 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=502
Air Conditioning System

12. Connect JT02051 Manifold with Gauges1 suction hose


to discharge port (A).
13. Close gauge set suction side valve.
14. Rotate drive shaft no faster than two turns per second
for six turns.
15. Record pressure after six complete turns. Pressure
should be 380 kPa (3.8 bar) (55 psi) minimum.
NOTE: Pressure normally leaks down when rotation stops.

16. Continue to rotate compressor at a uniform speed to


obtain peak pressure. Compression pressure should
increase smoothly and should not vary more than 34
kPa (0.34 bar) (5 psi) at peak pressure. Bleed off
pressure and repeat Steps 13, 14, and 15 four times.
NOTE: Pressure varying more than 34 kPa (0.34 bar)
(5 psi) indicates a leaking reed-valve or piston
seal. Inspect compressor valve plates and cylinder
walls for damage. Repair compressor.

RW40029A —UN—20AUG98
17. Leak test the compressor. (See Test Shaft Seal
Leakage in Section 90, Group 05.)

A—Discharge Port

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008F7 -19-09JAN13-2/2

TM100419 (02APR13) 90-05-23 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=503
Air Conditioning System

Discharge and Recover Air Conditioning


System
SPECIAL TOOL NEEDED:
• Recovery, Recycling, and Recharging Unit
Used to service air conditioning system using R-134a

TS266 —UN—23AUG88
refrigerant.
Tool Number—JDG10555

CAUTION: To prevent the risk of injury, always


wear protective goggles and gloves when
working on the air conditioning system.
Avoid injury. DO NOT remove high pressure
relief valve (A). If removed, the air conditioning
system can rapidly discharge.

IMPORTANT: To prevent compressor damage,


DO NOT mix R-134a equipment, refrigerant,
and refrigerant oils with R-12 systems. Use
only R-134a refrigerant recovery, recycling,
and charging units.

1. Operate air conditioning system for 10 minutes with


engine at 2000 rpm if compressor is operable.
2. Set temperature control for maximum cooling.

T8120002620 —UN—09JAN13
3. Turn blower switch to high.
4. Park machine on level surface. Shut off engine and
remove key.
5. Open engine compartment door and remove protective
caps to access air conditioning fittings.
6. Connect JDG10555 Recovery, Recycling, and
Recharging Unit1 to machine using the following
instructions:
• Connect low-side hose (blue) (B) from charging unit
to low pressure (suction) test port.
• Connect high-side hose (red) (C) to high pressure
(discharge) test port.
7. Follow manufacturer's instructions when using the
Recovery, Recycling, and Recharging Unit.
8. Cap fittings when finished to prevent contamination
from entering system.
T8120002622 —UN—09JAN13

A—Relief Valve C—High-Side Hose (red)


B—Low-Side Hose (blue)

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00008F8 -19-09JAN13-1/1

TM100419 (02APR13) 90-05-24 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=504
Group 10
System Components
Specifications
Item Measurement Specification

Air Conditioning High Pressure Torque 32 N·m


Switch (24 lb.-ft.)
PW66162,0000982 -19-12FEB13-1/1

Replace Receiver Dryer


1. Recover refrigerant from system. (See Discharge
and Recover Air Conditioning System in Section 90,
Group 05.)
NOTE: Receiver dryer is located near condenser
in cooling system package.

2. Open cooling package door.


3. Tag and disconnect refrigerant hoses (A and B). Cap
and plug hoses and fittings.

T8130000681 —UN—12FEB13
4. Remove cap screws (D) and receiver dryer (C).
IMPORTANT: Replace receiver dryer as often as
required to prevent moisture from contaminating
the system. Always install a new receiver dryer
when the system is opened up for service, or
when the compressor shaft seal leaks. Be sure
to keep the new receiver dryer capped until
installing. Install receiver dryer last.
A—Refrigerant Hose C—Receiver Dryer
5. Check and add compressor oil as necessary. (See B—Refrigerant Hose D—Cap Screws (2 used)
Compressor Oil Information in Section 90, Group 05.)
6. Install new receiver dryer.
9. Charge air conditioning. (See Charge Air Conditioning
7. Connect refrigerant hoses. System in Section 90, Group 05.)
8. Evacuate air conditioning system. (See Evacuate Air
Conditioning System in Section 90, Group 05.)
PW66162,0000938 -19-12FEB13-1/1

Remove and Install Condenser Condenser-Fuel Cooler in Section 20, Group 20 for
removal and installation of air conditioning condenser-fuel
Fuel cooler is integrated into the air conditioning system cooler.)
condenser. (See Remove and Install Air Conditioning
PW66162,0000935 -19-22JAN13-1/1

Repair Condenser

CAUTION: Avoid personal injury. Fins on 4. Place refrigerant container in a pail of water heated
condenser are sharp. Use protective clothing. to a maximum of 125 °F (51.5 °C), which gives a
pressure of 1200 kPa (12 bar) (170 psi.).
1. If contamination appears in the condenser, flush entire
system. 5. Connect refrigerant supply to the Schrader-type valve.

2. Inspect condenser. Fins must be straight and clean. 6. Open refrigerant container valve and test condenser
for leaks with a leak detector. Replace condenser if a
3. Cap outlet and install a Schrader-type service valve leak is observed. it.
in inlet.
7. Plug or cap openings until ready to install.
PW66162,0000936 -19-11FEB13-1/1

TM100419 (02APR13) 90-10-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=505
System Components

Replace High Pressure Switch


1. Recover refrigerant from air conditioning system. (See
Discharge and Recover Air Conditioning System in
Section 90, Group 05.)
NOTE: High pressure switch is located on high pressure
hose inside engine compartment.

2. Disconnect electrical connector (B).


3. Remove high pressure switch (A).

T8130000682 —UN—12FEB13
4. Replace high pressure switch and tighten to
specification.
Specification
Air Conditioning
High Pressure
Switch—Torque.............................................................................32 N·m
(24 lb.-ft.)

5. Connect electrical connector.


6. Evacuate air conditioning system. (See Evacuate Air A—High Pressure Switch B—Electrical Connector
Conditioning System in Section 90, Group 05.)
7. Charge Air Conditioning System. (See Charge Air
Conditioning System in Section 90, Group 05.)
PW66162,000093A -19-14FEB13-1/1

TM100419 (02APR13) 90-10-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=506
Group 15
Seats
Remove and Install Instructional Seat
1. Park machine on level surface, shut off engine, and
remove key.
2. Disconnect batteries. (See Battery Disconnect Switch
in Section 40, Group 05.)

N56385 —UN—22MAR01
3. Pull upward and remove storage bin (A).
4. Pull upward on knob (B) and remove seat back (C).

A—Storage Bin C—Seat Back


B—Knob

PW66162,000089E -19-09NOV12-1/3

NOTE: It is not necessary to remove screws (B)


around load center.

5. Remove screws (A) and pull instructional seat (C)


forward slightly.

N56386 —UN—29MAR01
A—Screws (8 used) C—Instructional Seat
B—Screws (4 used)

PW66162,000089E -19-09NOV12-2/3

6. Remove nuts (A) and set load center (B) with mounting
bracket aside.
7. Remove instructional seat from cab.
8. Inspect instructional seat and replace as necessary.
9. Install instructional seat in reverse order of removal.

N56383 —UN—29MAR01
A—Nuts (4 used) B—Load Center

PW66162,000089E -19-09NOV12-3/3

TM100419 (02APR13) 90-15-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=507
Seats

TM100419 (02APR13) 90-15-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=508
Group 20
Cab
Specifications
Item Measurement Specification

Windshield Clamps Approximate Spacing 600 mm


(24 in.)
Inner Cab Roof Weight 31 kg
(69 lb)
Striker Plate Socket Head Screws Torque 72 N·m
(53 lb.-ft.)
PW66162,0000984 -19-12FEB13-1/1

Remove and Install Cab Windshield—Style B


Do not attempt to install a replacement windshield unless
you are qualified in glass replacement.
The original factory adhesive used to bond the windshield
in place is a urethane type. When installing this glass,

H83632 —UN—07JUN05
use an adhesive method that is compatible with urethane
adhesive. These types of adhesive ARE NOT available
from John Deere.
Refer to the manufacturer's adhesive/primer label and the
SAFETY DATA SHEET for safety precautions.
Curing time of this type adhesive depends on weather
conditions (heat and humidity). After installing this glass,
it is preferred that the combine not be operated during harvester, for the first 48 hours use caution to avoid bumps
the cure time. However, if it is necessary to operate the and shock loads, such as when crossing a border, etc.
PW66162,0000895 -19-09NOV12-1/12

NOTE: Make sure wipers are in the parked position


before starting removal procedures.

1. Remove cap screws (A) and sun visor (B).

A—Cap Screw (3 used) B—Sun Visor

H63271 —UN—30MAR00

Continued on next page PW66162,0000895 -19-09NOV12-2/12

TM100419 (02APR13) 90-20-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=509
Cab

2. Remove front headliner (A) from cab by pulling back


and down on front edge of headliner to clear tabs (B).
3. Remove headliner. (See procedure in this group.)

A—Tab (5 used) B—Headliner

H63270 —UN—30MAR00
PW66162,0000895 -19-09NOV12-3/12

4. Remove nuts (A and B) and wiper arm (C).

A—Nut C—Wiper Arm


B—Nut

H83549 —UN—23MAY05
PW66162,0000895 -19-09NOV12-4/12

5. Remove cap screws (A) and grab handle (B).

A—Cap Screw (3 used) B—Grab Handle

H83552 —UN—23MAY05

Continued on next page PW66162,0000895 -19-09NOV12-5/12

TM100419 (02APR13) 90-20-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=510
Cab

6. Remove boot (A), nut (B) and plate (C).

A—Boot C—Plate
B—Nut

H83553 —UN—23MAY05
PW66162,0000895 -19-09NOV12-6/12

7. Disconnect connector (B).


8. Push wiper motor assembly (A) towards roof and
remove wiper motor assembly.

A—Wiper Motor Assembly B—Connector

H83554 —UN—23MAY05
PW66162,0000895 -19-09NOV12-7/12

9. Remove cap screws (A) and lower cab panel.

A—Cap Screw (3 used)

H76826 —UN—08MAY03

Continued on next page PW66162,0000895 -19-09NOV12-8/12

TM100419 (02APR13) 90-20-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=511
Cab

10. Remove front and rear inner roof mounts (A and B).

A—Front Inner Roof Mount (2 B—Rear Inner Roof Mount (2


used) used)

H83557 —UN—23MAY05
Front Cab Mount

H83558 —UN—23MAY05
Rear Cab Mount
PW66162,0000895 -19-09NOV12-9/12

11. Lift inner cab roof (A) up enough to gain access to


windshield and support front of inner cab roof with
blocks (B).

A—Inner Cab Roof B—Blocks

H83561 —UN—23MAY05
Continued on next page PW66162,0000895 -19-09NOV12-10/12

TM100419 (02APR13) 90-20-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=512
Cab

NOTE: The H128392 clips in the windshield kit will be


required for the purpose of installing and securing the
windshield during adhesive cure time of 2.5 hours.

12. Completely remove all of old windshield glass. Also


remove the two old clamps from head panel (two new
clamps (B) are supplied with the glass). Try to leave
a layer of the old adhesive on the frame. However, if
you remove all of the old adhesive, leaving bare metal,
use the correct primer to ensure a good bond between
metal and adhesive.
13. Apply a thin coat of adhesive to area (A) on both
clamps (B) provided.

H40068 —UN—10OCT88
14. Slip clamps (B) on windshield as specified (C).
Specification
Windshield
Clamps—Approximate
Spacing....................................................................................... 600 mm
(24 in.)

15. Bend leg (D) up on both clamps.


A—Area for Adhesive C—Clamp Placement
B—Clamp D—Clamp Leg

PW66162,0000895 -19-09NOV12-11/12

IMPORTANT: Edges of glass on both sides must


not contact cab frame.

16. Apply adhesive to cab frame and position new glass B


by pushing it up until the two new brackets (A) contact
the head panel (B).
17. Tighten two clamps attached to cab floor (C).
A E
18. Use nonmetallic shims (D) to hold glass in place.
19. Bend leg (E) up on both clamps to secure glass.
20. Tape sides of glass with duct tape to hold glass in
position.
21. Install all parts.
22. Remove tape after 48 hours.

A—Bracket D—Shims
B—Head Panel E—Clamp Leg
C—Clamp Screw
H67759 —UN—29MAY01

D C

PW66162,0000895 -19-09NOV12-12/12

TM100419 (02APR13) 90-20-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=513
Cab

Remove and Install Cab Outer Roof—Style B


1. Remove screws (A) and washers.
NOTE: Cap screw (C) is longer than cap screw (B).
Note locations to aid in installation.

H83614 —UN—26MAY05
2. Remove cap screws (B and C).
3. Remove communications/CB antenna (D).

A—Screw (12 used) C—Cap Screw


B—Cap Screw D—Communications/CB
Antenna

PW66162,0000896 -19-09NOV12-1/2

4. Lift up on front left-hand side of cab roof to access


antenna (A). Disconnect antenna.
5. Remove cab outer roof.
6. Repair or replace as necessary.
IMPORTANT: Inspect seal along cab outer roof for

H83571 —UN—23MAY05
defects. Replace as needed.

7. Install in reverse order of removal.

A—Antenna

PW66162,0000896 -19-09NOV12-2/2

Remove and Install Cab Inner Roof—Style B


1. Remove cab outer roof. (See procedure in this group.)
2. Remove cab headliner. (See procedure in this group.)
3. Remove nuts (A and B) and wiper arm (C).

H83549 —UN—23MAY05
A—Nut C—Wiper Arm
B—Nut

Continued on next page PW66162,0000897 -19-09NOV12-1/8

TM100419 (02APR13) 90-20-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=514
Cab

4. Remove cap screws (A) and grab handle (B).

A—Cap Screw (3 used) B—Grab Handle

H83552 —UN—23MAY05
PW66162,0000897 -19-09NOV12-2/8

5. Remove boot (A), nut (B) and plate (C).

A—Boot C—Plate
B—Nut

H83553 —UN—23MAY05
PW66162,0000897 -19-09NOV12-3/8

6. Disconnect connector (B).


7. Push wiper motor assembly (A) towards roof and
remove wiper motor assembly.

A—Wiper Motor Assembly B—Connector

H83554 —UN—23MAY05

Continued on next page PW66162,0000897 -19-09NOV12-4/8

TM100419 (02APR13) 90-20-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=515
Cab

8. Remove covers (A) and disconnect speaker wires.


9. Route speaker wires through access hole (B) and into
cab.

A—Cover (2 used) B—Access Hole

H83580 —UN—24MAY05
H83581 —UN—24MAY05
PW66162,0000897 -19-09NOV12-5/8

10. Remove clips (A) from cab roof.

A—Clip (3 used)

H83582 —UN—24MAY05
Continued on next page PW66162,0000897 -19-09NOV12-6/8

TM100419 (02APR13) 90-20-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=516
Cab

CAUTION: HID-Xenon lamps are powered


by 25,000 volts. Do not begin removal of
HID-Xenon lights or ballast unless the lights are
turned off, the engine is turned off, the key is
removed, appropriate eye protection is worn and
connectors to HID-Xenon lights are disconnected.

H83585 —UN—24MAY05
11. Remove screws and connector (A) from front of cab
roof.
12. Disconnect light connectors. Remove light grommets
(B) and pull harness and connectors up through roof.
13. Remove cap screw (G) and clamp.
14. Remove grommet and push antenna wire (F) into cab.
15. Disconnect connectors (D) from ballast.
16. Route main harness on top of cab through access
hole (C) and into cab.

H83586 —UN—24MAY05
17. Remove screw (E) and communications/CB radio
antenna cable.

A—Connector E—Screw
B—Light Grommet (4 used) F— Antenna Wire
C—Access Hole G—Cap Screw
D—Connector (2 used)

PW66162,0000897 -19-09NOV12-7/8

18. Remove front and rear cab mounts (A and B).


19. Disconnect washer hose from tee in front of cab and
remove washer hose (C) from cab roof.

CAUTION: Approximate weight of inner cab


roof is 31 kg (69 lb).

H83557 —UN—23MAY05
Specification
Inner Cab Roof—Weight.................................................................. 31 kg
(69 lb)

20. Remove inner cab roof from combine.


21. Repair or replace inner cab roof as necessary. Front Cab Mount

22. If replacing cab roof, perform the following steps:


• Remove speakers. (See procedure in Section 40,
Group 30.)
• Remove cab lights. (See procedure in Section 40,
Group 25.)

H83596 —UN—26MAY05

Remove ballast. (See procedure in Section 40,


Group 25.)
23. Install in reverse order of removal.

A—Front Cab Mount (2 used) C—Washer Hose


B—Rear Cab Mount (2 used)

PW66162,0000897 -19-09NOV12-8/8

TM100419 (02APR13) 90-20-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=517
Cab

Remove and Install Cab Headliner—Style B


1. Remove screws that attach sunvisor to cab roof (if
equipped).
2. Push up and pull back on forward edge of front
headliner (E) to release from clips. Remove front

H83575 —UN—01JUN05
headliner.
3. Remove rear window trim.
4. Remove coat hook.
5. Move door weatherstrip to access screw (C) and
remove screw.
NOTE: Overhead panel and dome light harnesses
do not need to be disconnected in order A—Overhead Control Panel E—Front Headliner
B—Sound Resonator Cover (2 F— Location
to remove headliner. used) G—Clip (4 used)
C—Screw
6. Lower overhead control panel (A) and dome light (D). D—Dome Light

7. Remove sound resonator covers (B).


8. Using a putty knife, move headliner away from cab
10. Install in reverse order of removal.
frame to release headliner from clips (G) at locations
(F) and lower headliner.
9. Move overhead control panel and dome light through
holes in headliner and remove headliner.
PW66162,0000898 -19-09NOV12-1/1

Remove and Install Cab Door


CAUTION: Support cab door prior to removing
hinge pins. Door may shatter if dropped.

1. Remove snap rings (A) and hinge pins (B).

H73474 —UN—01OCT02
2. Remove cab door.
3. Repair or replace cab door as necessary.
4. Install cab door using hinge pins (B) and snap rings (A).

A—Snap Ring B—Hinge Pin

H73475 —UN—01OCT02

PW66162,000089A -19-09NOV12-1/1

TM100419 (02APR13) 90-20-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=518
Cab

TM100419 (02APR13) 90-20-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=519
Cab

Disassemble and Assemble Cab Door

5 6
1
7

4 2
8 3
12
9
10
15
11
37
13
34 14

32 33
31

36
35
10
11
16
17

19
20
18

21

22

30
27
29
23
28

24

28
H73479 —UN—02OCT02

25
26

Continued on next page PW66162,000089B -19-09NOV12-1/2

TM100419 (02APR13) 90-20-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=520
Cab

1— Strap Nut 11— Washer (2 used) 22— Cap 31— Lock Nut (2 used)
2— Spring Washer (2 used) 12— Screw (2 used) 23— Screw 32— Washer (2 used)
3— Striker 13— Bracket 24— Pin (2 used) 33— Washer
4— Socket Head Screw (2 used) 14— Spacer 25— Hinge (2 used) 34— Screw
5— Screw 15— Door 26— Snap Ring (2 used) 35— Isolator
6— Cover 16— Bushing 27— Bushing 36— Washer
7— Latch 17— Gasket 28— Washer (8 used) 37— Lock Nut
8— Bearing 18— Handle 29— Lock Washer (4 used)
9— Tube 19— Gasket 30— Screw (4 used)
10— Nut (2 used) 20— Bushing
21— Washer

Disassemble and assemble door as required to make


repairs.
PW66162,000089B -19-09NOV12-2/2

Cab Door Latch Striker

C
B
D

H73480 —UN—02OCT02
A—Socket Head Screw (2 used) B—Striker Plate D—Strap Nut
C—Spring Washer (2 used)

NOTE: Make sure washers (C) are not lost when 5. Check proper operation of door latch from inside and
removing striker plate (B). outside cab. Make further adjustments as required.
1. Remove socket head screws (A), striker plate (B), 6. Tighten socket head screws (A) to specification.
spring washers (C), and strap nut (D).
Specification
2. Inspect parts for wear. Replace parts as required. Striker Plate Socket Head
Screws—Torque............................................................................72 N·m
3. Install striker plate (B) and washers (C), with cup side (53 lb.-ft.)
toward cab frame, using socket head screws (A). Do
not tighten at this time.
4. Check alignment of striker plate with door latch
assembly. Loosen striker plate and realign as required.
PW66162,000089C -19-09NOV12-1/1

TM100419 (02APR13) 90-20-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=521
Cab

Cab Tilt Procedure

NW271890 —UN—22MAY06

NW271870 —UN—19MAY06
Raise Cab
1. Park machine on level surface.
2. Engage topper and base cutter safety stops.

T8130000684 —UN—14FEB13
3. Lower topper and base cutter onto safety stops.
4. Lower the crop divider completely.
5. Shut off engine and remove key.
6. Remove all loose objects from cab.
7. Securely latch window and door.
8. Remove pin (A) from rear part of cab.
9. Open left-hand engine compartment door and locate
pump handle inside of door. Insert pump handle into
pump (B).

T8130000683 —UN—14FEB13
CAUTION: Do not leave cab partially tilted.
Completely tilt cab until the cab tilt lock
falls into position.

10. Turn tilt control lever (C) to the up position (D). Stroke
pump handle to tilt cab.
11. Pull cord (F) to position safety latch upward.
12. Remove pin (H) from lower hole and insert into upper
hole (G). A—Pin E—Down Position
B—Pump F— Cord
Lower Cab C—Control Lever G—Upper Hole
D—Up Position H—Pin

CAUTION: Ensure that area beneath cab is


clear of personnel and equipment. 3. Insert pump handle into pump. Pull cord (F) and stroke
pump handle until cab is completely lowered.
1. Rotate control lever to down position (E).
4. Return pump handle to storage in door.
2. Remove pin (H) from upper hole (G) and insert into
lower hole. 5. Install pin (A).
NOTE: If cord cannot release safety stop, repeat
necessary raise cab steps to allow safety
stop release.
PW66162,000089D -19-14FEB13-1/1

TM100419 (02APR13) 90-20-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=522
Cab

Remove and Install Cab


1. Park machine on level surface.
NOTE: If base cutter must be in raised position,
safety stops MUST be engaged.

T8130000406 —UN—29JAN13
2. Completely lower base cutter.
3. Completely lower crop dividers and topper.
4. Shut off engine and remove key.
5. Disconnect batteries. (See Battery Disconnect Switch
in Section 40, Group 05.)
6. Discharge air conditioning system. (See Discharge
and Recover Air Conditioning System in Section 90, A—Hose and Connector Shield B—Cap Screw (4 used)
Group 05.)
7. Drain radiator.
8. Remove cap screws (B) and shield (A).
DM84283,0000217 -19-28FEB13-1/8

9. Tag and disconnect air conditioning hoses (A and B).


10. Loosen clamps (C and E). Tag and disconnect heater
hoses.
11. Disconnect windshield washer hose (D).

T8130000407 —UN—29JAN13
12. Cap and plug all hoses and fittings.
13. Tag and disconnect harness connectors (F).
14. Tilt cab forward. (See Cab Tilt Procedure in Section
90, Group 20.)

A—Air Conditioning Hose D—Windshield Washer Hose


B—Air Conditioning Hose E—Clamp
C—Clamp F— Harness Connector (6 used)

T8130000408 —UN—29JAN13

Continued on next page DM84283,0000217 -19-28FEB13-2/8

TM100419 (02APR13) 90-20-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=523
Cab

15. Disconnect harness connectors (A and C).


16. Cut all necessary tie bands. Pull harness bundle (B)
and hose bundle (D) through lower cab frame and set
aside.

T8130000409 —UN—29JAN13
A—Harness Connector C—Harness Connector
B—Harness Bundle D—Hose Bundle

DM84283,0000217 -19-28FEB13-3/8

17. Disconnect evaporator drain hose (A) and set aside.

A—Evaporator Drain Hose

T8130000410 —UN—29JAN13
DM84283,0000217 -19-28FEB13-4/8

18. Remove cap screws (A) and washers.


19. Cut all necessary tie bands and set steering valve
aside.

A—Cap Screw (4 used)

T8130000411 —UN—29JAN13

Continued on next page DM84283,0000217 -19-28FEB13-5/8

TM100419 (02APR13) 90-20-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=524
Cab

20. Attach proper lifting strap (A) to three location shown


cab.

A—Lifting Strap

T8130000414 —UN—15FEB13
DM84283,0000217 -19-28FEB13-6/8

21. Disconnect ground cable (G).


22. Remove cap screw (B), lock nut (A), washers, and
safety cable (C).
23. Remove safety stop release rope (D).

T8130000413 —UN—29JAN13
24. Set lift cylinder (E) and safety stop (F) aside.
25. Lower cab to its upright position.

A—Lock Nut E—Lift Cylinder


B—Cap Screw F— Safety Stop
C—Safety Cable G—Ground Cable
D—Safety Stop Release Rope

DM84283,0000217 -19-28FEB13-7/8

NOTE: Left-hand side shown. Right-hand side same.

26. Remove cap screw (A), lock nut (B), and washers (C)
from each side.

T8130000412 —UN—29JAN13
CAUTION: Use extreme care when lifting cab
and NEVER permit any body part to be under
a load being lifted or suspended.

NOTE: Carefully remove cab ensuring that all lines


and harnesses are free from cab.

27. Lift and remove cab.


28. Repair or replace cab as needed and install in reverse
order using following special instructions: A—Cap Screw C—Washer (2 used)
B—Lock Nut
a. Fill cooling system with correct coolant.
b. Charge air conditioning system. (See Charge Air
Conditioning System in section 90, Group 05.) d. Start engine. Operate machine for 5 minutes and
operate all hydraulic systems and functions for 1
c. Ensure hydraulic reservoir is full. (See Hydraulic Oil minute.
in Section 10, Group 15.) for recommended oil.
e. Shut off engine. Check for oil leaks. Check reservoir
level and fill as necessary.
DM84283,0000217 -19-28FEB13-8/8

TM100419 (02APR13) 90-20-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=525
Cab

TM100419 (02APR13) 90-20-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=526
Section 100
Topper System
Contents

Page

Group 05—Topper
Replace Topper Blades ............................... 100-05-1
Topper Assembly Removal.......................... 100-05-1
Drum and Topper Assembly ........................ 100-05-1
Shredder Topper Exploded View ................. 100-05-2
Topper Assembly Removal.......................... 100-05-3
Drum and Topper Assembly ........................ 100-05-3

TM100419 (02APR13) 100-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 100-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Topper
Replace Topper Blades

CAUTION: Avoid serious injury. Shut OFF


engine and wait for topper to completely stop
rotating before replacing blades.
Avoid serious injury from sharp edges. Wear
gloves when handling blades.

1. Remove cap screws (A), lock nuts, and blade (B) from
severing disk.
2. Install new blades with serrated side (C) facing
upwards.

T8120002186 —UN—13NOV12
A—Cap Screws (2 used per C—Serrated Side
blade)
B—Blade (8 used)

PW66162,0000921 -19-18JAN13-1/1

Topper Assembly Removal 3. Remove the splined hub from topper motor shaft.

CAUTION: To prevent possible injury, 4. Label and disconnect hydraulic hoses. Cap and plug
remove topper blades from disk before hoses and fittings.
disassembling or remove the complete topper NOTE: If necessary, apply heat to remove nut. Araldite
assembly from harvester. or Loctite was used during assembly.
1. Remove topper segment blades. 5. Remove topper motor from topper frame.
2. Remove the topper disk and drum (9) together.
PW66162,0000929 -19-27FEB13-1/1

Drum and Topper Assembly 6. Heat the collector drum hub to 300 °F (149 °C).
1. Install collector drum motor, ensuring that the RH is 7. Install the collector drum on the motor.
on the right side and the LH is on the left. Torque
mounting bolts and nuts to 108 N·m (80 lb.-ft.). 8. Apply Araldite to the motor shaft and tighten the nut
to 33 N·m (25 lb.-ft.).
2. Apply Araldite to motor studs. Install nuts, washers,
and topper motor. Torque nuts to 108 N·m (80 lb.-ft.). 9. Install pin and bend the pin tabs to lock.
3. Install the drum assembly and toppers disk. 10. Install the hub cab.
4. Apply Thread Lock and Sealer (Medium Strength) and 11. Connect all hoses and fittings.
install twelve bolts and washers to mount with topper
disk and torque to 47 N·m (35 lb.-ft.). 12. Install blades with bolts and nuts. Torque to 35 N·m
(26 lb.-ft.).
5. Remove pin and the nut located on the collector motor.
PW66162,000092A -19-27FEB13-1/1

TM100419 (02APR13) 100-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=529
Topper

Shredder Topper Exploded View

CM053510267 —UN—16AUG05

Continued on next page PW66162,000092B -19-21JAN13-1/2

TM100419 (02APR13) 100-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=530
Topper

1— Shredder Frame Assembly 17— Support Washer 32— Throat Palte RH Sheet 45— Topper Blade Shim
2— Shredder Drum Cover 18— Bearing Hub 33— N/A 46— Shredder Topper Cover
3— Lock Nut 19— Bearing 34— Bolt 47— Rubber Grommet
4— Cotter Pin 20— Extractor Fan Adapter 35— Motor Mount Assembly 48— Grommet
5— Shredder Topper Cover 21— Topper Drum Assembly 36— N/A 49— RMT-Guard
6— Expansion Plug 22— Bolt 37— N/A 50— Shredder Topper Belt
7— Bolt 23— Segment Blade 38— Lock Washer 51— Shredder Topper Belt Mount
8— Lock Washer 24— Nut 39— Gathering Disc Plate 52— Bolt
9— Washer 25— Bolt 40— Gathering Hub Plate 53— Lock Nut
10— HB Bolt 26— Lock Washer 41— Drum Stop (Shipping Only)
11— Bolt 27— Topper Baseplate Assembly 42— N/A
12— HD Washer 28— Shear Bar Plate 43— N/A
13— Shredder Topper Shield 29— Shear Bar Plate 44— RMT-Elab Seal Frame
14— Bolt 30— Bolt (Position at final assembly
15— Lock Nut 31— Throat Plate LH Sheet with drum in place.)
16— Snap Ring
PW66162,000092B -19-21JAN13-2/2

Topper Assembly Removal 6. Remove the two bolts and washers that secure the
1. Remove bolts (22), nuts (24), and segment blades (23). motor to the frame (1) and hub assembly (18). It may
be necessary to apply heat to remove bolts, because
2. Remove drum cover (2), baseplate assembly (27), and Araldite and Loctite was used during assembly.
throat sheets (31 & 32).
7. Remove six bolts (34) and washers (26) holding
3. Remove six bolts (25) and washers (26). Remove bearing hub assembly (18).
drum assembly (21).
8. Remove snap-ring (16) and washer (17) to separate
4. Remove covers (5 & 46) to gain access to motor (33) hub (18) and adapter (20). Remove bearings (19)
and hydraulic hoses and fittings. from hub assembly (18).
5. Label and cap all hydraulic hoses and fittings.
PW66162,000092C -19-21JAN13-1/1

Drum and Topper Assembly


9. Install fixed blades (23) with bolts (22), shims (45) and
1. Install bearings (19) in hub assembly (18) with bearing nuts (24). Torque to 35 nm (26 lb-ft).
seals towards inside of housing (seals down). Pack
bearings with grease. 10. Install motor mount assemblies using bolts and nuts.

2. Place bearing hub assembly (18) onto extractor 11. Install collector drum motors ensuring that the LH is
adapter (20). Spin hub assembly (18) to check on the left side and the RH is on the right side. Torque
freedom of movement. bolts and nuts to 108 Nm (80 lb-ft).

3. Install bearing hub assembly (18) into frame assembly 12. Remove pins (4) and nut located on the collector motor.
(1). Install six bolts (34) and washers (26) with Loctite 13. Heat the collector drums (39 & 40) to 149°C (300°F) to
242 (0841304201) and torque to 108 Nm (80 lb-ft). clean off old araldite.
4. Install the topper motor (33) into the frame (1). Install 14. Install the collector drums (39 & 40) on the motors.
two bolts (42) and washers (26) with Loctite 242
(0841304201) and torque to 108 Nm (80 Lb-Ft). 15. Apply araldite to the motor shafts and tighten the nut
to 33 Nm (25 lb-ft).
5. Install all hoses and fittings.
16. Install pin (4) and bend the pin tabs to lock.
6. Place drum assembly (21) onto adapter (20). Install
six bolts (25) and washers (26) with loctite 242 17. Install throat plates (31 & 32) and shear bar plates (28
(0841304201) and torque bolts to 108 Nm (80 & 29) using bolts (14 & 11) and nuts (3 & 15). Do Not
lb-ft). Turn drum to check clearance and freedom of Tighten Bolts At This Time.
movement.
18. Install side shields (13) with bolts (14) and nuts (15).
7. Install drum cover (2) with six bolts (7), lock washers
19. Tighten all bolts and nuts on lower drum assembly.
(8) and flat washers (9).
20. Install segment blades (23) on topper drum assembly
8. Bolt baseplate assembly (27) to fixed legs on frame
(21). Turn drum to check for clearance and freedom of
(1) using bolts (14) and nuts (15). Do Not Tighten
movement.
Bolts At This Time.
PW66162,000092D -19-21JAN13-1/1

TM100419 (02APR13) 100-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=531
Topper

TM100419 (02APR13) 100-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=532
Section 110
Crop Divider System
Contents

Page

Group 05—Crop Divider


Crop Divider Linkage Exploded
View ......................................................... 110-05-1
Crop Divider Removal ................................. 110-05-2
Disassemble and Assemble Crop
Divider ..................................................... 110-05-2
Remove and Install Crop Divider
Shoe ........................................................ 110-05-2
Gauge Wheel Exploded View (If
Equipped) ................................................ 110-05-3

TM100419 (02APR13) 110-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 110-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Crop Divider
Crop Divider Linkage Exploded View

CM053510274 —UN—17AUG05

1— Upper Linkage Top Plate 3— Bushings (4 used) 5— Flat Washers (4 used) 7— Cap Screws (4 used)
2— Upper Linkage Bottom Plate 4— Grease Fittings (2 used) 6— Lock Washers (4 used)

PW66162,0000796 -19-09NOV12-1/1

TM100419 (02APR13) 110-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=535
Crop Divider

Crop Divider Removal repair can be performed while it is on the harvester. To


carry out work on the crop divider structures, they must be
NOTE: See Parts Manual for complete crop removed from the harvester chassis.
divider breakdowns.

It may not be necessary to remove the crop divider from


the harvester. If there is no structural or wear damage,
PW66162,0000797 -19-23OCT12-1/1

Disassemble and Assemble Crop Divider 6. Splined hub adapter is Araldited to the motor shaft and
retained by single bolt. To remove, loosen the center
1. Label, disconnect, and cap all necessary hoses and bolt and apply a puller to the drive spline.
fittings.
7. Assemble in reverse order using the following special
2. Disconnect floating shoe assembly from the main instructions:
frame at the chain adjustment end and remove
fasteners from the pivot point. • Replace damaged or worn parts as necessary.
3. Remove retaining fasteners from pivot pins and
• Check the condition of mating splines and shafts.
Repair or replace as necessary.
remove the pins. This frees the crop divider assembly
from the harvester for disassembly.
• Check motor seal for leakage and replace as
necessary.
4. Label, disconnect, and cap all hoses and fittings • The scroll adjustment is 3 mm (1/8 inch) up and
located on the motor. down movement in the splines.
• If drive spline is removed from drive motor, Araldite
5. Remove fasteners and remove motor mount along must be used to affix splines.
with the motor splined adapter hub.
NOTE: It may be necessary to apply heat to soften
Araldite for removal.
PW66162,0000798 -19-09NOV12-1/1

Remove and Install Crop Divider Shoe 1. Lower crop divider to the ground.
NOTE: Due to differing crop conditions and types of 2. Disconnect support chain and remove cap screw.
cultivation, crop divider shoe assemblies are used to
direct cane into the base cutters. Shoe assemblies 3. Raise crop divider until the main frame clears the crop
are secured to the crop divider with a cap screw and divider shoe assembly and remove.
supported by an adjustment chain at the rear.
PW66162,000079C -19-27FEB13-1/1

TM100419 (02APR13) 110-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=536
Crop Divider

Gauge Wheel Exploded View (If Equipped)


IMPORTANT: Install nut (N) and tighten until heavy Apply John Deere SD POLYUREA Grease
drag is felt on hub as it is rotated. Then back or an equivalent SAE multipurpose-type
nut off one rotation. Install cotter pin and grease to fittings (J).
bend one leg of pin over spindle.

CQ282584 —UN—11FEB09

Continued on next page PW66162,000079D -19-27FEB13-1/2

TM100419 (02APR13) 110-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=537
Crop Divider

1— Nut 10— Roller Race 16— Lock Washer 22— Bushing


2— Washer 11— Bearing 17— Nut 23— Lock Nut
3— Stand 12— Roller Race 18— Dust Cap 24— Axle
4— Bolt 13— Washer 19— Slotted Nut 25— Tire and Wheel
5— Seal Kit 14— Fitting 20— Cotter Pin
6— Bolt 15— Cap Screw 21— Cap Screw
7— Hub
8— Nut
9— Bearing
PW66162,000079D -19-27FEB13-2/2

TM100419 (02APR13) 110-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=538
Section 120
Knockdown Roller
Contents

Page

Group 05—Knockdown Roller


Specifications .............................................. 120-05-1
Knockdown Roller Exploded View................ 120-05-2
Remove and Install Knockdown
Roller ....................................................... 120-05-3
Disassemble and Assemble
Knockdown Roller.................................... 120-05-3

TM100419 (02APR13) 120-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 120-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Knockdown Roller
Specifications
Item Measurement Specification

Spline Hub Cap Screws Torque 75 N·m


(55 lb.-ft.)
Hydraulic Motor-to-Motor Mount Torque 110 N·m
cap Screws (81 lb.-ft.)
Hub Spline Adapter-to Knockdown Torque 34 N·m
Roller Cap Screws (25 lb.-ft.)
Motor Mount-to Frame Cap Screws Torque 81 N·m
(60 lb.-ft.)
Guard Assembly Cap Screws Torque 24 N·m
(18 lb.-ft.)
PW66162,000098C -19-13FEB13-1/1

TM100419 (02APR13) 120-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=541
Knockdown Roller

Knockdown Roller Exploded View

CM053510275 —UN—17AUG05

Flush with edge (A). Bolt Placement Detail (B).

Continued on next page PW66162,0000962 -19-13FEB13-1/2

TM100419 (02APR13) 120-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=542
Knockdown Roller

1— Knockdown Roller 5— Hex Bolt 11— Hex Bolt 16— Lock Washer
2— Lock Washer 6— Cap Screws 12— Lock Nut 17— Lock Nut
3— Lock Washer 7— Spline Hub 13— Hex Nut 18— Expansion Plug
4— Hub Spline Adapter 8— Spacer 14— Paddle Plate
9— Motor Mount 15— Cap Screw
10— Guard Assembly
PW66162,0000962 -19-13FEB13-2/2

Remove and Install Knockdown Roller


NOTE: Hydraulic motors and motor mounts are
1. Park machine on level surface, shut off engine, and removed as an assembly.
remove key,
6. Remove nuts (13) and lock washers (3) that secure
2. Clean knock down roller and surrounding area. motor mount assembly (9).
3. Label and disconnect hoses connected to the two 7. Remove both motor mount assemblies and knockdown
knockdown motors. Cap and plug hoses and fittings. roller.
4. Remove cap screws (11) and nuts (12) that secure the 8. Install in reverse order of removal.
roller guards. Remove roller guards.
5. Using an appropriate lifting device, support knockdown
roller.
PW66162,0000963 -19-13FEB13-1/1

Disassemble and Assemble Knockdown 4. Assemble in reverse order using the following special
Roller instructions.
Disassemble NOTE: Do not apply to splines of adapter.
1. Remove knockdown roller. (See Remove and Install
Knockdown Roller in Section 120, Group 05.)
• Apply Araldite to all fasteners before installation.
• Tighten spline hub cap screws to specification.
NOTE: Heat fasteners to soften Araldite and • Tighten hydraulic motors to motor mounts to
aid in disassembly. specification.
• Tighten hub spline adapter cap screws to
2. Remove cap screws (6), lock washers (3), and spline specification.
hubs (7) from each side of knockdown roller. • Tighten motor mount-to frame cap screws to
specification.
3. Remove cap screws (15), lock nuts (17), and paddle • Tighten guard assembly cap screws to specification.
plates (14).
Specification
4. Remove hydraulic motor from motor mount (9). Spline Hub Cap
Screws—Torque............................................................................75 N·m
5. Remove cap screws (5), lock washers (2) and hub (55 lb.-ft.)
spline adapters (4) from each hydraulic motor. Hydraulic Motor-to-
Motor Mount cap
Assemble
Screws—Torque.......................................................................... 110 N·m
IMPORTANT: Be sure to inspect splines of hub adapter (81 lb.-ft.)
and spline hub. Replace hub adapter and spline Hub Spline Adapter-to
hub as a set. Do not mix old parts with new. Knockdown Roller Cap
Screws—Torque............................................................................34 N·m
1. Clean all parts and inspect for wear or damage. Repair (25 lb.-ft.)
or replace as necessary. Motor Mount-to Frame
Cap Screws—Torque....................................................................81 N·m
2. Inspect hydraulic motor for leakage. (60 lb.-ft.)
Guard Assembly Cap
3. Clean remaining Araldite from all internal and external
Screws—Torque............................................................................24 N·m
threads and splines. Inspect, repair, or replace as
(18 lb.-ft.)
necessary.
PW66162,0000964 -19-22FEB13-1/1

TM100419 (02APR13) 120-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=543
Knockdown Roller

TM100419 (02APR13) 120-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=544
Section 130
Base Cutter System
Contents

Page

Group 05—Base Cutter Gear Case


Other Material.............................................. 130-05-1
Special Tools ............................................... 130-05-1
Specifications .............................................. 130-05-1
Base Cutter Gear Case—3520.................... 130-05-2
Base Cutter Gear Case—3522.................... 130-05-4
Base Cutter Gear Case Assembly................ 130-05-5

TM100419 (02APR13) 130-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 130-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Base Cutter Gear Case
Other Material
Number Name Use
PM38652 (U.S.) Bearing Mount (High Temperature) Used to mount and retain bearing
620 (LOCTITE®) assemblies.

PM37553 (U.S.) Loctite® Hi-Tack Gasket Sealant To hold gaskets in place during
installation.

PM37477 (U.S.) Thread Lock and Sealer (Medium Used to lock and seal threads.
TY9473 (Canadian) Strength)
242 (LOCTITE®)

AT385391 (U.S.) Molylube To lubricate parts.

Loctite is a trademark of Henkel Corporation


PW66162,00009AE -19-27FEB13-1/1

Special Tools
For more information, or to order tools referenced in this
group, see the SERVICEGARD™ online tool catalog or
your John Deere dealer.
SERVICEGARD is a trademark of Deere & Company
PW66162,00009CC -19-19MAR13-1/1

Specifications
Item Measurement Specification

Base Cutter Shaft Nut Torque 149 N·m


(110 lb.-ft.)
Gear Case Cover Cap Screws Torque 47.4 N·m
(35 lb.-ft.)
Hub Cap Cap Screws Torque 13.5N·m
(119 lb.-in.)
Base Cutter Motor Cap Screws Torque 119.3 N·m
(88 lb.-ft.)
PW66162,00009B0 -19-27FEB13-1/1

TM100419 (02APR13) 130-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=547
Base Cutter Gear Case

Base Cutter Gear Case—3520

CM073510663 —UN—15OCT07

Continued on next page PW66162,000097D -19-27FEB13-1/2

TM100419 (02APR13) 130-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=548
Base Cutter Gear Case

1— Shaft Assembly (2) 10— Leg Gear (2 used) 20— Cover 32— O-ring
2— Seal Carrier (2) 11— Leg Washer (2) 21— Bolt (30) 33— Shield Mount (2 used)
3— Single Lip (Top) Seal (2 used) 12— Shaft Nut (2 used) 22— Hub Cap Gasket (3) 34— Magnetic Plug (3)
4— Seal (Bottom) (2) 13— Bolt (2 used) 23— Cap (3) 35— Sight Gauge
5— Gear Case 14— Lock Nut (2 used) 24— Bolt (18) 36— V-Ring Seal (2)
6— Bolt (4) 15— Bearing (4) 25— Fitting 37— Grease Fitting (2 used)
7— Bearing Cone (4 used) 16— Pinion Gear 26— Kickers (8) 38— Check Valve (5 pound) (2
8— Flat Washer (4 used) 17— Idler Gear 27— Lock Nuts (16) used)
9— Bearing Cup (4 used) 18— Pin (3 used) 28— Bolt (16)
19— Cover Gasket 29— Flat Washer (16)
30— Lock Washer (30)
31— Snap-Ring (2)
PW66162,000097D -19-27FEB13-2/2

TM100419 (02APR13) 130-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=549
Base Cutter Gear Case

Base Cutter Gear Case—3522


21

33
30
33
18
31
23
22
20

12
11

10

17

16

15

7
9

3
34
5 37
38
35
34

7
36
4

1 CQ282569 —UN—11DEC08

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TM100419 (02APR13) 130-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=550
Base Cutter Gear Case

1— Base Cutter Shaft Assembly 10— Base Cutter Leg Gear (2) 19— Base Cutter Cover Gasket 31— Snap-Ring (2)
(2) 11— Base Cutter Leg Washer (2) 20— Base Cutter Cover 32— O-ring
2— Base Cutter Seal Adapter (2) 12— Slotted Fine Thread Nut (2) 21— Bolt (30) 33— Shield Mount (2)
3— Single Lip (Top) Seal (2) 13— Bolt (2) 22— Hub Cap Gasket (3) 34— Magnetic Plug (3)
4— Seal (Bottom) (2) 14— Lock Nut (2) 23— Cap (3) 35— Sight Gauge
5— Base Cutter Gear Case 15— Bearing (4) 24— Bolt (18) 36— V-Ring Seal (2)
Assembly 16— Base Cutter Pinion Gear 25— Fitting 37— Zerk (2)
6— Bolt (4) 17— Base Cutter Idler Gear 26— Kickers (8) 38— Check Valve (5 pound) (2)
7— Cone Bearing (4) 18— Dowel Pin (3) 27— Lock Nuts (16)
8— Flat Washer (4) 28— Bolt (16)
9— Bearing Cup (4) 29— Flat Washer (16)
30— Lock Washer (30)
PW66162,000097E -19-12FEB13-2/2

Base Cutter Gear Case Assembly


SPECIAL TOOLS NEEDED:
• Base Cutter Gear Case Support
Used to support base cutter gear case for repairs.
Tool Number—CB11444166

CQ280263 —UN—27FEB08
• Base Cutter Holding Tool
Used to hold base cutter leg in position.
Tool Number—CB11422828
• Base Cutter Timing Tool
Used to time base cutter assembly.
Tool Number—1190290188
1. Check base cutter shaft (1) where seal carrier (2) fits
for smooth clean surface.

CM073510664 —UN—03MAR08

Continued on next page PW66162,000097F -19-27FEB13-1/29

TM100419 (02APR13) 130-05-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=551
Base Cutter Gear Case

NOTE: Clean gear case with air pressure all


during assembly.

2. Install base cutter gear case into CB11444166 Base


Cutter Gear Case Support1.

CM073510665 —UN—03MAR08
3. Clean base cutter gear case (5) with hot water. Blow
dry with compressed air and wipe clean.

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,000097F -19-27FEB13-2/29

4. Apply Teflon tape to plug (34) and install into gear


case (5).
5. Apply Teflon Thread Paste to sight glass (35) and
install into gear case.

CM073510666 —UN—03MAR08
Continued on next page PW66162,000097F -19-27FEB13-3/29

TM100419 (02APR13) 130-05-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=552
Base Cutter Gear Case

6. Apply Teflon Tape to plugs (34). Install one plug into


top port of each gear case leg.

34— Plug (2 used)

CM073510694 —UN—03MAR08
CQ280274 —UN—27FEB08
CM073510695 —UN—03MAR08
Continued on next page PW66162,000097F -19-27FEB13-4/29

TM100419 (02APR13) 130-05-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=553
Base Cutter Gear Case

7. Apply liquid Teflon to grease fittings (37) and install in


each bottom port on gear case leg.

37— Grease Fittings (2 used)

CM073510696 —UN—03MAR08
CQ280270 —UN—27FEB08
PW66162,000097F -19-27FEB13-5/29

8. Place shaft bearing cups (9) in freezer for at least 30


minutes.

CM073510667 —UN—03MAR08
Continued on next page PW66162,000097F -19-27FEB13-6/29

TM100419 (02APR13) 130-05-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=554
Base Cutter Gear Case

9. Install seal carrier (2) onto shaft (1) with Bearing


Mount (High Temperature) or blue silicone.

1— Shaft (2 used) 2— Seal Carrier (2 used)

CM073510668 —UN—03MAR08
CM073510664 —UN—03MAR08
Continued on next page PW66162,000097F -19-27FEB13-7/29

TM100419 (02APR13) 130-05-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=555
Base Cutter Gear Case

10. Install pinion bearings (15) and idler bearings (15) in


gear case (5) with Bearing Mount (High Temperature).

CM073510669 —UN—03MAR08
3520

15

CQ282574 —UN—20JAN09
3522

CM073510670 —UN—03MAR08
Continued on next page PW66162,000097F -19-27FEB13-8/29

TM100419 (02APR13) 130-05-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=556
Base Cutter Gear Case

NOTE: Apply Bearing Mount (High Temperature)


around the lower outer edge of bearing. Let dry
for 4—6 hours before adding oil.

11. Install V-ring seal (36) on top of seal carriers (2).


Insure the thick lip of V-ring seal is against the seal

CQ280264 —UN—27FEB08
carrier.

1— Shafts (2 used) 36— V-Ring Seal


2— Seal Carriers (2 used)

CM073510671 —UN—03MAR08
PW66162,000097F -19-27FEB13-9/29

12. Heat bearing cones (7) in oven for 15 minutes.

CM073510672 —UN—03MAR08
Continued on next page PW66162,000097F -19-27FEB13-10/29

TM100419 (02APR13) 130-05-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=557
Base Cutter Gear Case

IMPORTANT: Make sure bearing cone (7) is


fully seated on shaft.

NOTE: Wear welding gloves when handling


heated bearings.

CM073510673 —UN—03MAR08
13. Install bearing cones (7) onto each shaft (1).

Continued on next page PW66162,000097F -19-27FEB13-11/29

TM100419 (02APR13) 130-05-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=558
Base Cutter Gear Case

NOTE: Insure the seal is installed before installing


bearing cup (9). Grease port must be visible
once the seal is fully seated.

14. Install top single lip seals (3) into gear case (5).

CQ280265 —UN—27FEB08
3— Single Lip Seals (2 used) 5— Gear Case

CM073510674 —UN—03MAR08
CM073510675 —UN—03MAR08
CM073510676 —UN—03MAR08

Continued on next page PW66162,000097F -19-27FEB13-12/29

TM100419 (02APR13) 130-05-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=559
Base Cutter Gear Case

15. Remove bearing cup (9) from freezer.


16. Apply Bearing Mount (High Temperature) and install
the cold shaft bearing cups (9) into gear case (5).
Insure that bearing cup is fully seated.

CM073510677 —UN—03MAR08
CQ280266 —UN—27FEB08
CM073510678 —UN—03MAR08
PW66162,000097F -19-27FEB13-13/29

17. Position gear case (5) with legs of gear case facing
upward. CM073510679 —UN—03MAR08

Continued on next page PW66162,000097F -19-27FEB13-14/29

TM100419 (02APR13) 130-05-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=560
Base Cutter Gear Case

18. Apply Bearing Mount (High Temperature) and install


cold shaft bearing cups (9) into gear case (5). Insure
that bearing cup is fully seated.

CM073510680 —UN—03MAR08
PW66162,000097F -19-27FEB13-15/29

19. Install bottom seal (4) into gear case (5).


20. Insure the bottom seal is fully seated.

CM073510681 —UN—03MAR08
CM073510682 —UN—03MAR08
Continued on next page PW66162,000097F -19-27FEB13-16/29

TM100419 (02APR13) 130-05-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=561
Base Cutter Gear Case

21. Position gear case (5) with gear case legs facing
downward.
22. Install shaft assembly (1) into gear case.

CM073510683 —UN—15OCT07
CM073510684 —UN—03MAR08
Continued on next page PW66162,000097F -19-27FEB13-17/29

TM100419 (02APR13) 130-05-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=562
Base Cutter Gear Case

NOTE: Clean shaft area before installing bearing.

23. Install top (hot) bearing cone (7). Tap bearing cone on
inner race lightly to seat in cup (9).

CM073510685 —UN—03MAR08
CM073510686 —UN—03MAR08
Continued on next page PW66162,000097F -19-27FEB13-18/29

TM100419 (02APR13) 130-05-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=563
Base Cutter Gear Case

24. Install gear (10), washer (11), and nut (12) onto shaft
(1).

CM073510687 —UN—03MAR08
CQ280267 —UN—27FEB08
CM073510688 —UN—03MAR08
Continued on next page PW66162,000097F -19-27FEB13-19/29

TM100419 (02APR13) 130-05-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=564
Base Cutter Gear Case

25. Using CB11422828 Base Cutter Holding Tool1, secure


shaft (1) to CB11444166 Base Cutter Gear Case
Support.
26. Tighten base cutter shaft nut to specification.

CM073510689 —UN—03MAR08
Specification
Base Cutter Shaft
Nut—Torque................................................................................149 N·m
(110 lb.-ft.)

27. Rotate shaft several times to seat bearings.


28. Check that base cutter nut is tightened to specification.
IMPORTANT: If necessary, tighten base cutter shaft
nut to line up hole in shaft with the slot in nut.
Do Not loosen nut to install bolt (13).

29. Install bolt (13) and lock nut (14).

CQ280268 —UN—27FEB08
CM073510690 —UN—03MAR08
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,000097F -19-27FEB13-20/29

30. Repeat necessary steps and install second base


cutter shaft.
CM073510691 —UN—03MAR08

Continued on next page PW66162,000097F -19-27FEB13-21/29

TM100419 (02APR13) 130-05-19 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=565
Base Cutter Gear Case

31. Install bearings (15) and idler gear (17) into gear case
(5).
32. Attach 1190290188 Base Cutter Timing Tool to base
cutter legs.

CM073510692 —UN—03MAR08
33. With base cutter legs in the “timed” position, install
pinion gear (16).

3520

15
17
16

CQ282576 —UN—21JAN09
3522

CM073510693 —UN—03MAR08
PW66162,000097F -19-27FEB13-22/29

NOTE: Use SAE multi-purpose extreme pressure


performance grease containing 3 to 5%
molybdenum disulfide to fill grease cavities.
Grease emitted from check valve indicates
CM073510697 —UN—03MAR08

grease cavity is full.

34. Pump grease into grease fitting (37) until grease


begins coming out of the 5 psi check valve (38).
35. Repeat grease procedure to opposite leg.
36. Check for grease leaking from perimeter of grease
fitting and check valve. If necessary tighten to
eliminate leakage.
Continued on next page PW66162,000097F -19-27FEB13-23/29

TM100419 (02APR13) 130-05-20 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=566
Base Cutter Gear Case

37. Using Hi-Tack Gasket Sealant, attach gasket (19) to


base cutter cover.

CM073510698 —UN—03MAR08
PW66162,000097F -19-27FEB13-24/29

38. Install cover (20) to gear case (5) and install pins (18).

CM073510699 —UN—03MAR08
PW66162,000097F -19-27FEB13-25/29

NOTE: Start from the middle of the cover and


work your way outward.
Apply Thread Lock and Sealer (Medium Strength)
on all gear case bolts.

CM073510700 —UN—03MAR08
39. Install shield mounts (33), cap screws (21), and lock
washers (30) to gear case. Tighten gear case cap
screws to specification.
Specification
Gear Case Cover Cap
Screws—Torque.........................................................................47.4 N·m
(35 lb.-ft.)

20— Cover 30— Lock washers


21— Cap Screws 33— Shield Mounts (2 used)

Continued on next page PW66162,000097F -19-27FEB13-26/29

TM100419 (02APR13) 130-05-21 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=567
Base Cutter Gear Case

40. Install snap rings (31), one for pinion gear and one
for idler gear.

CM073510701 —UN—03MAR08
PW66162,000097F -19-27FEB13-27/29

NOTE: Apply Thread Lock and Sealer (Medium


Strength) to hub cap cap screws.

41. Install gaskets (22), hub cap (23) and cap screws.
Tighten shaft cover cap screws to specification.

CM073510702 —UN—03MAR08
Specification
Hub Cap Cap
Screws—Torque..........................................................................13.5N·m
(119 lb.-in.)

CQ280271 —UN—27FEB08
Continued on next page PW66162,000097F -19-27FEB13-28/29

TM100419 (02APR13) 130-05-22 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=568
Base Cutter Gear Case

NOTE: Apply AT385391 Molylube to splines of


motor shaft and pinion gear.
Apply Thread Lock and Sealer (Medium Strength)
to base cutter mounting bolts.

42. Install base cutter motor, cap screws (6), and


washers (8). Tighten base cutter motor cap screws
to specification.
Specification
Base Cutter Motor Cap
Screws—Torque....................................................................... 119.3 N·m
(88 lb.-ft.)

CM073510703 —UN—16OCT07
43. Fill gear case with 85W140 gear oil and check for leaks.

PW66162,000097F -19-27FEB13-29/29

TM100419 (02APR13) 130-05-23 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=569
Base Cutter Gear Case

TM100419 (02APR13) 130-05-24 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=570
Section 140
Feed Roller System
Contents

Page

Group 05—Buttlifter Roller (B1)


Butt-Lifter Roller (B1)................................... 140-05-1
Remove and Install Butt-Lifter
Roller ....................................................... 140-05-2
Clean and Inspect........................................ 140-05-2
Assembly ..................................................... 140-05-3

Group 10—Bottom Feed Roller


Bottom Feed Roller (B2, B3, B4,
B5) ........................................................... 140-10-1
Bottom Feed Roller Repair (B2,
B3, B4, B5) .............................................. 140-10-2
Clean and Inspect........................................ 140-10-2
Assembly ..................................................... 140-10-2

Group 15—Top Feed Roller


Top Floating Feed Roller (T1, T2,
T3, T4, T5)............................................... 140-15-1
Top Floating Feed Roller Repair.................. 140-15-2
Clean and Inspect........................................ 140-15-2
Assembly ..................................................... 140-15-2

TM100419 (02APR13) 140-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 140-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Buttlifter Roller (B1)
Butt-Lifter Roller (B1)

CM053510276 —UN—22AUG05

Continued on next page PW66162,0000973 -19-22FEB13-1/2

TM100419 (02APR13) 140-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=573
Buttlifter Roller (B1)

1— External Bearing Cradle 11— Cart Sphere Bearing 21— External Roller Shaft 28— Rubber Stop
2— Lock Washer 12— Zerk 22— Motor Mount 29— Set Screw
3— Nut 13— Wave Bar Plate 23— Feed Roller Bearing Mount 30— Socket Bolt
4— Splined Hub Adapter 14— Hex Nut 24— Cap Screw 31— Hex Nut
5— Lock Washer 15— Roller Pin 25— Feed Roller Cast Stop 32— Lock Washer
6— Cap Screw 16— External Bearing Cradle 26— Stop Spacer 33— Zerk
7— Bolt 17— Roller 27— Lock Nut 34— Expansion Plug
8— Splined Hub 18— Zerk 35— Zerk
9— Hex Bolt 19— Zerk
10— Hex Bolt 20— Spacer Sheet
PW66162,0000973 -19-22FEB13-2/2

Remove and Install Butt-Lifter Roller 10. Remove nuts (3) and washers (2), and cap screws
holding motor to motor mount. Remove motor.
1. Park machine on level surface. Shut off engine and
remove key. 11. Clean all parts and inspect for wear or damage and
replace as necessary.
2. Clean butt-lifter roller and surrounding area.
12. Install butt-lifter in reverse order using these special
3. Tag and disconnect motor hydraulic hoses on each instructions:
side of harvester. Cap and plug hoses and fittings.
4. Using an appropriate lifting device, support butt-lifter
• If splined hub or splined hub adapter need replaced,
replace as a set.
roller.
• Clean remaining Araldite from all internal and
NOTE: Heat may be necessary to loosen Araldite external threads and splines.
applied to mounting hardware. • Apply Araldite to the internal splines of splined hub
adapter.
5. Remove four nuts (3) and washers (2) attaching motor • Apply Araldite and tighten motor-to-motor mount
mount (22) to frame on each side of machine. nuts (3) to specification.
• Apply Araldite and tighten splined hub cap screw
NOTE: Install two 1/2 inch NC bolts to jack the (24) to specification.
housing in frame if necessary. • Apply Araldite and tighten splined hub adapter cap
screw (6) to specification.
6. Pull motor mounts outward until splined hub adapters
Specification
(4) clear splined hubs (8) and roller rests on motor
Butt-Lifter Motor-to-Motor
mounts.
Mount Nuts—Torque...................................................................109 N·m
7. Check that lifting device supporting butt-lifter is (80 lb.-ft.)
positioned correctly. Butt-Lifter Splined Hub
Cap Screws—Torque..................................................................109 N·m
8. Remove motor mounts from each side. Lower (80 lb.-ft.)
butt-lifter roller to ground. Butt-Lifter Splined
Hub Adapter Cap
NOTE: Heat may be necessary to loosen Araldite applied
Screw—Torque..............................................................................32 N·m
to splined hub adapter cap screw (6).
(24 lb.-ft.)
9. Remove cap screw (6), washers (5), and splined hub • The maximum out-of-alignment to the side wall is 5
adapter (4) from adapter. mm (0.197 inch). The end float of the roller between
the two motors, is a maximum of 7 mm (0.275 inch).
NOTE: A slot located in motor mount to aid in
motor removal.
PW66162,0000974 -19-22FEB13-1/1

Clean and Inspect 3. Clean remaining Araldite (this should have crystallized
1. Clean all parts and inspect for wear or damage; after application from heat) from all internal and
replace as necessary. external threads and splines. Inspect, repair, or
replace as necessary.
2. Pay particular attention to the splines of hub adapter
(4) and hub (8). If these are damaged, John Deere
recommends that both parts be replaced together for
maximum efficiency.
PW66162,0000975 -19-12FEB13-1/1

TM100419 (02APR13) 140-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=574
Buttlifter Roller (B1)

Assembly 3. Apply Araldite and torque bolt (3, 24) to 109 N·m (80
1. Assembly is the reverse of disassembly. lb-ft).

NOTE: Do not apply Araldite to the splines of the 4. Apply Araldite and torque bolt (6) to 32 N·m (24 lb-ft).
adapter. The Araldite will travel backward to the 5. The maximum out-of-alignment to the side wall is 5 mm
motor seal if is applied to the adapter. (0.197 inch). The end float of the rollers is between
the two motors, is a maximum of 7 mm (0.275 inch).
2. Apply Araldite to the internal splines of hub (4) only.
PW66162,0000976 -19-12FEB13-1/1

TM100419 (02APR13) 140-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=575
Buttlifter Roller (B1)

TM100419 (02APR13) 140-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=576
Group 10
Bottom Feed Roller
Bottom Feed Roller (B2, B3, B4, B5)

CM053510277 —UN—22AUG05

Continued on next page PW66162,000096B -19-12FEB13-1/2

TM100419 (02APR13) 140-10-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=577
Bottom Feed Roller

1— External Bearing Cradle 11— Cart Sphere Bearing 21— External Roller Shaft 29— Set Screw
2— Lock Washer 12— Zerk 22— Motor Mount 30— Socket Bolt
3— Hex Nut 13— Wave Bar Plate 23— Feed Roller Bearing Mount 31— Hex Nut
4— Splined Hub Adapter 14— Hex Nut 24— Hex Bolt 32— Lock Washer
5— Lock Washer 15— Roller Pin 25— Feed Roller Cast Stop 33— Zerk
6— Hex Bolt 16— External Bearing Cradle 26— Stop Spacer 34— Expansion Plug
7— Bolt 17— Roller 27— Lock Nut 35— Zerk
8— Splined Hub 18— Zerk 28— Rubber Stop
9— Hex Bolt 19— Zerk
10— Hex Bolt 20— Spacer Sheet
PW66162,000096B -19-12FEB13-2/2

Bottom Feed Roller Repair (B2, B3, B4, B5) Loosen Allen set screws in bearing (11). Remove
bearing assembly from roller. Remove bolts (9) and
1. Label, remove and cap hydraulic hoses and fittings. washers (2) from external shaft (21). Remove external
2. Remove four nuts (3) and washers (2) holding motor shaft (21). Remove the motor housing (22) on the
mount assembly (22) to the frame.1 opposite end; this will leave the roller suspended on the
supports. The roller can now be lowered to the ground.
NOTE: Heat may need to be used.
6. Remove fasteners (5 & 6) securing adapter (4) to the
3. Pull the housing outward until hub adapter (4) is clear motor.
of hub (8) and roller rests on mount (22). This can 7. Using a hex head (Allen) wrench, loosen bolts holding
be done by using two 1/2 inch bolts NC to jack hub the motor mount (22). There is a slot located in the
from the frame. housing for this purpose.
4. On the opposite side of the roller, remove four nuts (3) 8. Remove the motor from the housing.
and washers (2) from bearing flange (23).
5. Support the roller and remove the last nut (3) and
washer (2) located on the bearing housing (23).
1
All fasteners have been installed using Araldite. They must be heated
to soften the fixative before they can be removed.
PW66162,000096C -19-12FEB13-1/1

Clean and Inspect 3. Clean remaining Araldite (this should have crystallized
1. Clean all parts and inspect for wear or damage; after application of heat) from all internal and external
replace as necessary. threads and splines. Inspect, repair, or replace as
necessary.
2. Pay particular attention to the splines of hub adapter
(4) and hub (8). If these are damaged, John Deere
recommends that both parts be replaced together for
maximum efficiency.
PW66162,000096D -19-12FEB13-1/1

Assembly The Araldite will travel backward to the motor seal if


it is applied.
The maximum out-of-alignment to the side wall is 5 mm
(0.197 inch). The end float of the rollers, between the two 3. Apply Araldite and torque nut (3) and bolt (9, 24) to
motors, is a maximum of 7 mm (0.275 inch). 109 N·m (80 lb-ft).
1. Assembly is the reverse of disassembly. 4. Apply Araldite and torque bolt (6) to 32 N·m (24 lb-ft).
2. Apply Araldite to the internal splines of hub (4) only;
do not apply Araldite to the splines of the adapter.
PW66162,000096E -19-12FEB13-1/1

TM100419 (02APR13) 140-10-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=578
Group 15
Top Feed Roller
Top Floating Feed Roller (T1, T2, T3, T4, T5)

CM053510278 —UN—22AUG05

Continued on next page PW66162,000096F -19-12FEB13-1/2

TM100419 (02APR13) 140-15-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=579
Top Feed Roller

1— External Bearing Cradle 11— Cart Sphere Bearing 21— External Roller Shaft 29— Set Screw
2— Lock Washer 12— Zerk 22— Motor Mount 30— Socket Bolt
3— Hex Nut 13— Wave Bar Plate 23— Feed Roller Bearing Mount 31— Hex Nut
4— Splined Hub Adapter 14— Hex Nut 24— Hex Bolt 32— Lock Washer
5— Lock Washer 15— Roller Pin 25— Feed Roller Cast Stop 33— Zerk
6— Hex Bolt 16— External Bearing Cradle 26— Stop Spacer 34— Expansion Plug
7— Bolt 17— Roller 27— Lock Nut 35— Zerk
8— Splined Hub 18— Zerk 28— Rubber Stop
9— Hex Bolt 19— Zerk
10— Hex Bolt 20— Spacer Sheet
PW66162,000096F -19-12FEB13-2/2

Top Floating Feed Roller Repair 5. Remove three nuts (14), and washers (5) from each
1. If necessary, remove the bottom roller that will provide pivot pin (15). These are located on both ends of the
better access to the top. roller.

2. Label, remove and cap hydraulic hoses and fittings. 6. With the weight of the roller still supported, remove
both pivot pins (15). This will allow the roller to be
3. Remove bolt (24) and washer (2) that are securing lowered to the ground through space provided when
motor mount (22). Support the weight of the roller and the appropriate bottom roller was removed.
remove the mount (22). This can be done using two
1/2 inch NC bolts to jack the mount from the frame.1 7. Remove fasteners (6 & 5) which are securing adapter
(4) to the motor.
4. On the opposite side of the roller, remove four bolts
(9) and washers (2) from bearing flange (23). Loosen 8. Remove the motor from the motor mount assembly.
Allen set screws in bearing (11). Remove bearing
assembly from roller. Remove bolts (9) and washers
(2) from external shaft (21). Remove external shaft.1
1
All fasteners have been installed using Araldite. They must be heated
to soften the fixative before they can be removed.
PW66162,0000970 -19-12FEB13-1/1

Clean and Inspect 3. Inspect bearing (11) and flange (23) for wear or
1. Clean all parts and inspect for wear or damage; damage.
replace as necessary. 4. Clean the remaining Araldite (this should have
2. Pay particular attention to the splines of hub adapter crystallized after application of heat) from all internal
(4) and hub (8). If these are damaged, John Deere and external threads and splines. Inspect, repair or
recommends that both parts be replaced together for replace as necessary.
maximum efficiency.
PW66162,0000971 -19-12FEB13-1/1

Assembly Araldite will travel backward to the motor seal if it is


applied.
The maximum out-of-alignment to the side wall is 5 mm
(0.197 inch). The end float of the rollers, between the two 4. Apply Araldite and torque bolts (9, 10, 24) to 109 N·m
motors, is a maximum of 7 mm (0.275 inch). (80 lb-ft).
1. Assembly is the reverse of disassembly. 5. Apply Araldite and torque bolt (6) to 32 N·m (36 lb-ft).
2. Check the floating roller stop; this prevents the motor 6. Apply Araldite and torque nuts (14) to 68 N·m (36 lb-ft).
mount from hammering the side wall.
3. Apply Araldite to the internal splines of hub only. Do
not apply Araldite to the splines of the adapter. The
PW66162,0000972 -19-12FEB13-1/1

TM100419 (02APR13) 140-15-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=580
Section 150
Chopper System
Contents

Page

Group 05—Chopper
Other Material.............................................. 150-05-1
Special Tools ............................................... 150-05-1
Specifications .............................................. 150-05-2
Chopper Gear Case Exploded
View ......................................................... 150-05-3
Chopper Drum Exploded View .................... 150-05-5
Remove and Install Chopper
Assembly ................................................. 150-05-6
Disassemble and Assemble
Chopper Gear Case .............................. 150-05-23
Remove and Install Chopper
Blades and Kicker Plates....................... 150-05-25
Chopper Timing ......................................... 150-05-27
Adjust Chopper Flywheel Clutch ............... 150-05-29

TM100419 (02APR13) 150-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 150-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Chopper
Other Material
Number Name Use
0841306708 (U.S.) Araldite Cartridge Used to retain and lock threads.

(0841306707 Araldite Applicator


and 0841306709 Araldite Applicator
Nozzle are required to dispense
Araldite cartridge.)

PM38654 (U.S.) Thread Lock and Sealer (High Used to seal and lock threads.
271 (LOCTITE®) Strength)

PM37477 (U.S.) Thread Lock and Sealer (Medium To seal and retain threads.
242 (LOCTITE®) Strength)

PM37566 (U.S.) Loctite®Anti-Seize Lubricant To prevent seizing of components.

Loctite is a trademark of Henkel Corporation


PW66162,000095C -19-11FEB13-1/1

Special Tools
For more information, or to order tools referenced in this
group, see the SERVICEGARD™ online tool catalog or
your John Deere dealer.
SERVICEGARD is a trademark of Deere & Company
PW66162,00009CD -19-19MAR13-1/1

TM100419 (02APR13) 150-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=583
Chopper

Specifications
Item Measurement Specification

Inner Gear Case Backing Plate Torque 237.2 N·m


Cap Screws (175 lb.-ft.)
Duocone Seal Plate Cap Screws Torque 119.3 N·m
(88 lb.-ft.)
Drum Adapter Cap Screws Torque 119.3 N·m
(88 lb.-ft.)
Backing Plate Cap Screws Torque 119.3 N·m
(88 lb.-ft.)
Bearing Shaft Hub Cap Screws Torque 119.3 N·m
(88 lb.-ft.)
Chopper Bearing Cap Screws Torque 379.6 N·m
(280 lb.-ft.)
Chopper Gear-to-Drum Adapter Torque 427 N·m
Cap Screws (315 lb.-ft.)
Chopper Adjustment Lever Torque 427 N·m
Cap Screws (315 lb.-ft.)
Gear Case cover Cap Screws Torque 110 N·m
(80 lb.-ft.)
Chopper Access Cover Cap Screws Torque 27 N·m
(20 lb.-ft.)
Chopper Bearing Holder Cap Screws Torque 108.4 N·m
(80 lb.-ft.)
Bearing Seal Housing Cap Screws Torque 48.8 N·m
(36 lb.-ft.)
Bearing Keeper Ring Cap Screws Torque 48.8 N·m
(36 lb.-ft.)
Chopper Blade Cap Screws Torque 298.2 N·m
(220 lb.-ft.)
Kicker Plate Cap Screws) Torque 155.9 N·m
(115 lb.-ft.)
Flywheel Clutch Nut Torque 610 N·m
(450 lb.-ft.)
Flywheel Clutch Slippage Rotation Position 1/8—1/4 (movement from original
position)
PW66162,000095D -19-11FEB13-1/1

TM100419 (02APR13) 150-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=584
Chopper

Chopper Gear Case Exploded View

CM053510283 —UN—23AUG05

Continued on next page PW66162,00007B2 -19-11FEB13-1/2

TM100419 (02APR13) 150-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=585
Chopper

1— Gear Case 14— Gear (2 used) 29— Access Cover Gasket 45— Chopper Adjustment Lever
2— Cap Screw 15— Washer 30— Access Cover Gasket 46— Pin Adjustment
3— Bearing Hub 16— Cap Screw 31— Bearing Holder Gasket 47— Hex Bolt
4— Drum Adapter (2 used) 17— Bearing Cup 32— O-ring 48— Backing Plate (2 used)
5— Expansion Plug 18— Pinion Shaft 33— Fitting 49— Retainer Plate
6— Hex Bolt 19— Bearing Cone 34— O-ring 50— Washer
7— Seal Housing Bearing 20— Bearing Retainer 35— Cover 51— Cap Screw
8— Cap Screw 21— Washer 36— Breather 52— Sight Gauge
9— Dowel Pin 22— Hex Bolt 37— Access Cover 53— Duocone (2 used)
10— Spherical Roller Bearing 23— Seal 38— Access Cover 54— Hex Bolt
11— Bearing Keeper Ring 24— Clutch 39— Cap Screw 55— Hex Bolt
12— Cap Screw 25— Flywheel 40— Cap Screw 56— Washer
13— Duocone Seal 26— O-ring 41— Gear
27— Drain Magnetic Plug 42— N/A
28— Cover Gasket 43— Washer
44— Cap Screw
PW66162,00007B2 -19-11FEB13-2/2

TM100419 (02APR13) 150-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=586
Chopper

Chopper Drum Exploded View

CM073510704 —UN—23OCT07

A—Gear Box Side 3— Washer 7— Chopper Blade (3 used) 10— Cap Screw
B—Bearing Side 4— Kicker Chopper Keeper 8— Cap Screw (7 used each 11— Lock Nut
C—Cane Flow 5— Rubber Chopper Kicker blade) 12— Cap Screw
1— Upper Chopper Drum 6— Blade Clamping Bar (3 used) 9— Washer (7 used each blade) 13— Cap Screw
2— Lower Chopper Drum
PW66162,0000953 -19-08FEB13-1/1

TM100419 (02APR13) 150-05-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=587
Chopper

Remove and Install Chopper Assembly


Remove
SPECIAL TOOLS NEEDED:
1. Park machine on level surface. Shut off engine and
• Araldite Applicator remove key.
Used to dispense Araldite.
Tool Number—0841306707 2. Clean chopper gear case and surrounding area.
• Araldite Applicator Nozzle 3. Remove chopper motor. (See Remove and Install
Used to dispense Araldite. Chopper Motor in Section 70, Group 25.)
Tool Number—0841306709
• Araldite Cartridge 4. Remove chopper blades and retainers. (See Remove
Used to retain and lock threads. and Install Chopper Blades and Kicker Plates in
Tool Number—0841306708 Section 150, Group 05.)

CM073510585 —UN—10OCT07
5. Remove flywheel hub cap, nut, washers, clutch
pressure plate, metal locking disk, friction disk,
flywheel, and splined hub.
Continued on next page PW66162,00009DF -19-02APR13-1/40

TM100419 (02APR13) 150-05-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=588
Chopper

CAUTION: Dowel pins hold cover to gear case.


Be careful, cover is heavy.

6. Remove cap screws (40 and 44) from cover (35).


Using an appropriate pry bar, remove cover.

CM073510586 —UN—10OCT07
35— Cover 44— Cap Screws
40— Cap Screws

PW66162,00009DF -19-02APR13-2/40

7. Remove cap screws (39) and access covers (37 and


38).

37— Access Cover 39— Cap Screws


38— Access Cover

CM073510643 —UN—24MAR08
Continued on next page PW66162,00009DF -19-02APR13-3/40

TM100419 (02APR13) 150-05-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=589
Chopper

8. Remove adjustment lever (45).


9. Remove timing gears (14).

14— Timing Gears (2 used) 45— Adjustment Lever

CM073510587 —UN—03MAR08
CM073510588 —UN—03MAR08
PW66162,00009DF -19-02APR13-4/40

NOTE: Where Araldite has been used, the application


of heat aids in disassembly.

10. Remove bearings on opposite side of chopper.

CM073510589 —UN—10OCT07
Continued on next page PW66162,00009DF -19-02APR13-5/40

TM100419 (02APR13) 150-05-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=590
Chopper

11. Remove bearing shaft hubs.

CM073510590 —UN—03MAR08
PW66162,00009DF -19-02APR13-6/40

12. Install chopper shaft hanger tool into the bottom


bearing adapter (A) and chopper shaft.
13. Unbolt bearing adapters.

CM073510591 —UN—03MAR08
PW66162,00009DF -19-02APR13-7/40

NOTE: Where Araldite has been used, the application


of heat aids in disassembly

14. Remove shield ring halves from inside choppers.

CM073510592 —UN—03MAR08

Continued on next page PW66162,00009DF -19-02APR13-8/40

TM100419 (02APR13) 150-05-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=591
Chopper

15. Remove drum adapter (4).


16. Remove lower chopper drum.
17. Repeat necessary steps for upper drum removal.

CM073510593 —UN—03MAR08
PW66162,00009DF -19-02APR13-9/40

18. Remove bearing keeper rings (11).


19. Remove bearing (10) and bearing hub (3).

3— Bearing Hub (2 used) 11— Bearing Keeper Rings (2

CM073510594 —UN—24MAR08
10— Bearing (2 used) used)

CM073510595 —UN—24MAR08
Continued on next page PW66162,00009DF -19-02APR13-10/40

TM100419 (02APR13) 150-05-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=592
Chopper

CAUTION: Some chopper components are


sharp, heavy, and oily.

20. Remove bearing retainer (20).

CM073510596 —UN—24MAR08
21. Remove pinion shaft assembly (18).

18— Pinion Shaft Assembly 20— Bearing Holder

CM073510597 —UN—24MAR08
PW66162,00009DF -19-02APR13-11/40

22. Remove bearing seal (13) and housing (7).

7— Housing 13— Bearing Seal

CM073510598 —UN—24MAR08
Continued on next page PW66162,00009DF -19-02APR13-12/40

TM100419 (02APR13) 150-05-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=593
Chopper

CAUTION: Some chopper components are


sharp, heavy, and oily.

23. Using an appropriate lifting device, support gear case.


24. Remove cap screws (2) and gear case backing plates
(48). Remove gear case from frame.

2— Cap Screws (4 used each 48— Backing Plates (2 used)


plate)

CM073510599 —UN—24MAR08
PW66162,00009DF -19-02APR13-13/40

Install
1. Install chopper gear case (1) onto frame as shown
NOTE: Apply 0841306708 Araldite1 to backing plate
cap screws. 0841306707 Araldite Applicator1

CM073510609 —UN—03MAR08
and 0841306709 Araldite Applicator Nozzle1 are
required to apply 0841306708 Araldite1.

2. Install inner gear case backing plates (48) and cap


screws (2). Tighten backing plate cap screws to
specification.
Specification
Inner Gear Case
Backing Plate Cap
Screws—Torque.......................................................................237.2 N·m
(175 lb.-ft.)

CM073510610 —UN—03MAR08

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page PW66162,00009DF -19-02APR13-14/40

TM100419 (02APR13) 150-05-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=594
Chopper

NOTE: Always install upper chopper drum first.

3. Apply 0841306708 Araldite1 to Duocone seal plate


cap screws.Install Duocone seal plate (53) and cap
screws to top chopper drum. Tighten Duocone seal

CM073510611 —UN—03MAR08
plate cap screws to specification.
Specification
Duocone Seal Plate Cap
Screws—Torque....................................................................... 119.3 N·m
(88 lb.-ft.)

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00009DF -19-02APR13-15/40

4. Lightly sand with mild sandpaper bearing seal housing


(7) in chopper gear case and Duocone seal plate (53)
on chopper drum. Clean both parts with solvent and
blow dry with compressed air.

CM073510612 —UN—03MAR08
Continued on next page PW66162,00009DF -19-02APR13-16/40

TM100419 (02APR13) 150-05-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=595
Chopper

5. Remove half of seal from wrapping (one O-ring and


one retainer). Clean O-ring and retainer with alcohol.
Lubricate and install O-ring and retainer into seal
installer (2221352540).

CM073510613 —UN—03MAR08
a. Place seal with installer onto bearing seal housing
(7).
b. Tap installer lightly and install into bearing seal
housing (7) to seat seal.

CM073510614 —UN—03MAR08
CM073510615 —UN—03MAR08
PW66162,00009DF -19-02APR13-17/40

6. Remove the other half of seal from wrapping. Clean


O-ring and retainer with alcohol. Lubricate and install
O-ring and retainer into seal installer (2221352540).
a. Place seal with installer onto Duocone seal plate
CM073510616 —UN—03MAR08

(53) on chopper drum.


b. Tap installer lightly onto Duocone seal plate (53)
to seat seal.

Continued on next page PW66162,00009DF -19-02APR13-18/40

TM100419 (02APR13) 150-05-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=596
Chopper

7. Lubricate and install O-ring (26) onto bearing hub (3).

CM073510617 —UN—03MAR08
PW66162,00009DF -19-02APR13-19/40

8. Lightly oil the seal retainer surfaces of both halves of


seal.

CM073510618 —UN—03MAR08
PW66162,00009DF -19-02APR13-20/40

9. Install line up pins (three long bolts with heads


removed) into Duocone seal plate (53) on drum.

CM073510619 —UN—03MAR08

Continued on next page PW66162,00009DF -19-02APR13-21/40

TM100419 (02APR13) 150-05-15 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=597
Chopper

10. Install bearing adapter on chopper shaft hanger, then


slide hanger into chopper drum from opposite side of
seal.

CM073510620 —UN—03MAR08
PW66162,00009DF -19-02APR13-22/40

11. Install drum into frame with line up pins going through
bearing hub (3).

CM073510621 —UN—03MAR08
PW66162,00009DF -19-02APR13-23/40

12. Install gear adapter (4) onto line up pins and bearing
hub (3).

CM073510622 —UN—03MAR08

Continued on next page PW66162,00009DF -19-02APR13-24/40

TM100419 (02APR13) 150-05-16 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=598
Chopper

NOTE: Apply Thread Lock and Sealer (High Strength)


to drum adapter cap screws.

13. Install cap screws (6) with flat washers (43) into the
remaining nine holes of drum adapter (4). Tighten cap

CM073510623 —UN—03MAR08
screws slowly to pull chopper drum , bearing hub (3)
and drum adapter (4) together. Remove line up pins
and install cap screws (6) and washers (43). Tighten
drum adapter cap screws to specification.
Specification
Drum Adapter Cap
Screws—Torque....................................................................... 119.3 N·m
(88 lb.-ft.)

PW66162,00009DF -19-02APR13-25/40

NOTE: Apply 0841306708 Araldite1 to backing


plate cap screws.

14. Install bearing adapter, cap screws, and washers (10)


onto frame wall (A) with two backing plates on inside
wall. Tighten backing plate cap screws to specification.
Specification
Backing Plate Cap
Screws—Torque....................................................................... 119.3 N·m
(88 lb.-ft.)

15. Remove copper drum support device.

A—Frame Wall

CM073510624 —UN—10OCT07
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00009DF -19-02APR13-26/40

16. Drive expansion plugs (5) in bearing shaft hub (3)


opposite bolt flange side.
CM073510625 —UN—03MAR08

Continued on next page PW66162,00009DF -19-02APR13-27/40

TM100419 (02APR13) 150-05-17 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=599
Chopper

NOTE: Apply Thread Lock and Sealer (High Strength)


to bearing shaft hub cap screws.

17. Install bearing shaft hub, cap screws (9), and washers
(10) onto chopper drum. Tighten bearing shaft hub

CM073510626 —UN—03MAR08
cap screws to specification.
Specification
Bearing Shaft Hub Cap
Screws—Torque....................................................................... 119.3 N·m
(88 lb.-ft.)

18. Apply Anti-seize on bearing shaft hub (3) opposite bolt


flange side.
PW66162,00009DF -19-02APR13-28/40

NOTE: Apply Thread Lock and Sealer (High


Strength) to bearing cap screws and bearing
locking collar set screws.
Install bearing with grease fitting downward.

CM073510627 —UN—03MAR08
Drum assembly must rotate freely.

19. Install bearing (4), cap screws, and washers (12).


Tighten bearing cap screws to specification.
Specification
Chopper Bearing Cap
Screws—Torque.......................................................................379.6 N·m
(280 lb.-ft.)

20. Install locking collar on bearing and tighten set screws.

CM073510628 —UN—03MAR08
Continued on next page PW66162,00009DF -19-02APR13-29/40

TM100419 (02APR13) 150-05-18 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=600
Chopper

21. Install blades and kickers on top drum. (See Remove


and Install Chopper Blades and Kicker Plates in
Section 150, Group 05.)
22. Repeat necessary steps and install lower chopper

CM073510629 —UN—03MAR08
drum.
23. Clean inside of chopper gear case with solvent and
blow dry with compressed air.

PW66162,00009DF -19-02APR13-30/40

NOTE: Heat bearing cone in an oven to aid in assembly.

24. Install bearing cones (19) onto pinion shaft (18). Place
pinion shaft assembly and bearing cups (17) into
freezer to cool.

CM073510630 —UN—24MAR08
1— Chopper Gear Case 18— Pinion Shaft
17— Bearing Cup (2 used) 19— Bearing Cone (2 used)

PW66162,00009DF -19-02APR13-31/40

25. Install gear (14) on lower chopper drum adapter


(4). Apply 0841306708 Araldite1 and install bolts
(16) and washers (15) into round holes in gear (14).
Tighten gear-to-chopper drum adapter cap screws to
specification.

CM073510631 —UN—03MAR08
Specification
Chopper Gear-to-Drum
Adapter Cap
Screws—Torque..........................................................................427 N·m
(315 lb.-ft.)

1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
Continued on next page PW66162,00009DF -19-02APR13-32/40

TM100419 (02APR13) 150-05-19 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=601
Chopper

26. Install gear (14) on top chopper drum adapter (4).


Start all bolts (16) then turn gear all the way counter
clockwise until bolts hit end of slot in gear or as close
as possible. Tighten gear-to-drum adapter cap screws
to specification.

CM073510632 —UN—03MAR08
Specification
Chopper Gear-to-Drum
Adapter Cap
Screws—Torque..........................................................................427 N·m
(315 lb.-ft.)

PW66162,00009DF -19-02APR13-33/40

27. Install pin (46) into upper gear (14).


28. Line up chopper adjustment lever (45) slot with two
holes in drum adapter (4). Install cap screws (47) into
slot as near to the end of slot as possible. Tighten

CM073510633 —UN—03MAR08
chopper adjustment lever cap screws to specification.
Specification
Chopper Adjustment
Lever Cap
Screws—Torque..........................................................................427 N·m
(315 lb.-ft.)

4— Drum Adapter 46— Pin


14— Upper Gear 47— Cap Screws (2 used)
45— Adjustment Lever

PW66162,00009DF -19-02APR13-34/40

29. Remove pinion shaft assembly from freezer and install


assembly in chopper gear case.

CM073510597 —UN—24MAR08

Continued on next page PW66162,00009DF -19-02APR13-35/40

TM100419 (02APR13) 150-05-20 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=602
Chopper

30. Using gasket adhesive, attach gasket (28) to cover


(35).

28— Gasket 35— Cover

CM073510640 —UN—24MAR08
PW66162,00009DF -19-02APR13-36/40

31. Apply Loctite Thread Lock and Sealer (Medium


Strength) to chopper gear case cover cap screws (44).
32. Install cover (35) and cap screws to chopper gear case.
Tighten gear case cover cap screws to specification.

CM073510641 —UN—24MAR08
Specification
Gear Case cover Cap
Screws—Torque.......................................................................... 110 N·m
(80 lb.-ft.)

44— Gear Case Cover Cap 35— Cover


Screws

PW66162,00009DF -19-02APR13-37/40

33. Using gasket adhesive, attach gaskets (29 and 30) to


covers (37 and 38).
34. Apply Loctite Thread Lock and Sealer (Medium
Strength) to access cover cap screws.

CM073510634 —UN—24MAR08
35. Install access covers and cap screws (39) to chopper
gear case cover (35). Tighten access cover cap
screws to specification.
Specification
Chopper Access Cover
Cap Screws—Torque....................................................................27 N·m
(20 lb.-ft.)

29— Gasket 37— Access Cover


30— Gasket 38— Access Cover
35— Chopper Gear Case Cover 39— Cap Screws

Continued on next page PW66162,00009DF -19-02APR13-38/40

TM100419 (02APR13) 150-05-21 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=603
Chopper

36. Install seal (23) to bearing retainer (20).


37. Using gasket adhesive, attach gasket (31) to bearing
retainer.
38. Apply Loctite Thread Lock and Sealer (Medium

CM073510635 —UN—24MAR08
Strength) to bearing retainer cap screws (22).
39. Install bearing retainer onto gear case with cap screws
and washers (21). Tighten bearing retainer cap screws
to specification.
Specification
Chopper Bearing Holder
Cap Screws—Torque...............................................................108.4 N·m
(80 lb.-ft.)

20— Bearing Retainer 23— Seal


21— Washer 31— Gasket
22— Cap Screw

CM073510636 —UN—24MAR08
PW66162,00009DF -19-02APR13-39/40

40. Install Teflon tape on magnetic drain plug (27) and


install.
41. Install chopper motor. (See Remove and Install
Chopper Motor in Section 70, Group 25.)

CM073510644 —UN—24MAR08
42. Fill chopper gear case with oil. (See Pump Drive,
Base Cutter, and Chopper Gear Case Oil in Section
10, Group 15.)

PW66162,00009DF -19-02APR13-40/40

TM100419 (02APR13) 150-05-22 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=604
Chopper

Disassemble and Assemble Chopper Gear


Case
1. Clean chopper gear case. Wash with hot water
pressure washer and rinse with Geoguard

CM073510600 —UN—03MAR08
(SUP1405706). Blow dry with compressed air.
NOTE: Apply Thread Lock and Sealer (High Strength)
to bearing seal housing cap screws.
Apply Blue Silicone (0430024221) to bearing
seal housing.

2. Install bearing housing (7) into gear case (1) with cap
screws and dowel pins. Tighten bearing seal housing
cap screws to specification.
Specification
Bearing Seal Housing
Cap Screws—Torque.................................................................48.8 N·m
(36 lb.-ft.)

CQ280272 —UN—27FEB08
CQ280273 —UN—27FEB08
CM073510602 —UN—03MAR08

Continued on next page PW66162,00007B4 -19-11FEB13-1/5

TM100419 (02APR13) 150-05-23 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=605
Chopper

NOTE: Install the oil filler groove to top of gear case.

3. Install expansion plug (5) into bearing hub (3).

CM073510603 —UN—03MAR08
PW66162,00007B4 -19-11FEB13-2/5

4. Press bearing (10) onto bearing hub (3).

3— Bearing Hub 10— Bearing

CM073510604 —UN—03MAR08
PW66162,00007B4 -19-11FEB13-3/5

NOTE: Block and support gear case before applying


press force to install bearing assembly.

5. Press bearing assembly into bearing seal housing (7).

CM073510605 —UN—03MAR08

Continued on next page PW66162,00007B4 -19-11FEB13-4/5

TM100419 (02APR13) 150-05-24 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=606
Chopper

NOTE: Apply Thread Lock and Sealer (High Strength)


to bearing keeper ring cap screws.

6. Install bearing keeper ring (11) and cap screws. Tighten


bearing keeper ring cap screws to specification.

CM073510606 —UN—03MAR08
Specification
Bearing Keeper Ring Cap
Screws—Torque.........................................................................48.8 N·m
(36 lb.-ft.)

11— Bearing Keeper Ring

CM073510608 —UN—03MAR08
PW66162,00007B4 -19-11FEB13-5/5

Remove and Install Chopper Blades and


Kicker Plates
Remove

CM073510708 —UN—24MAR08
1. Remove nuts (11), cap screws (10), and kickers plates
(5).

5— Kicker Plate (3 used) 11— Nut


10— Cap Screw

Continued on next page PW66162,00007BB -19-11FEB13-1/4

TM100419 (02APR13) 150-05-25 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=607
Chopper

2. Remove cap screws (8), washers (9), clamping bar


(6), and blades (7).

6— Clamping Bar (3 used) 8— Cap Screw (7 used each


7— Blade (3 used) blade)

CM073510707 —UN—24MAR08
9— Washer (7 used each blade)

PW66162,00007BB -19-11FEB13-2/4

Install
1. Clean chopper drum and clamping bars.
2. Apply Anti-Seize Lubricant to cap screws (8).

CM073510707 —UN—24MAR08
3. Install cap screws, washers (9), and clamping bar (6).
Do not tighten cap screws until instructed.
NOTE: Make sure that the blade is seated correctly on
inside ledge before tightening cap screws .

4. Install blade (7) into slot of drum between clamping bar


and drum with slanting side facing outward. Tighten
blade cap screws to specification.
Specification
Chopper Blade Cap 6— Clamping Bar (3 used) 8— Cap Screw (7 used each
7— Blade (3 used) blade)
Screws—Torque.......................................................................298.2 N·m 9— Washer (7 used each blade)
(220 lb.-ft.)

PW66162,00007BB -19-11FEB13-3/4

5. Install cap screws (10), kicker plates (5), and nuts (11).
Tighten kicker plate cap screws to specification.
Specification
Kicker Plate Cap
Screws)—Torque......................................................................155.9 N·m

CM073510708 —UN—24MAR08
(115 lb.-ft.)

5— Kicker Plate (3 used) 11— Nut


10— Cap Screw

PW66162,00007BB -19-11FEB13-4/4

TM100419 (02APR13) 150-05-26 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=608
Chopper

Chopper Timing
SPECIAL TOOLS NEEDED:
• Araldite Applicator
Used to dispense Araldite.

NW271120 —UN—15MAY06
Tool Number—0841306707
• Araldite Applicator Nozzle
Used to dispense Araldite.
Tool Number—0841306709
• Araldite Cartridge
Used to retain and lock threads.
Tool Number—0841306708
1. Park machine on level surface. Shut off engine and Cane flow
remove key.
2. Clean chopper drums, gear case, and surrounding
area.
3. If necessary, install new blades and kicker plates.
(See Remove and Install Chopper Blades and Kicker

CQ291723 —UN—16APR12
Plates in Section 150, Group 05.)
4. Ensure that blades are installed correctly, as shown.
Upper blade leads the lower blade as the cane is cut
into billets.
5. Open flywheel cover (A) and rotate flywheel clockwise
to view normal rotation. Upper blades should contact
lower blades along the entire length of the blade with
a minimum amount of impact. A mark showing the
contact pattern should appear on the lower blades. If
blades are not making proper contact, remove access
cover (B).
6. Loosen cap screws located in gear and the two cap
screws securing adjustment lever.
7. Using a rubber mallet, tap adjustment lever
counterclockwise at location (C) until cap screws hit
end of slots in gear, or as close as possible. Tighten
two opposing cap screws in gear.
8. Repeat steps necessary to check blade contact.

CM023500100 —UN—07FEB05
9. If further adjustment is needed, remove cap screw (D)
and install into position (E). Repeat step 7.
NOTE: Apply 0841306708 Araldite1 to gear-to-drum
adapter and adjustment lever cap screws.
0841306707 Araldite Applicator1 and 0841306709
Araldite Applicator Nozzle1 are required to
apply 0841306708 Araldite1.

10. When blade contact is correct, tighten gear-to-drum A—Flywheel Cover D—Cap Screw
adapter and adjustment lever cap screws to B—Access Cover E—Position
specification. C—Location
Specification
Chopper Adjustment
Chopper Gear-to-Drum
Lever Cap
Adapter Cap
Screws—Torque..........................................................................427 N·m
Screws—Torque..........................................................................427 N·m
(315 lb.-ft.)
(315 lb.-ft.)

Continued on next page PW66162,00009E0 -19-02APR13-1/2

TM100419 (02APR13) 150-05-27 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=609
Chopper

NOTE: Apply Loctite Thread Lock and Sealer (Medium Specification


Strength) to access cover cap screws. Chopper Access Cover
Cap Screws—Torque....................................................................27 N·m
11. Install access cover and tighten cap screws to (20 lb.-ft.)
specification.
1
For further information, see SERVICEGARD online tool catalog
or your John Deere dealer.
PW66162,00009E0 -19-02APR13-2/2

TM100419 (02APR13) 150-05-28 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=610
Chopper

Adjust Chopper Flywheel Clutch

CAUTION: Avoid serious injury or death.


Shut OFF engine and wait for harvesting
functions to completely stop before servicing
chopper assembly.

1. Rotate latch and lower flywheel shield (C) to the open


position.
2. Remove cap screws (A) and cover (B).

T8130000594 —UN—07FEB13
3. Check that flywheel clutch nut (F) is tightened to
specification.
Specification
Flywheel Clutch
Nut—Torque................................................................................610 N·m
(450 lb.-ft.)

NOTE: Crop conditions can affect flywheel clutch slippage.

4. Test chopper flywheel clutch slippage:


a. Mark a line (D) across flywheel and housing as
shown. Close flywheel shield.
b. Harvest one row or a minimum of approximately
200 m (656 ft.) of crop.
c. Compare the new position of flywheel mark to the
housing mark. Check that flywheel clutch slippage
(H) is to specification.

T8130000595 —UN—07FEB13
Specification
Flywheel Clutch
Slippage—Rotation
Position................................. 1/8—1/4 (movement from original position)

IMPORTANT: Overtightening flywheel clutch


causes premature failure of chopper, gears,
shaft, bearings, and seals.
Excessive flywheel clutch slippage can cause
chopper to “choke” and flywheel clutch
to wear out prematurely. A—Cap Screw (6 used) E—Rotate Flywheel Clutch Nut
B—Cover Clockwise (less slippage)
C—Flywheel Shield F— Flywheel Clutch Nut
5. Determine adjustment needs: D—Line G—Rotate Flywheel Clutch Nut
Counterclockwise (more
• Flywheel rotation is within specification — no slippage)
adjustments are necessary. H—Flywheel Clutch Slippage
• Flywheel rotation is more than 1/4 turn — clutch set
too loose. Rotate nut clockwise (E).
• Flywheel rotation is less than 1/8 turn — clutch set 7. Install cover and cap screws.
too tight. Rotate nut counterclockwise (G).
6. If adjustments are made, repeat necessary steps and 8. Close flywheel shield.
check slippage.
PW66162,00007BD -19-14FEB13-1/1

TM100419 (02APR13) 150-05-29 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=611
Chopper

TM100419 (02APR13) 150-05-30 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=612
Section 160
Cleaning System
Contents

Page

Group 05—Primary Extractor


Other Material.............................................. 160-05-1
Specifications .............................................. 160-05-1
Adjust Primary Extractor Chain
Tension .................................................... 160-05-1
Primary Extractor Fan Blade
Assembly Exploded View ........................ 160-05-2
Installing the Hub to the Motor
Shaft ........................................................ 160-05-2
Install Fan Blades, Doubler Plates,
and Backing Plates.................................. 160-05-3
Safety Start-Up ............................................ 160-05-4

TM100419 (02APR13) 160-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 160-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Primary Extractor
Other Material
Number Name Use
PM38654 (U.S.) Thread Lock and Sealer (High Used to seal and lock threads.
271 (LOCTITE®) Strength)

Loctite is a trademark of Henkel Corporation


PW66162,0000989 -19-13FEB13-1/1

Specifications
Item Measurement Specification

Fan Hub Cap Screws Torque 169 N·m


(125 lb.-ft.)
Fan Carriage Bolts Torque 135.6 N·m
(100 lb.-ft.)
PW66162,000098A -19-13FEB13-1/1

Adjust Primary Extractor Chain Tension

CAUTION: Avoid serious injury or death, Shut


OFF engine, remove ignition key, and wait
for harvesting functions to completely stop

T8120002636 —UN—07JAN13
before servicing extractor.

NOTE: Tension is adjusted on the right-hand side


of extractor hood.

1. Loosen jam nut (A).


2. Turn adjustment nut (B) to increase or decrease chain
tension.
• Clockwise rotation (C) — increase chain tension A—Jam Nut C—Increase Tension Rotation
• Counterclockwise rotation — decrease chain tension B—Adjustment Nut D—Extractor Chain

3. Adjust tension until chain (D) does not sag around


hood ring. Do not overtighten.
PW66162,00009AB -19-27FEB13-1/1

TM100419 (02APR13) 160-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=615
Primary Extractor

Primary Extractor Fan Blade Assembly


Exploded View
7— Hub Cap Screw (16 used) 21— Tube
9— Cap Screw 24— Hub
10— Lock Nut 25— Fan Blade (4 used)
11— Washer 26— Doubler Plate
15— Washer 27— Backing Plate
16— Nut 29— Carriage Bolt (4 used)
17— Cotter Pin 32— Washer
19— Lock Washer

CM073510645 —UN—15OCT07
PW66162,00007BF -19-13FEB13-1/1

Installing the Hub to the Motor Shaft


NOTE: Use the proper lock-out tag-out procedure
before working on machine. Never remove the
complete fan assembly from the motor shaft.
Always remove the blades and doubler plates
before removing the blade hub.

1. Remove shaft nut (16) and cotter key (17) from the
motor shaft.
2. Remove any tape that may be holding the cotter key
in place.
3. Clean the shaft and apply one “dab” of grease to CM073510646 —UN—15OCT07
keyway.
NOTE: Washers may be needed to adjust the height
of the nut where as the motor shaft pin hole is
at least half the height of the nut.

4. Reinstall key to keyway.


5. Line up keyways on shaft and hub, then install hub on
shaft (larger opening hub). Press firmly against the
hub upward to ensure that the hub has topper out on
shaft shoulder. 7. Do not back off nut (16) to install the cotter pin (17).
Tighten if needed, then install cotter pin.
6. Install and torque motor shaft nut (16) to 542 N·m (400
lb-ft).
PW66162,00007C0 -19-23OCT12-1/1

TM100419 (02APR13) 160-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=616
Primary Extractor

Install Fan Blades, Doubler Plates, and


Backing Plates
IMPORTANT: Always replace fan blades as a complete
set. Do not install new blades with old blades.
Always replace doubler plates as a complete
set. Do not install new plates with old plates

NOTE: It is not necessary to replace doubler plates


each time fan blades are replaced.

1. Temporarily install, but do not tighten two hub cap


screws (7) into hub (24).

CM073510648 —UN—15OCT07
NOTE: Backing plate (27) must be on bottom of fan
blade with curvature facing upward.

2. Insert one fan blade (25) and doubler plate (26)


between hub and backing plate (27) and between two
temporary hub cap screws.
3. Start two cap screws through backing plate, fan blade,
and doubler plate to penetrate hub by approximately
19 mm (3/4”).
7— Hub Cap Screws (16 used) 26— Doubler Plate
4. Repeat step 2 at 180° from the first blade. 24— Hub 27— Backing Plate
25— Fan Blade (4 used)
5. Remove the first two temporary hub cap screws from
step 1.
6. Repeat step 2 for remaining fan blades.
Continued on next page PW66162,00007C1 -19-13FEB13-1/2

TM100419 (02APR13) 160-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=617
Primary Extractor

NOTE: Apply Thread Lock and Sealer (High Strength)


to fan hub cap screws.

7. Install remaining eight hub cap screws (7) with Thread


Lock and Sealer (High Strength) and flat washer (15).
Start cap screws to penetrate hub by 19 mm (3/4”).
8. Remove hub cap screws without Thread Lock and
Sealer (High Strength) from step 2 through step 5.
9. Apply Thread Lock and Sealer (High Strength) and
install the remaining eight hub cap screws (7) with and
flat washer (15). Start hub cap screws to penetrate
hub by approximately 19 mm (3/4”).

CM073510649 —UN—15OCT07
NOTE: Apply Thread Lock and Sealer (High Strength)
to fan carriage bolts.

10. Install carriage bolts (29), flat washers (11), and


vibration resistant nuts (5) on doubler plates and
blades.
11. Tighten all fan hub cap screws in an alternating pattern
to specification.
12. Tighten fan carriage bolts to specification.
Specification
Fan Hub Cap
Screws—Torque..........................................................................169 N·m
(125 lb.-ft.)
Fan Carriage
Bolts—Torque...........................................................................135.6 N·m
(100 lb.-ft.)

5— Nut 15— Flat Washer


7— Hub Cap Screw 29— Carriage Bolt (4 used)
11— Flat Washer

CM073510650 —UN—15OCT07
PW66162,00007C1 -19-13FEB13-2/2

Safety Start-Up 4. Slowly increase fan speed at a rate of 100 RPMs


1. Be sure all personnel and tools have evacuated the per 1/2 minute until full speed has been achieved.
area. If any vibration was observed from the fan, STOP
the machine immediately and follow proper Lock-Out
2. Follow proper Lock-Out Tag-Out procedure for starting Tag-Out procedures before investigating any possible
up the machine problem.
3. Start fan at 100 to 200 RPMs to check for vibration. (Be 5. If no vibration was observed, proceed with normal and
sure no personnel are within 300 feet of the machine.) safe machine operation.
PW66162,00007C2 -19-23OCT12-1/1

TM100419 (02APR13) 160-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=618
Section 170
Elevator System
Contents

Page

Group 05—Elevator Systems Installation


Elevator Floor and Wearstrips
Installation ............................................... 170-05-1
Elevator Extension....................................... 170-05-3
Elevator Group ............................................ 170-05-4
Adjust Elevator Chain .................................. 170-05-4
Remove and Install Elevator Chain
Slats......................................................... 170-05-6
Remove and Install Elevator Wear
Strips ....................................................... 170-05-7
Changing Chain and Sprockets................... 170-05-7
Chain Removal on Repair ........................... 170-05-7
Elevator Sprocket and Chain....................... 170-05-8
Elevator Swing Table ................................. 170-05-10
Standard Elevator...................................... 170-05-12
Elevator Extensions................................... 170-05-13

TM100419 (02APR13) 170-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 170-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Elevator Systems Installation
Elevator Floor and Wearstrips Installation

CM053510309 —UN—21SEP05

1— Tail End Wearstrip 5— Middle Middle Wearstrip 9— Middle Left Hand Floor 13— Lock Nut
2— Lower Middle Wearstrip 6— Middle Bottom Wearstrip Assembly 14— Floor Bottom Retainer
3— Lower Bottom Wearstrip 7— Rolled Wearstrip 10— Middle Right Hand Floor
4— Middle Top Wearstrip 8— Bottom Corner Floor Assembly
Assembly 11— Bolt
12— Washer
Continued on next page PW66162,00007C3 -19-23OCT12-1/2

TM100419 (02APR13) 170-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=621
Elevator Systems Installation

1. Install items 1-7.


2. Install items 8-10.
PW66162,00007C3 -19-23OCT12-2/2

TM100419 (02APR13) 170-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=622
Elevator Systems Installation

Elevator Extension

CM053510310 —UN—21SEP05

Continued on next page PW66162,00007C4 -19-23OCT12-1/2

TM100419 (02APR13) 170-05-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=623
Elevator Systems Installation

1— Elevator Frame — 12 in. Left 6— Floor Assembly — 12 in. 12— Hi Ridge Slat Assembly 26— Nut
Hand Top Extension Extension Right Hand 13— Sheet — Wild Cart Guard 27— Bolt
2— Elevator Frame — 12 in. Right 7— Floor Assembly — 12 in. 14— Sheet — Cart Guard Clip 28— Hose Clamp
Hand Top Extension Extension Left Hand 15— Elevator Chain 29— Bolt
3— Elevator Frame — 12 in. Right 8— Sheet — Top Brace 12 in. 16— Connecting Link 30— Bolt
Hand Bottom Extension Extension 17— Inner Link 31— Elevator Cover Plate
4— Elevator Frame — 12 in. Left 9— Wearstrip — Top 12 in. 18— Bolt 32— Flex Trim
Hand Bottom Extension Extension 19— Nut 33— Bolt
5— N/A 10— Wearstrip — Middle 20— Bolt 34— Bolt
11— Wearstrip — Bottom 21— Bolt 35— Direct Drive Mount
22— Washer Assembly
23— Nut 36— Direct Drive Mount
24— Bolt Assembly
25— Washer 37— Washer

1. Install items 1 and 2.


5. Install item 9.
2. Install items 6 and 7.
6. Install items 13 and 14.
3. Install item 11.
4. Install item 10.
PW66162,00007C4 -19-23OCT12-2/2

Elevator Group links. The conveyor is driven by orbital motors, mounted


on both sides, and it is fully reversible to clear blockages.
The elevator has a high clearance to minimize the
damage caused by various cane collection containers that To maintain correct chain tension, the drive shaft grease
come into contact with the underside of the elevator. The cylinders are mounted in order to allow chain adjustment.
elevator is adjustable in height; this is controlled from the The chains are driven by two sprockets that are bolted to
cab by two hydraulic cylinders supporting the elevator. the motors. The idler shaft sprockets are held in place by
This allows the elevator to be lowered for traveling in areas a machined shaft, bearings, and retaining nuts. There
of overhead obstructions, and to minimize the height of are replaceable wearstrips bolted to the elevator chain
platforms required to work on the secondary extractor. runners. When these have excessive wear, they should
be replaced along with all retaining bolts.
The elevator swings through 180°.
The elevator is made up of twin lengths of roller type
chain, connected by slats, which are bolted to the chain
PW66162,00007C5 -19-23OCT12-1/1

Adjust Elevator Chain


Adjusting Tension

CAUTION: Be extremely careful when relieving

T8120002637 —UN—07JAN13
grease from the adjusting cylinder (B). Grease
under pressure can penetrate the skin. Eye
protection needs to be worn.

IMPORTANT: The cylinders on both sides should be


adjusted equally until the correct tension is
obtained in order to maintain perpendicularity
between the slats and side wall.

1. To increase chain tension: pump an equal amount


A—Grease Fitting B—Grease Relief Valve
of grease into fitting (A) on each side of elevator.
Cylinders must have chain tension increased equally
to maintain proper movement of chain slats along
elevator side walls. Cylinders must have tension released equally on each
side of the elevator.
2. To decrease chain tension: slowly open valve (B)
to allow grease to escape from tension cylinder.
Continued on next page PW66162,00009A8 -19-27FEB13-1/2

TM100419 (02APR13) 170-05-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=624
Elevator Systems Installation

Checking Elevator Chain Tension

T8130000349 —UN—24JAN13
CAUTION: Avoid serious injury. Shut OFF
engine and remove ignition key before
checking chain tension.

1. Starting from the lower part of the elevator, measure

T8130000350 —UN—24JAN13
up 305 mm (12 in.) (A). The chain rollers should start
touching the wear strip (B) at this point.
• Chain rollers touch wear strip before this point —
chain is too loose.
• Chain rollers touch wear strip after this point — chain
is too tight.
Add or release grease to adjust chain tension (see
Adjusting Tension in this section).
A—Measurement D—Idler Sprocket
NOTE: Verify wear strips are not excessively worn B—Lower Wear Strip E—Adjustment Nut
when checking chain tension. Replace wear C—Gap
strips if necessary (refer to Remove and Install
Elevator Wear Strips in this section).
3. It may be necessary to adjust the idler sprocket (D)
2. Under lower part of elevator, measure gap (C) between position to obtain proper tension readings.
end of the wear strip and adjacent chain roller.
Specification
• To lower sprocket (increases chain tension), tighten
adjustment nut (E).
Roller to Wear
Strip—Gap..................................................................................... 25 mm
• To raise sprocket (decreases chain tension), loosen
adjustment nut (E).
(1 in.)
IMPORTANT: Always check chain tension after
• Gap is less than specification — chain is too loose. changing idler sprocket position. Position
• Gap is more than specification — chain is too tight. of idler sprocket will affect amount of
Add or release grease to adjust chain tension (see chain tension applied.
Adjusting Tension in this section).
PW66162,00009A8 -19-27FEB13-2/2

TM100419 (02APR13) 170-05-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=625
Elevator Systems Installation

Remove and Install Elevator Chain Slats


1. Shut OFF engine and remove ignition key.
2. Remove cap screws and lock nuts (A) from both ends
of slat (B).

T8120002638 —UN—07JAN13
3. Remove slat from chain.
4. Every 500 Hours of Operation: Move every slat to the
next link (C) and reinstall.
5. Install slats in reverse order of removal.
IMPORTANT: Slats must be oriented correctly for
proper operation. Raised edges (D) must be
facing the forward direction of chain travel.
Adding extra slats to elevator chain will
decrease chain life.

T8120002411 —UN—03DEC12
A—Cap Screws and Lock Nuts C—Chain Link
(4 used) D—Slat Edges
B—Slat (23 used)

PW66162,00009A9 -19-27FEB13-1/1

TM100419 (02APR13) 170-05-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=626
Elevator Systems Installation

Remove and Install Elevator Wear Strips

T8130000203 —UN—21JAN13
A—Wear Strips (22 used)

The elevator chain follows a channel that is lined with Wear strips are installed with socket-drive screws,
replaceable wear strips (A). These strips can be replaced washers, and lock nuts.
individually if necessary.
PW66162,00009AA -19-27FEB13-1/1

Changing Chain and Sprockets 2. Separate (break) both chains and remove them from
If either the elevator chains or sprockets need changing, the elevator.
John Deere recommends that both are changed at the 3. Remove the two bolts securing each hydraulic motor
same time. A worn part mated to a new one will not to the bearing carrier assembly. Pull out the motors
operate at its optimal capacity. and store on the floor, inside of the elevator.
1. Loosen and remove the bolts and slats from the chain
assembly.
PW66162,00007C7 -19-23OCT12-1/1

Chain Removal on Repair


3. To rejoin the chain, the same link can be reused.
1. Locate the position where the chain is to be broken, Replace the link pins with 2 - 1/4 inch x 3/8 inch bolts
and grind the peened edge of both pins located in and 2-3/8 inch nuts. Place them through the link to
the link. locate the link's side plate.
2. Remove the side plate from the link and remove that
link from the two ends of the chain.
PW66162,00007C8 -19-23OCT12-1/1

TM100419 (02APR13) 170-05-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=627
Elevator Systems Installation

Elevator Sprocket and Chain

CM053510311 —UN—30SEP05

Continued on next page PW66162,00007C9 -19-23OCT12-1/2

TM100419 (02APR13) 170-05-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=628
Elevator Systems Installation

1— Tailshaft 13— Sprocket 24— Bearing In Retainer 38— Bolt


2— Tailshaft Mount 14— Sprocket 25— O-ring 39— Bolt
3— Sprocket Chain Adjuster 15— Sprocket Spindle 26— Lock Nut 40— Lock Nut
4— N/A 16— Lower Lift Link Spacer 27— Washer 41— Bolt
5— N/A 17— Ball Bearing 28— Elevator Chain 42— Bolt
6— Direct Drive Adjuster 18— Snap Ring 29— Inner Link 43— Bolt
7— N/A 19— Retaining Ring 30— Connecting Link 44— FMS - Floor Retainer
8— Floor Support 20— Bearing 31— Bolt 45— RMT- Spacer
9— Elevator Chain Assembly 21— Special Set Screw 32— Nut 46— Bolt
10— Slat Assembly 22— Bearing Out Retainer 33— Bolt 47— Washer
11— Sprocket Hub 23— Zerk 34— Washer 48— Lock Washer
12— Sprocket 35— Washer 49— Nut
36— Lock Nut 50— Nut
37— Bolt 51— Washer

A - In Seat Right Side B - In Seat Left Side


PW66162,00007C9 -19-23OCT12-2/2

TM100419 (02APR13) 170-05-9 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=629
Elevator Systems Installation

Elevator Swing Table

CM053510312 —UN—30SEP05

Continued on next page PW66162,00007CA -19-23OCT12-1/2

TM100419 (02APR13) 170-05-10 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=630
Elevator Systems Installation

1— Lock Nut 12— Lock Nut 23— Sheave Pin Assembly 34— Washer
2— Bolt 13— Washer 24— RMT - Spacer 35— Bolt
3— RMT- Spacer Swing 14— Zerk 25— Elevator Sheave Cable 36— Sheave Pin Cylinder
4— Washer 15— Washer 26— Elevator Sheave Assembly
5— Swing Table Assembly 16— Lower Table Washer 27— Bolt 37— KLIK Pin
6— Trunnion Pin 17— Upper Table Washer 28— N/A 38— Washer
7— Table Pin 18— Zerk 29— Washer 39— Elevator Block Plate
8— Cylinder Pin 19— Bolt 30— Lock Nut 40— Bolt
9— Ball Bushing 20— Lock Washer 31— Cylinder Pin 41— Washer
10— Bolt 21— Bushing 32— Spacer 42— Lubricant
11— Swing Table Pin Assembly 22— Elevator Sheave Assembly 33— Washer 43— Modified Bolt

Item (A) is welded to Item (5). bearings and is controlled by two opposing cylinders,
which are pin attached. The two cylinders operate in
Fill gaps (B) with shims, items (13 and 16). opposition and turn the table through 180°. The two pivot
The elevator swing table is mounted to the main frame by pins secure the swing table to the main frame with nylon
two pins (7 and 11). The table pivots on two spherical locknuts on each pin.
PW66162,00007CA -19-23OCT12-2/2

TM100419 (02APR13) 170-05-11 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=631
Elevator Systems Installation

Standard Elevator

CM053510314 —UN—03OCT05

1— Upper Top Wearstrip 5— Upper Right Hand Floor Assy 11— Bolt 16— Lock Washer
2— Upper Mid Wearstrip 6— Bolt 12— Bolt 17— Wiper Belt
3— Upper Bottom Wearstrip 7— Washer 13— Direct Drive Mount Assy R 18— Bolt
4— Upper Left Hand Floor Assy 8— Lock Nut 14— Direct Drive Mount Assy L 19— Backing Plate
9— Cart Guard Sheet 15— Bolt
10— Cart Guard Clip
Continued on next page PW66162,00007CB -19-23OCT12-1/2

TM100419 (02APR13) 170-05-12 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=632
Elevator Systems Installation

A - The last set of studs on this end do not require nuts


2. Install items 4 & 5.
and washers until installation of drive components.
1. Install items 1, 2 & 3.
PW66162,00007CB -19-23OCT12-2/2

Elevator Extensions
See parts catalog for installation of 12 inch or 24 inch
elevator extensions.
PW66162,00007CC -19-23OCT12-1/1

TM100419 (02APR13) 170-05-13 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=633
Elevator Systems Installation

TM100419 (02APR13) 170-05-14 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=634
Section 199
Dealer Fabricated Tools
Contents

Page

Group 05—Dealer Fabricated Tools


DFRW20—Compressor Holding
Fixture...................................................... 199-05-1

TM100419 (02APR13) 199-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Contents

TM100419 (02APR13) 199-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Group 05
Dealer Fabricated Tools
DFRW20—Compressor Holding Fixture

RW13619 —UN—20SEP89
A—102 mm (4 in.) D—6.4 mm (0.25 in.) G—254 mm (10 in.) J— Weld
B—76 mm (3 in.) E—19 mm (0.75 in.) H—114 mm (4.5 in.) K—Two Holes
C—70 mm (2.75 in.) F— 152 mm (6 in.) I— 178 mm (7 in.)

Material Required: 4—Matching Lock Washers and Nuts


2—Steel Plates (4 x 2.75 in.) and (10 x 6 in.) Tool is used to hold air conditioner compressor during
2—Threaded Steel Rods (0.5 x 7 in.) disassembly and assembly.
PW66162,00008C7 -19-03DEC12-1/1

TM100419 (02APR13) 199-05-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=637
Dealer Fabricated Tools

TM100419 (02APR13) 199-05-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=638
Index
Page
Page
A
Test shaft seal leakage .................................... 90-05-21
Accumulator Test volumetric efficiency ................................. 90-05-22
Base cutter Air filter
Charge............................................................ 70-30-2 Restriction switch
Crop divider Remove and install......................................... 40-20-7
Charge............................................................ 70-30-2 Air intake system
Elevator Air cleaner inlet assembly
Charge............................................................ 70-30-4 Remove and install......................................... 30-10-2
Topper Turbocharger repair ........................................... 30-10-2
Charge............................................................ 70-30-4 Alternator
Adhesives Remove and install ............................................ 40-40-1
Specifications..................................................... 10-10-4 Alternator repair
Adhesives and sealants....................................... 10-10-15 Engine accessories............................................ 40-40-1
Adjust elevator chain ........................................... 170-05-4 Auxiliary coolers
Adjusting tension.............................................. 170-05-4 Fuel
Checking elevator chain tension ...................... 170-05-4 Remove and install......................................... 20-20-1
Adjust primary extractor chain tension ................ 160-05-1 Axle
Air cleaner Maintenance ...................................................... 55-05-7
Inlet assembly
Remove and install......................................... 30-10-2 B
Air conditioning system
Charge ............................................................. 90-05-10 Base cutter lift (track harvester)
Clutch hub clearance Cylinder
Check ........................................................... 90-05-20 Disassemble and assemble ......................... 70-20-28
Compressor Remove and install....................................... 70-20-26
Remove and install....................................... 90-05-14 Base cutter lift (wheel harvester)
Repair........................................................... 90-05-15 Cylinder
Compressor clutch Disassemble and assemble ......................... 70-20-20
Repair........................................................... 90-05-19 Remove and install....................................... 70-20-17
Compressor manifold Batteries
Replace ........................................................ 90-05-20 Remove and install ............................................ 40-05-5
Compressor oil Battery
Information ................................................... 90-05-11 Charging ............................................................ 40-05-3
Compressor relief valve Disconnect switch .............................................. 40-05-4
Replace ........................................................ 90-05-13 Fluid level........................................................... 40-05-2
Condenser Preventing damage............................................ 40-05-2
Remove and install...........................20-20-1, 90-10-1 Servicing ............................................................ 40-05-1
Discharge and recover system ........................ 90-05-24 Belt
Evacuate ............................................................ 90-05-9 Tensioner ........................................................... 20-05-2
Flush .................................................................. 90-05-6 Bolt and screw torque values
High pressure switch Metric ................................................................. 10-10-6
Replace .......................................................... 90-10-2 Unified inch ........................................................ 10-10-5
Hose and tubing O-ring connection Bottom Feed Roller.............................................. 140-10-1
torque ............................................................... 90-05-3 Repair .............................................................. 140-10-2
Leak test with dye .............................................. 90-05-5 Break-in engine oil................................................. 10-15-1
Oil Bushings and Pins............................................... 55-05-10
Determine correct charge............................. 90-05-12 Butt-lifter
Purge ................................................................. 90-05-8 Motor
Refrigerant Disassemble and assemble ........................... 70-25-3
Proper handling .............................................. 90-05-4 Buttlifter Roller ..................................................... 140-05-1
R-134a precautions ........................................ 90-05-4
Refrigerant oil charge....................................... 90-05-10 C
Service information ............................................ 90-05-3
Service parts kits................................................ 90-05-2 Cab
System components Remove and install .......................................... 90-20-15
Receiver dryer
Replace....................................................... 90-10-1

Continued on next page

TM100419 (02APR13) Index-1 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=1
Index

Page Page

Cab door R-K repair procedure ....................................... 40-10-27


Disassemble and assemble ............................. 90-20-12 R-M repair procedure....................................... 40-10-29
Latch striker R-N repair procedure ....................................... 40-10-31
Remove and install....................................... 90-20-13 Connectors
Remove and install .......................................... 90-20-10 Handling and repair............................................ 40-10-2
Cab inner roof Coolant
Remove and install Additional information ........................................ 10-15-6
Style B ............................................................ 90-20-6 Diesel engine ..................................................... 10-15-4
Cab roof John Deere Cool-Gard II Coolant
Remove and install Extender........................................................... 10-15-5
Style B ............................................................ 90-20-6 Supplemental additives...................................... 10-15-7
Cab tilt Testing................................................................ 10-15-8
Cylinder Warm temperature climates ............................... 10-15-7
Disassemble and assemble ........................... 70-20-6 Cooling system
Remove and install......................................... 70-20-3 Surge tank cap
Carrier Roller ....................................................... 55-05-16 Test................................................................. 20-10-2
Charging system Test radiator ....................................................... 20-10-2
Alternator Test radiator cap ................................................ 20-10-1
Remove and install......................................... 40-40-1 Test surge tank................................................... 20-10-2
Chopper Critical torque
Motor Specifications..................................................... 10-10-4
Remove and install....................................... 70-25-11 Crop divider
Chopper drum Disassemble and assemble ............................. 110-05-2
Exploded view.................................................. 150-05-5 Guage wheel
Chopper system Exploded view .............................................. 110-05-3
Assembly Position sensor (if equipped)
Remove and install....................................... 150-05-6 Remove and install......................................... 40-20-6
Blades and kicker plates Crop Divider
Remove and install..................................... 150-05-25 Removal........................................................... 110-05-2
Drum Crop divider lift
Exploded view .............................................. 150-05-5 Cylinder
Flywheel clutch Disassemble and assemble ......................... 70-20-13
Adjust ......................................................... 150-05-29 Remove and install....................................... 70-20-11
Gear case Crop divider linkage
Disassemble and assemble ....................... 150-05-23 Exploded view.................................................. 110-05-1
Exploded view .............................................. 150-05-3 Crop divider shoe
Timing ............................................................ 150-05-27 Remove and install .......................................... 110-05-2
Cleaning system Crop Divider System
Fan blades, doubler plates, and backing Buttlifter............................................................ 140-05-1
plates Crop divider tilt
Install ............................................................ 160-05-3 Cylinder
Primary extractor Disassemble and assemble ......................... 70-20-35
Fan assembly Remove and install....................................... 70-20-33
Exploded view........................................... 160-05-2 Crop divider valve, floating
Condenser Remove and install ............................................ 70-15-2
Air conditioning
Remove and install......................................... 20-20-1 D
Repair ................................................................ 90-10-1
Connector repair Dealer fabricated tools
R-A repair procedure ......................................... 40-10-3 Compressor holding fixture
R-B repair procedure ......................................... 40-10-6 DFRW20....................................................... 199-05-1
R-C repair procedure ......................................... 40-10-9 Diesel fuel.............................................................. 10-15-3
R-D repair procedure ....................................... 40-10-12 Diesel fuel system
R-E repair procedure ....................................... 40-10-14 Cooler
R-F repair procedure........................................ 40-10-16 Remove and install......................................... 30-05-9
R-G repair procedure ....................................... 40-10-19 Filters
R-I repair procedure......................................... 40-10-20 Remove and install......................................... 30-05-2
R-J repair procedure ........................................ 40-10-22

Continued on next page

TM100419 (02APR13) Index-2 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=2
Index

Page Page

Fuel tank Repair ................................................................ 20-05-1


Remove and install......................................... 30-05-4 Specifications..................................................... 10-10-2
Drum and Topper................................................. 100-05-3 Thermostat repair............................................... 20-10-3
Drum and Topper Assembly ................................ 100-05-1 Water pump repair ............................................. 20-10-3
Engine oil
E Break-In ............................................................. 10-15-1

Electrical F
Air filter restriction switch
Remove and install......................................... 40-20-7 Feed roller
Component handling precautions ...................... 40-10-1 Motor
Engine Disassemble and assemble ........................... 70-25-3
Replace sensors and switches....................... 40-20-1 Feed roller system
Position sensor (if equipped) Butt-lifter
Crop divider Remove and install....................................... 140-05-2
Remove and install ..................................... 40-20-6 Feed Roller System
Starting motor Bottom Feed Roller .......................................... 140-10-1
Remove and install......................................... 40-45-1 Top Floating Feed Roller.................................. 140-15-1
Visual inspection ................................................ 40-10-1 Filter
Electrical system Engine air
Batteries Remove and install......................................... 30-10-1
Remove and install......................................... 40-05-5 Primary engine air
Switch Clean and inspect........................................... 30-10-1
Engine access door Filters
Remove and install ..................................... 40-20-2 Fuel
Elevator Remove and install......................................... 30-05-2
Motor Final drive
Disassemble and assemble ........................... 70-25-3 Assemble
Sprocket Tightening ........................................... 55-05-7 (S.N. --100986)............................................. 55-10-36
Elevator discharge flap (S.N. 120701--)............................................. 55-10-12
Cylinder Disassemble
Disassemble................................................. 70-20-47 (S.N. --100986)............................................. 55-10-27
Remove and install....................................... 70-20-46 (S.N. 120701-- ).............................................. 55-10-5
Elevator lift Gear oil ............................................................ 10-15-10
Cylinder Lifetime seal
Disassemble and assemble ......................... 70-20-41 Assemble
Remove and install....................................... 70-20-39 (S.N. --100986) ......................................... 55-10-48
Elevator swing (S.N. 120701-- )
Cylinder View................................................................ 55-10-4
Disassemble and assemble ........................... 70-20-6 Final Drive
Remove and install......................................... 70-20-5 (S.N. --100986)
Elevator System View.............................................................. 55-10-26
Chain and Sprockets........................................ 170-05-7 Flange
Elevator Floor................................................... 170-05-1 Fittings ............................................................. 10-10-12
Extension ......................................................... 170-05-3 Four bolt
Standard ........................................................ 170-05-12 Flange fittings................................................... 10-10-12
Swing Table.................................................... 170-05-10 Front axle
Wearstrips........................................................ 170-05-1 Toe-in
Elevator valve Adjust ............................................................. 60-15-4
Remove and install .......................................... 70-15-15 Check ............................................................. 60-15-3
Emergency exit...................................................... 10-05-2 Front wheel
Engine Bearings
Air filters Remove and install......................................... 57-05-3
Remove and install......................................... 30-10-1 Fuel
Electrical Diesel ................................................................. 10-15-3
Replace sensors and switches....................... 40-20-1 Lubricity.............................................................. 10-15-3
Primary filter Fuel and lubricants
Clean and inspect........................................... 30-10-1 Lubricate machine properly................................ 10-15-1

Continued on next page

TM100419 (02APR13) Index-3 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=3
Index

Page Page

Fuel cooler Remove and Install ................................... 70-20-17


Remove and install ..............................20-20-1, 30-05-9 Cab tilt
Fuel level sensor Disassemble and assemble........................ 70-20-6
Remove and install ............................................ 40-20-3 Remove and install ..................................... 70-20-3
Fuel system Crop divider lift
Bleed.................................................................. 30-05-3 Disassemble and assemble...................... 70-20-13
Repair ................................................................ 30-05-1 Remove and install ................................... 70-20-11
Fuel tank Crop divider tilit
Remove and install ............................................ 30-05-4 Remove and install ................................... 70-20-33
Fuse and relay Crop divider tilt
Identification....................................................... 40-30-2 Disassemble and assemble...................... 70-20-35
Fuse and relay panel Elevator discharge flap
Location ............................................................. 40-30-1 Disassemble and assemble...................... 70-20-47
Fuses Remove and install ................................... 70-20-46
Replacing ........................................................... 40-30-1 Elevator lift
Disassemble and assemble...................... 70-20-41
G Remove and install ................................... 70-20-39
Elevator swing
Gauge wheel Disassemble and assemble........................ 70-20-6
Exploded view.................................................. 110-05-3 Remove and install ..................................... 70-20-5
Gear oil Knockdown tilt
Final drive ........................................................ 10-15-10 Disassemble and assemble...................... 70-20-35
Grease................................................................. 10-15-10 Remove and install ................................... 70-20-31
Steering (wheel harvester)
H Disassemble and assemble........................ 70-20-8
Remove and install ..................................... 70-20-7
Hardware torque values Topper
Metric ................................................................. 10-10-6 Disassemble and assemble........................ 70-20-6
Unified inch ........................................................ 10-10-5 Remove and install ..................................... 70-20-2
Headliner Elevator
Remove and install Accumulator
Style B .......................................................... 90-20-10 Charge ........................................................ 70-30-4
High pressure switch Fixed displacement ground drive motor
Replace.............................................................. 90-10-2 (Track harvester)
Hydraulic Repair ....................................................... 70-25-84
oil ....................................................................... 10-15-9 Motor
Hydraulic filter assemblies Chopper
Remove and install ............................................ 70-05-2 Remove and install ................................... 70-25-11
Hydraulic reservoir Cooling package........................................... 70-25-58
Drain .................................................................. 70-05-1 Secondary extractor rotate
Level switch Disassemble and assemble...................... 70-25-65
Remove and install......................................... 40-20-5 Topper severing disk (whole topper)
Hydraulic system and secondary extractor fan
Base cutter Disassemble and assemble...................... 70-25-30
Accumulator Exploded view........................................... 70-25-29
Charge ........................................................ 70-30-2 Motors
Chopper motor Variable displacement ground drive
Disassemble and assemble ......................... 70-25-15 motor (optional)
Crop divider Exploded view........................................... 70-25-86
Accumulator Mulitple gear pump
Charge ........................................................ 70-30-2 Repair............................................................. 70-10-2
Cylinder Topper
Base cutter lift (track harvester) Accumulator
Disassemble and assemble...................... 70-20-28 Charge ........................................................ 70-30-4
Remove and install ................................... 70-20-26 Valve
Base cutter lift (wheel harvester) Improved height control
Disasseble and assemble......................... 70-20-20 Remove and install ..................................... 70-15-4

Continued on next page

TM100419 (02APR13) Index-4 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=4
Index

Page Page

Valves Miscellaneous
Control Rails and platform
Repair ......................................................... 70-15-5 Left-hand ladder
Elevator Remove and install ..................................... 80-05-1
Remove and install ................................... 70-15-15 Motor
Floating crop divider Butt-lifter
Remove and install ..................................... 70-15-2 Disassemble and assemble ........................... 70-25-3
Variable displacement ground drive motor Chopper
(wheel harvester) Remove and install....................................... 70-25-11
Repair........................................................... 70-25-88 Elevator
Hydraulic System Disassemble and assemble ........................... 70-25-3
Filter assemblies Feed roller
Remove and install......................................... 70-05-2 Disassemble and assemble ........................... 70-25-3
Scroll
I Disassemble and assemble ........................... 70-25-3
Side knife
Idler Disassemble and assemble ........................... 70-25-3
Lubrication ......................................................... 55-05-3 Topper gathering disk
Improved height control valve Disassemble and assemble ........................... 70-25-3
Remove and install ............................................ 70-15-4 Whole topper
Instructional seat Remove and install ..................................... 70-25-2
Remove and install ............................................ 90-15-1
O
J
Oil
Jack locations ........................................................ 57-05-1 Hydraulic ............................................................ 10-15-9

K P

Knockdown roller Pitch.....................................................55-05-12, 55-05-13


Disassemble and assemble ............................. 120-05-3 Power train
Exploded view.................................................. 120-05-2 Pump drive
Remove and install .......................................... 120-05-3 Gear case
Knockdown tilt Exploded view............................................. 50-05-2
Cylinder Pump drive gear case
Disassemble and assemble ......................... 70-20-35 Disassemble and assemble ........................... 50-05-5
Remove and install....................................... 70-20-31 Remove and install......................................... 50-05-3
Pump drive gear case
L Disassemble and assemble ............................... 50-05-5
Exploded view.................................................... 50-05-2
Ladder Remove and install ............................................ 50-05-3
Left-hand
Remove and install......................................... 80-05-1 R
Link Rail Wear ....................................................... 55-05-9
Lubricants, Safety Radiator
Safety, Lubricants ............................................ 10-15-10 Test .................................................................... 20-10-2
Lubrication Radiator cap
Idler .................................................................... 55-05-3 Test .................................................................... 20-10-1
Lubricity of diesel fuel ............................................ 10-15-3 Recoil Spring Repair.............................................. 55-05-8
Remove and install
M Elevator chain slats.......................................... 170-05-6
Elevator wear strips ......................................... 170-05-7
Metric bolt and screw torque values ...................... 10-10-6 Reservoir
Metric O-Ring Torque Chart Hydraulic
Torque Chart O-Ring Metric ............................... 10-10-8 Drain............................................................... 70-05-1
Roller Lubrication................................................... 55-05-2

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TM100419 (02APR13) Index-5 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=5
Index

Page Page

Roller wear Steering (wheel harvester)


Specifications................................................... 55-05-19 Cylinder
Disassemble and assemble ........................... 70-20-8
S Remove and install......................................... 70-20-7
Steering and brakes
Safety Relief valve
Transport.......................................................... 10-05-11 Steering
Safety, Avoid High-Pressure Fluids Adjust.......................................................... 60-10-8
Avoid High-Pressure Fluids ............................. 10-05-12 Steering linkage
Safety, Handle Fuel Safely, Avoid Fires Exploded view ................................................ 60-15-2
Avoid Fires, Handle Fuel Safely......................... 10-05-9 Steering valve (wheel harvester)
Safety, Steps and Handholds Exploded view ................................................ 60-10-2
Use Steps and Handholds Correctly.................. 10-05-8 Steering relief valve
Scroll Adjust ................................................................. 60-10-8
Motor Steering valve (wheel harvester)
Disassemble and assemble ........................... 70-25-3 Exploded view.................................................... 60-10-2
Seal fittings Surge tank
Assembly and installation .................................. 10-10-7 Cap
Seat Test................................................................. 20-10-2
Instructional Test .................................................................... 20-10-2
Remove and install......................................... 90-15-1 Swing Table ....................................................... 170-05-10
Secondary extractor fan Switch
Motor Air filter restriction
Disassemble and assemble ......................... 70-25-30 Remove and install......................................... 40-20-7
Exploded view .............................................. 70-25-29 Engine access door
Senors and switches Remove and install......................................... 40-20-2
Fuel level sensor System components
Remove and install......................................... 40-20-3 Condenser
Sensor Remove and install......................................... 90-10-1
Hydraulic oil temperature Receiver dryer
Remove and install......................................... 40-20-4 Replace .......................................................... 90-10-1
Sensors and switches
Hydraulic reservoir level switch T
Remove and install......................................... 40-20-5
Service Thermostat
Adjust elevator chain........................................ 170-05-4 Repair ................................................................ 20-10-3
Adjust primary extractor chain Toe-in
tension............................................................ 160-05-1 Front axle
Remove and install elevator chain Adjust ............................................................. 60-15-4
slats................................................................ 170-05-6 Check ............................................................. 60-15-3
Remove and install elevator wear Top Floating Feed Roller ..................................... 140-15-1
strips............................................................... 170-05-7 Topper
Shredder Topper.................................................. 100-05-2 Blades
Side knife Replace ........................................................ 100-05-1
Motor Cylinder
Disassemble and assemble ........................... 70-25-3 Disassemble and assemble ........................... 70-20-6
Specifications Remove and install......................................... 70-20-2
Adhesives .......................................................... 10-10-4 Gathering disk motor
Critical torque..................................................... 10-10-4 Whole topper
Engine................................................................ 10-10-2 Remove and install ..................................... 70-25-2
Sprocket Topper gathering disk
Wear Patterns .................................................. 55-05-18 Motor
Sprocket Tightening............................................... 55-05-7 Disassemble and assemble ........................... 70-25-3
Starting motor Topper severing disk (whole topper)
Remove and install ............................................ 40-45-1 Motor
Repair ................................................................ 40-45-1 Disassemble and assemble ......................... 70-25-30
Exploded view .............................................. 70-25-29

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TM100419 (02APR13) Index-6 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=6
Index

Page Page

Topper system Unified inch bolt and screw torque


Assembly values .................................................................. 10-10-5
Removal ....................................................... 100-05-1
Topper System V
Assembly ......................................................... 100-05-3
Drum and Topper Assembly............................. 100-05-1 Valve
Shredder Topper .............................................. 100-05-2 Elevator
Torque charts Remove and install....................................... 70-15-15
Metric ................................................................. 10-10-6 Floating crop divider
Unified inch ........................................................ 10-10-5 Remove and install......................................... 70-15-2
Track Improved height control
Adjust tension .................................................... 55-05-7 Remove and install......................................... 70-15-4
Alignment ........................................................... 55-05-2
Assembly ........................................................... 55-05-1 W
Bushing ............................................................ 55-05-11
Bushings and Pins ........................................... 55-05-10 Water pump, repair................................................ 20-10-3
Link Rail Wear.................................................... 55-05-9 Welding precautions, Safety.................................. 10-05-5
Recoil Spring Repair .......................................... 55-05-8 Wheel
Roller Lubrication ............................................... 55-05-2 Remove and Mount Tire .................................... 57-05-4
Roller wear....................................................... 55-05-19 Wheel assembly
Rollers.............................................................. 55-05-13 Remove and install ............................................ 57-05-2
Track shoes ........................................................... 55-05-4 Wheel bearings
Track tension Remove and install ............................................ 57-05-3
Adjust ................................................................. 55-05-7 Whole topper
Tune-up and adjustments...................................... 10-20-1 Gathering disk motor
Turbocharger repair Remove and install......................................... 70-25-2
Air intake system................................................ 30-10-2 Windshield, cab
Remove and install
U Style B ............................................................ 90-20-1

Undercarriage...................................................... 55-05-19

TM100419 (02APR13) Index-7 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=7
Index

TM100419 (02APR13) Index-8 3520 and 3522 Sugar Cane Harvester Repair
040213

PN=8

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