Manual De Reparaciones De Cosechadora John Deere

3520 and 3522 Sugar Cane Harvester Repair Manual

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

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.

(ENGLISH)

Introduction Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. RW67285,0000B0A -19-22OCT01-1/1

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Contents Section 10—General Group Group Group Group

Section 90—Operator's Station

05—Safety 10—General Specifications 15—Fuels and Lubricants 20—Tune-Up and Adjustments

Group Group Group Group

05—Air Conditioning System 10—System Components 15—Seats 20—Cab

Section 20—Engine Section 100—Topper System

Group 05—Component Removal and Installation Group 10—Cooling System Group 20—Auxiliary Coolers

Group 05—Topper

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 Group 10—Electrical Harness and Connectors Group 15—Wire Harness Routings Group 20—Sensors and Switches Group 30—Fuses and Relays Group 40—Charging System Group 45—Starting System

Section 130—Base Cutter System Group 05—Base Cutter Gear Case

Section 140—Feed Roller System Group 05—Buttlifter Roller (B1) Group 10—Bottom Feed Roller Group 15—Top Feed Roller

Section 50—Power Train

Section 150—Chopper System

Group 05—Pump Drive Gear Case

Group 05—Chopper

Section 55—Track

Section 160—Cleaning System

Group 05—Track Group 10—Final Drive Repair

Group 05—Primary Extractor

Section 170—Elevator System

Section 57—Wheel

Group 05—Elevator Systems Installation

Group 05—Wheel

Section 199—Dealer Fabricated Tools

Section 60—Steering and Brakes

Group 05—Dealer Fabricated Tools

Group 10—Steering Valve Group 15—Steering Arms and Pivots

Section 70—Hydraulic System Group Group Group Group Group Group

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

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Contents

TM100419 (02APR13)

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Contents

Section 10 General

Page Page

Group 05—Safety Recognize Safety Information ....................... 10-05-1 Understand Signal Words.............................. 10-05-1 Follow Safety Instructions.............................. 10-05-1 Work in Clean Area ....................................... 10-05-2 Service Machines Safely ............................... 10-05-2 Emergency Exit ............................................. 10-05-2 Work In Ventilated Area................................. 10-05-3 Illuminate Work Area Safely .......................... 10-05-3 Replace Safety Signs .................................... 10-05-3 Use Proper Lifting Equipment........................ 10-05-4 Support Machine Properly ............................. 10-05-4 Avoid Heating Near Pressurized Fluid Lines ................................................. 10-05-4 Remove Paint Before Welding or Heating ...................................................... 10-05-5 Precautions for Welding ................................ 10-05-5 Live With Safety............................................. 10-05-6 Construct Dealer-Made Tools Safely......................................................... 10-05-6 Seat Safety Switch ........................................ 10-05-7 Tilting the Cab ............................................... 10-05-7 Protect Bystanders ....................................... 10-05-8 Use Steps and Handholds Correctly .................................................... 10-05-8 Wear Protective Clothing............................... 10-05-8 Handle Fuel Safely—Avoid Fires................... 10-05-9 Service Accumulator Systems Safely......................................................... 10-05-9 Service Cooling System Safely ..................... 10-05-9 Prepare for Emergencies............................. 10-05-10 Use Safety Lights and Devices.................... 10-05-10 Using Cylinder Safety Stops........................ 10-05-11 Safe Transport of Harvester ........................ 10-05-11 Avoid High-Pressure Fluids ......................... 10-05-12 Use Caution on Hillsides ............................. 10-05-12 Use Caution On Slopes When Turning..................................................... 10-05-13 Stopping and Parking .................................. 10-05-13 Service Tires Safely..................................... 10-05-14 Avoid Electrical Power Lines ....................... 10-05-14 Keep Hands Away from Knives ................... 10-05-15 Dispose of Waste Properly .......................... 10-05-15 Prevent Battery Explosions ......................... 10-05-15 Prevent Acid Burns...................................... 10-05-16 Fire Prevention ............................................ 10-05-17 Stay Clear of Harvesting Units .................... 10-05-17 Stay Clear of Rotating Drivelines................. 10-05-18 Keep Riders and Children Off Machine ................................................... 10-05-18 Instructional Seat......................................... 10-05-18 Install All Guards ......................................... 10-05-19

Avoid Hot Exhaust ....................................... 10-05-19 Group 10—General Specifications Dimensions.................................................... 10-10-1 Engine Specifications .................................... 10-10-2 Capacities...................................................... 10-10-3 Critical Torque and Adhesive Specifications ............................................ 10-10-4 Identifying Zinc-Flake Coated Fasteners................................................... 10-10-4 Unified Inch Bolt and Screw Torque Values ........................................................ 10-10-5 Metric Bolt and Screw Torque Values ........................................................ 10-10-6 Face Seal Fittings Assembly and Installation—All Pressure Applications ............................................... 10-10-7 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures ...................... 10-10-8 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications................................ 10-10-9 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures .................... 10-10-10 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications.............................. 10-10-11 Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications ............................................. 10-10-12 SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications.............................. 10-10-13 SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications ............................................. 10-10-14 Sealants and Adhesives Cross-Reference Chart............................ 10-10-15 Harvester Specialty Tools and Part Numbers .................................................. 10-10-16 Group 15—Fuels and Lubricants Lubricate Machine Properly........................... 10-15-1 Diesel Engine Break-In Oil ............................ 10-15-1 Diesel Engine Oil ........................................... 10-15-2 Diesel Fuel..................................................... 10-15-3 Lubricity of Diesel Fuel .................................. 10-15-3 Diesel Engine Coolant ................................... 10-15-4

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. T81389 —UN—07DEC88

Follow recommended precautions and safe operating 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. TS187 —19—30SEP88

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

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

Follow Safety Instructions

TS201 —UN—23AUG88

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 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. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer. DX,READ -19-16JUN09-1/1

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Safety

Work in Clean Area

• Clean work area and machine. • Make sure you have all necessary tools to do your job. • Have the right parts on hand. • Read all instructions thoroughly; do not attempt shortcuts.

T6642EJ —UN—18OCT88

Before starting a job:

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

Service Machines Safely

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

TS228 —UN—23AUG88

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.

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

Emergency Exit

CQ294327 —UN—27MAR13

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.

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

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Safety

Work In Ventilated Area

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

TS220 —UN—23AUG88

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.

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

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

Illuminate Work Area Safely

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

Replace Safety Signs

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator's manual.

TS201 —UN—23AUG88

Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement.

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

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Safety

Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage.

TS226 —UN—23AUG88

Follow recommended procedure for removal and installation of components in the manual.

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

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. 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.

TS229 —UN—23AUG88

Support Machine Properly

DX,LOWER -19-24FEB00-1/1

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 burst when heat goes beyond the immediate flame area.

TS953 —UN—15MAY90

Avoid Heating Near Pressurized Fluid Lines

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

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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. TS220 —UN—23AUG88

Remove paint before heating:

• 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 before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly. DX,PAINT -19-24JUL02-1/1

Precautions for Welding

CAUTION: Avoid potentially toxic fumes and dust. 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 area before welding. Allow fumes to disperse at least 15 minutes before welding or heating. IMPORTANT: Welding on the engine is NOT ALLOWED. If welding must be performed on the machine, follow these precautions. IMPORTANT: High currents or electrostatic discharge into electronic components from welding may cause permanent damage.

TS953 —UN—15MAY90

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

3. Disconnect the positive (+) battery cable(s) or open battery (+) switch if equipped. 4. Clear or move any wiring harness sections away from the welding area. 5. Welding on engine components is not allowed. 6. Never connect the welder ground to any engine component or engine driven components that may be connected to the engine. 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

TS231 —19—07OCT88

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

DX,LIVE -19-25SEP92-1/1

Construct Dealer-Made Tools Safely

Do not weld tools unless you have the proper equipment and experience to perform the job.

LX1016749 —UN—01JUL97

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

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

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Safety

CM023500020 —UN—07FEB05

Seat Safety Switch

The operator must be seated and reset switch activated to start harvesting functions.

functions, the operator must return to seated position and 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

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 to prevent damage. (See Service Section for tilting the cab procedure).

T8130000499 —UN—21FEB13

Tilting the Cab

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

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Safety

Protect Bystanders

CM989999005 —UN—06JAN00

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

T803324,000062F -19-13APR05-1/1

Prevent falls by facing the machine when getting on and 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.

T133468 —UN—30AUG00

Use Steps and Handholds Correctly

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

Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job.

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.

TS206 —UN—23AUG88

Prolonged exposure to loud noise can cause impairment or loss of hearing.

DX,WEAR -19-10SEP90-1/1

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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. TS202 —UN—23AUG88

Always stop engine before refueling machine. Fill fuel 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 before removing can lid. Keep fuel dispenser nozzle in contact with fuel container inlet when filling.

Do not store fuel container where there is an open flame, spark, or pilot light such as within a water heater or other appliance. DX,FIRE1 -19-12OCT11-1/1

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 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.

TS281 —UN—23AUG88

Service Accumulator Systems Safely

Accumulators cannot be repaired. DX,WW,ACCLA2 -19-22AUG03-1/1

Service Cooling System Safely

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

TS281 —UN—23AUG88

Explosive release of fluids from pressurized cooling system can cause serious burns.

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

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Safety

Prepare for Emergencies Be prepared if a fire starts.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

TS291 —UN—23AUG88

Keep a first aid kit and fire extinguisher handy.

DX,FIRE2 -19-03MAR93-1/1

Use Safety Lights and Devices

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 Deere dealer.

TS951 —UN—12APR90

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.

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

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Safety

Using Cylinder Safety Stops

CM989999016 —UN—06JAN00

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.

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.

CQ280276 —UN—27FEB08

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.

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

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Safety

Avoid High-Pressure Fluids

X9811 —UN—23AUG88

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. 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. 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 in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636. 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.

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 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.

CM989999019 —UN—06JAN00

The danger of an overturn increases greatly with narrow tread, 2032 mm (80 in.) or less, and with high speed.

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

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Safety

Use Caution On Slopes When Turning

When operating on slopes, elevator MUST be centered behind machine before turning. The danger of an overturn increases greatly when elevator is swung to left or right during a turn.

T8130000097 —UN—10JAN13

Ballast of machine is greatly affected by position of elevator.

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.

stopping, if possible.

• 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.

CM989999020 —UN—06JAN00

• Pull over to right-hand shoulder of highway before

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

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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.

TS211 —UN—23AUG88

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

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.

CM989999024 —UN—06JAN00

Maintain minimum distance of 3 m (10 ft.) plus twice the length of power line insulators.

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

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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.

CM989999025 —UN—06JAN00

Cutting/Shearing areas: topper, side knives, vine knives, base cutter blades, cooling fans, extractors, and elevator slats.

WM05597,0000800 -19-19FEB13-1/1

Dispose of Waste Properly

TS1133 —UN—26NOV90

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. 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 recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste 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.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

TS204 —UN—23AUG88

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

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

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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. 2. 3. 4. 5.

Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. 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.

1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately.

TS203 —UN—23AUG88

If acid is swallowed:

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

TM100419 (02APR13)

10-05-16

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=22

Safety

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 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 extinguisher will have reduced capability and may not work a second time. 7. Prior to welding or brazing on any part of the machine, the part and the surrounding area should be cleaned and a fire extinguisher should be made readily available.

CM989999028 —UN—10NOV00

Fire Prevention

8. Smoking, naked flames, etc., should not be permitted around any machine during fueling operations and/or when the fuel system is open to the atmosphere. 9. Do not weld where hydraulic hoses or electrical wiring can be damaged. Depressurize hydraulic hoses and move or protect. Move or protect electrical wiring/harnesses. WM05597,0000802 -19-19FEB13-1/1

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

ES118704 —UN—21MAR95

Stay Clear of Harvesting Units

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

Keep all shields in place at all times. Make sure rotating shields turn freely. 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.

TS1644 —UN—22AUG95

Entanglement in rotating driveline can cause serious injury or death.

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

Keep Riders and Children Off Machine

Riders are subject to injury such as being thrown off the 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.

TS253 —UN—23AUG88

Only allow the operator on the machine. Keep riders off the machine except for periods of training or short periods of observation.

KR43067,0000BB4 -19-25SEP12-1/1

Instructional Seat

RXA0103436 —UN—15JUN09

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

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.

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.

TS677 —UN—21SEP89

Keep all guards in place at all times during engine operation.

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

Avoid Hot Exhaust

Exhaust parts and streams become very hot during operation. Exhaust gases and components reach temperatures hot enough to burn people, ignite, or melt common materials.

RG17488 —UN—21AUG09

Servicing machine or attachments with engine running can result in serious personal injury. Avoid exposure and skin contact with hot exhaust gases and components.

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

CQ285205 —UN—02FEB10

Dimensions

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 Warmed to 105°C (220°F)

290 kPa (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

Fuel Tank—Diesel

3522 568 L (150 gal.)

568 L (150 gal.)

397 L (105 gal.) World

397 L (105 gal.) World

69.6 L (16.5 gal.)

69.6 L (16.5 gal.)

Final Drive of Track— 85W/140 oil or 80W/140 Synthetic oil

4.2 L (1.1 gal.)

4.2 L (1.1 gal.)

Final Drive of Wheel—85W/140 oil or 80W/140 Synthetic oil

4.2 L (1.1 gal.)

4.2 L (1.1 gal.)

Hydraulic Oil Tank—SAE 10W30 super high performance, heavy-duty diesel engine oil Radiator Coolant—50% Clean Water and 50% Ethylene Glycol

Chopper Gear Case— 85W/140 oil

11.01 L (2.9 gal.)

11.01 L (2.9 gal.)

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 R-134a compressor oil

3.4 kg (7.5 lb.) 118 mL (4 oz.)

3.4 kg (7.5 lb.) 118 mL (4 oz.)

Approximate Weight of Harvester

19 050 kg (42 000 lb.)

19 780 kg (43 600 lb.)

Base Cutter Gear Case— 85W/140 oil

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

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.)

Bottom Feed Roller Mounting Studs

Chopper Gear Case Access Cover Cap Screws 25 N·m (20 lb.-ft.) Loctite 242

Chopper Case Cover Cap Screws

110 N·m (80 lb.-ft.)

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.)

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.)

Loctite 271

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 529 N·m (390 lb.-ft.) BNA

Loctite 271 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-Flake Coated cap screws (C) have a dull silver color. A—Standard Cap Screws B—Zinc-plated Cap Screw

C—Zinc-Flake Cap Screw (20 mm and larger)

RXA0073812 —UN—03MAR04

Zinc plated cap screws (B) have a reflective gold color.

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 Size 1/4 5/16

SAE Grade 2a

SAE Grade 1 Lubricatedb

Dryc

Lubricatedb

SAE Grade 5, 5.1 or 5.2

Dryc

Lubricatedb

Dryc

SAE Grade 8 or 8.2 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

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.

28

20.5

35

26

7.7

68

3/8

13.5

120

7/16

22

194

N·m

lb.-ft.

9.8

86

12

106

15.5

137

17.5

155

22

194

27

240

N·m

lb.-ft.

N·m

lb.-ft.

N·m

lb.-ft.

28

20.5

35

26

44

32.5

lb.-in.

N·m

lb.-in.

19.5

172

25

221

N·m

lb.-ft.

N·m

lb.-ft.

35

26

44

32.5

49

36

63

46

56

41

70

52

80

59

100

74

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 or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Replace fasteners with the same or higher grade. If higher grade fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts 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

Bolt or Screw Size M6 M8 M10

4.8

8.8

9.8

10.9

12.9

12.9

4.8

8.8

9.8

10.9

12.9

12.9

Class 4.8 Lubricateda

Class 8.8 or 9.8 Dryb

Lubricateda

Class 10.9

Dryb

Lubricateda

Class 12.9 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

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.

32

23.5

40

29.5

37

27.5

47

35

63

46

80

59

75

55

95

70

11.5

102

14.5

128

22

194

27.5

243

N·m

lb.-ft.

N·m

lb.-ft.

N·m

lb.-ft.

29

21

43

32

55

40

lb.-in.

23

204

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 the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U-bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, 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 and/or defects.

Face Seal Straight Stud End O-Ring Installation

2. Inspect the O-ring. It must be free of damage and/or defects.

1. Install a thimble over the fitting threads to protect the O-ring from nicks. 2. Slide the O-ring over the thimble into the turned down section of the fitting.

3. Lubricate O-rings and install into groove using petroleum jelly to hold in place. 4. Push O-ring into groove with petroleum jelly so O-ring is not displaced during assembly. 5. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place.

3. Remove thimble. Fitting Installation 1. Install fitting by hand until snug. 2. Position adjustable fittings by unscrewing the fitting no more than one turn.

6. Tighten fitting or nut to torque value shown on the 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 turned down section of the fitting.

1. Use one wrench to hold the connector body and one wrench to tighten nut.

2. Install a thimble over the fitting threads to protect the O-ring from nicks.

2. For a hydraulic hose, it may be necessary to use three 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

H

G

I

F

C

G A

A—Stud Straight and Tube Nut B—Bulkhead Union and Bulkhead Lock Nut

B

E

F D

C—90° Swivel Elbow and Tube Nut D—90° Adjustable Stud Elbow

E—Port Plug F— Stud End G—Tube Nut H—Swivel Nut

I— Lock Nut

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressure-Below 27.6 MPA (4,000 PSI) Nominal Tube OD Hose ID Metric Tube OD

Bulkhead Jam Nut TorqueA

O-Ring Face Seal/ Tube Swivel Nut Thread Size

Tube Nut Swivel Nut Hex Swivel Nut Torque Size

Jam Nut Hex Size

mm

Dash Size

in.

mm

in.

mm

N·m

lb-ft

mm

N·m

lb-ft

mm

mm

Adj Lock Nut Hex Size mm

4

-2

0.12 5

3.18

—

—

—

—

—

—

—

M8 X 1

12

12

8

6

5

4

5

-3

0.18 8

4.76

—

—

—

—

—

—

—

M10 X 1

14

14

15

11

10

7

6

-4

0.25 0

6.35

9/16-18

17

16

12

22

32

24

M12 X 1.5

17

17

25

18

17

12

8

-5

0.31 2

7.92

—

—

—

—

—

—

—

M14 X 1.5

19

19

40

30

27

20

10

-6

0.37 5

9.53

11/16-16

22

24

18

27

42

31

M16 X 1.5

22

22

45

33

30

22

12

-8

0.50 12.70 13/16-16 0

24

50

37

30

93

69

M18 X 1.5

24

24

50

37

33

25

16

-10

0.62 15.88 5

30

69

51

36

118

87

M22 X 1.5

27

27

69

51

46

34

20

-12

0.75 19.05 1-3/16-1 0 2

36

102

75

41

175

129

M27 X 2

32

32

100

74

67

49

22

-14

0.87 22.23 1-3/16-1 5 2

36

102

75

41

175

129

M30 X 2

36

36

130

96

87

64

25

-16

41

142

105

46

247

182

M33 X 2

41

41

160

118

107

79

28

—

1.00 25.40 1-7/16-1 0 2 — — —

—

—

—

—

—

—

M38 x 2

46

46

176

130

117

87

32

-20

1.25 31.75 0

1-11/1 6-12

50

190

140

50

328

242

M42 X 2

50

50

210

155

140

103

38

-24

1.50 38.10 0

2-12

60

217

160

60

374

276

M48 X 2

55

55

260

192

173

128

50

-32

2.00 50.80 0

—

—

—

—

—

—

—

M60 X 2

65

65

315

232

210

155

Inch Tube OD

1-14

Jam Nut Torque

O-Ring Straight, Adjustable, and External Port Plug Stud EndsA Thread Size

Straight Hex SizeB

Steel or Gray Iron Torque

Aluminum or Brass TorqueC

N·m

lb-ft

N·m

lb-ft

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

H

G

I

F

C

G A

A—Stud Straight and Tube Nut B—Bulkhead Union and Bulkhead Lock Nut

B

E

F D E—Port Plug F— Stud End G—Tube Nut H—Swivel Nut

C—90° Swivel Elbow and Tube Nut D—90° Adjustable Stud Elbow

I— Lock 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 Hose ID MetInch Tube OD ric Tube OD mm Damm in. sh Size 4

-2

0.125

Bulkhead Jam Nut TorqueA

O-Ring Face Seal/ Tube Swivel Nut Tube Nut/Swivel Nut Torque

Jam Nut Hex Size

Jam Nut Torque

O-Ring Straight, Adjustable, and External Port Plug Stud EndsA Thread Size

Adj Straight Hex SizeB Lock Nut Hex Size

Thread Size

Swivel Nut Hex Size

Steel or Gray Iron Torque

in.

mm

N·m

lb-ft

mm

N·m

lb-ft

mm.

mm

mm

N· m

lb-ft

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

17 —

24 —

18 —

22 —

32 —

24 —

M12 X 1.5

17

17

35

26 33

8

-5

0.312

7.92

9/16-18 —

M14 X 1.5

19

19

45

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

M38 x 2

46

46

320

236

286

211

50

328

242

M42 X 2

50

50

360

266

326

240

60

374

276

M48 X 2

55

55

420

310

28 32

-20 1.250 31.75

1-11/16-12

—

38

-24 1.500 38.10

2-12

—

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

H

G

I

F

C

G A

A—Stud Straight and Tube Nut B—Bulkhead Union and Bulkhead Lock Nut

B

E

F D

C—90° Swivel Elbow and Tube Nut D—90° Adjustable Stud Elbow

E—Port Plug F— Stud End G—Tube Nut H—Swivel Nut

I— Lock Nut

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressure-Below 27.6 MPA (4,000 PSI) Nominal Tube OD Hose ID Metric Tube OD

Bulkhead Jam Nut TorqueA

O-Ring Face Seal/ Tube Swivel Nut

Inch Tube OD

Thread Size

Swivel Tube Nut Nut Hex Swivel Nut Size Torque

Jam Nut Hex Size

Jam Nut Torque

O-Ring Straight, Adjustable, and External Port Plug Stud EndsA Thread Size

Straight Hex SizeB

Adj Lock Nut Hex Size

in.

in.

in.

Steel or Gray Iron Torque

Aluminum or Brass TorqueC

mm

Dash Size

in.

mm

5

-3

0.188

4.78

—

—

—

—

—

—

lb-ft —

3/8-24

5/8

9/16

12

9

8

6

6

-4

0.250

6.35

11/16 —

16 —

12 —

13/16 —

32 —

24 —

7/16-20

5/8

5/8

16

12

11

8 12

in.

in.

N· m

N· m

lb-ft

N·m

lb-ft

N·m

lb-ft

8

-5

0.312

7.92

9/16-18 —

1/2-20

3/4

11/16

24

18

16

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 6

11 8

87

7/8-14

1-1/16

1-1/16

69

51

46

34

20

-12

0.750

19.05

1-3/16-12

1-3/8

10 2

75

1-1/2

17 5

12 9

1-1/16-12

1-1/4

1-3/8

102

75

68

50

22

-14

0.875

22.23

1-3/16-12

—

10 2

75

—

17 5

12 9

1-3/16-12

1-3/8

1-1/2

122

90

81

60

25

-16

1.000

25.40

1-7/16-12

1-5/8

14 105 2

1-3/4

24 7

18 2

1-5/16-12

1-1/2

1-5/8

142

105

95

70

32

-20

1.25

31.75

1-11/16-1 2

1-7/8

19 140 0

2

32 8

24 2

1-5/8-12

1-3/4

1-7/8

190

140

127

93

38

-24

1.50

38.10

2-12

2-1/4

2-3/8

2-1/8

217

160

145

107

2.000

50.80

—

—

27 6 —

2-1/8

-32

37 4 —

1-7/8-12

50.8

21 160 7 — —

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

H

G

I

F

C

G A

A—Stud Straight and Tube Nut B—Bulkhead Union and Bulkhead Lock Nut

B

E

F D E—Port Plug F— Stud End G—Tube Nut H—Swivel Nut

C—90° Swivel Elbow and Tube Nut D—90° Adjustable Stud Elbow

I— Lock 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 Hose ID Metric Tube OD

Inch Tube OD

Bulkhead Jam Nut TorqueA

O-Ring Face Seal/ Tube Swivel Nut Thread Size

Swivel Nut Hex Size

Tube Nut/Swivel Nut Torque

mm

Dash Size

in.

mm

in.

in.

N·m

lb-ft

5

-3

0.188

4.78

—

—

—

—

6

-4

0.250

6.35

11/16 —

24 —

Jam Nut Hex Size

Jam Nut Torque

O-Ring Straight, Adjustable, and External Port Plug Stud EndsA Thread Size

Straight Hex SizeB

Adj Lock Nut Hex Size

in.

in.

in.

Steel or Gray Iron Torque

N·m

lb-ft

N·m

—

—

—

3/8-24

5/8

9/16

18

13

18 —

13/16 —

32 —

24 —

7/16-20

5/8

5/8

24

18

lb-ft

8

-5

0.312

7.92

9/16-18 —

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

152

112

129

1-1/16-12

1-1/4

1-3/8

177

131

-14 0.875 22.23

1-3/16-12

152

112

1-1/2 —

175

22

1-3/8 —

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.

3. Split flange (B): Loosely assemble split flange halves. Make sure split is centrally located and perpendicular 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.

CM992600061 —UN—12JAN00

2. Install the correct o-ring (and backup washer if required) into groove using petroleum jelly to hold it in place.

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

H70423 —UN—30NOV01

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

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

H70423 —UN—30NOV01

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

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

1/2

5/16-18 UNC

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

Min

Max

20

31

Min 15

Max 23

a

JDM A17D, SAE Grade 5 or better cap screws with plated hardware. 1.5.1.2 Lock washers are permissible but not recommended.

b

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 Canadian Part Number

Color

Size

Description

LOCTITE® Number

PM37513

PM38606

BLACK and WHITE

4 gm

Epoxy Adhesive

445

PM37391

PM38615

CLEAR

2 gm

Gel Super Glue

454

PM38655

PM38625

PURPLE

50 mL

Flexible Form-in-Place Gasket

PM37559

PM38600

BROWN

4 oz

General Purpose Gasket Dressing

515 —

PM38657

BLUE

50 mL

High-Flex Form-in-Place Gasket

PM37553

PM38628 —

BURGUNDY

16 oz

High Tack Gasket Dressing

17430 —

PM37465

PM38616

METALLIC BLUE

80 mL

Ultra Blue RTV Silicone

587

H154379

—

Green

—

Sealant

—

PM38611

GREEN

4.5 oz

Cure Primer

7649

PM38612 —

SILVER

50 mL

QUICK METAL® Press Fit

660

PM37485

GREEN

36 mL

Maximum Strength

680

PM38652

PM38626

GREEN

36 mL

High-Temperature

620

U.S. Part Number

Bonding

Gasketing

Priming PM37509 Retaining PM38651

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

CB01439350 (U.S.)

Torque Multiplier Tool

Use

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

1190290188 (U.S.)

Tool - Base Cutter Leg-Timing

Use

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

CB01444732 (U.S.)

Tool - Flywheel Seal

Use

CB01444779 (U.S.)

Tool - Chopper Box Freeze Plug

CB21443671 (U.S.)

Motor Lift Tool

CB11444588 (U.S.)

Flywheel Lifter Continued on next page

TM100419 (02APR13)

10-10-16

PW66162,000099D -19-21FEB13-1/2

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

CB11446203 (U.S.)

Base Cutter Cylinder Trunnion Seal Installer

Use

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. Lubricate at the intervals listed in the machine's Operator's Manual.

IMPORTANT: Correct selection and proper use of lubricating oils and grease is very important in 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 Deere Break-In™ or John Deere Break-In Plus™ Engine Oil. During the break-in period, add John Deere Break-In™ or Break-In Plus ™ Engine Oil, respectively, as needed to maintain the specified oil level. Operate the engine under various conditions, particularly heavy loads with minimal idling, to help seat engine components properly.

• API Service Classification CC • ACEA Oil Sequence E2 • ACEA Oil Sequence E1 IMPORTANT: Do not use Plus-50™ II, Plus-50 or engine oils meeting any of the following for the initial break-in of a new or rebuilt engine: API CJ-4

ACEA E9

API CI-4 PLUS

ACEA E7

If John Deere Break-In Engine Oil is used during the initial operation of a new or rebuilt engine, change the oil and filter at a maximum of 250 hours.

API CI-4

ACEA E6

API CH-4

ACEA E5

API CG-4

ACEA E4

If John Deere Break-In Plus Engine Oil is used, change the oil and filter at a minimum of 100 hours and a maximum equal to the interval specified for John Deere Plus-50™ II or Plus-50 oil.

API CF-4

ACEA E3

API CF-2 API CF

These oils will not allow the engine to break in properly.

After engine overhaul, fill the engine with either John Deere Break-In™ or Break-In Plus™ Engine Oil. If John Deere Break-In or Break-In Plus Engine Oil is not available, use an SAE 10W-30 viscosity grade diesel engine oil meeting one of the following and change the oil and filter at a maximum of 100 hours of operation:

• API Service Classification CE • API Service Classification CD

John Deere Break-In Plus™ Engine Oil can be used for all John Deere diesel engines at all emission certification levels. After the break-in period, use John Deere Plus-50™ II, John Deere Plus-50, or other diesel engine oil as 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

John Deere Plus-50™ II oil is preferred.

30 o C

86 o F

20 o C

68 o F

10 o C

50 o F

0o C

32 o F

-10 o C

14 o F

-20 o C

-4 o F

-30 o C

-22 o F

-40 o C

-40 o F

John Deere Plus-50™ is also recommended. Other oils may be used if they meet one or more of the following:

• John Deere Torq-Gard™ • API Service Category CJ-4 • API Service Category CI-4 PLUS • API Service Category CI-4 • ACEA Oil Sequence E9 • ACEA Oil Sequence E7 • ACEA Oil Sequence E6 • ACEA Oil Sequence E5 • ACEA Oil Sequence E4 Multi-viscosity diesel engine oils are preferred. Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates.

TS1691 —UN—18JUL07

104o F

SAE 10W-30

40 o C

SAE 15W-40

122o F

SAE 10W-40

50 o C

Use oil viscosity based on the expected air temperature range during the period between oil changes.

SAE 5W-30

Diesel Engine Oil

SAE 0W-40

Fuels and Lubricants

Oil Viscosities for Air Temperature Ranges

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

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Fuels and Lubricants

Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed. Diesel fuels specified to EN 590 or ASTM D975 are recommended. Renewable diesel fuel produced by hydrotreating animal fats and vegetable oils is basically identical to petroleum diesel fuel. Renewable diesel that meets EN 590 or ASTM D975 is acceptable for use at all percentage mixture levels.

Sulfur Content for Tier 3 and Stage III A Engines

• Use of diesel fuel with sulfur content less than 1000 mg/kg (1000 ppm) is RECOMMENDED

• Use of diesel fuel with sulfur content 1000–5000 mg/kg (1000–5000 ppm) REDUCES oil and filter change intervals.

• BEFORE using diesel fuel with sulfur content greater

than 5000 mg/kg (5000 ppm), contact your John Deere dealer

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:

• Use of diesel fuel with sulfur content 500–5000 mg/kg

Cetane number of 43 minimum. Cetane number greater than 47 is preferred, especially for temperatures below –20°C (–4°F) or elevations above 1500 m (5000 ft.). Cold Filter Plugging Point (CFPP) should be at least 5°C (9°F) below the expected lowest temperature or Cloud Point below the expected lowest ambient temperature. Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1. Diesel fuel quality and sulfur content must comply 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). Sulfur content for Interim Tier 4 and Stage III B engines

• Use ONLY ultra low sulfur diesel (ULSD) fuel with a maximum of 15 mg/kg (15 ppm) sulfur content.

mg/kg (500 ppm) is RECOMMENDED.

•

(500–5000 ppm) REDUCES the oil and filter change interval BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm), contact your John Deere dealer

Sulfur Content for Other Engines

• Use of diesel fuel with sulfur content less than 5000 mg/kg (5000 ppm) is recommended.

• Use of diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm) REDUCES the oil and filter change intervals.

IMPORTANT: Do not mix used diesel engine oil or any other type of lubricating oil with diesel fuel. IMPORTANT: Improper fuel additive usage may 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, Canada, and the European Union have adequate lubricity to ensure proper operation and durability of fuel injection system components. However, diesel fuels manufactured in some areas of the world may lack the necessary lubricity.

If fuel of low or unknown lubricity is used, add John Deere Fuel-Protect Diesel Fuel Conditioner (or equivalent) at the specified concentration.

IMPORTANT: Make sure the diesel fuel used in your machine demonstrates good lubricity characteristics.

Fuel lubricity can improve significantly with biodiesel blends up to B20 (20% biodiesel). Further increase in lubricity is limited for biodiesel blends greater than B20.

Lubricity of Biodiesel Fuel

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

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Fuels and Lubricants

Diesel Engine Coolant The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37°C (-34°F).

A 50% mixture of propylene glycol engine coolant in water provides freeze protection to -33°C (-27°F).

John Deere COOL-GARD is preferred for service.

If protection at lower temperatures is required, consult your John Deere dealer for recommendations.

If John Deere COOL-GARD is not available, use a low silicate ethylene glycol or propylene glycol base coolant concentrate in a 50% mixture of concentrate with quality water. The coolant concentrate shall be of a quality that provides cavitation protection to cast iron and aluminum parts in the cooling system. John Deere COOL-GARD meets this requirement. Freeze protection A 50% mixture of ethylene glycol engine coolant in water provides freeze protection to -37°C (-34°F).

Water quality Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate. IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives. IMPORTANT: Do not mix ethylene glycol and 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 winter freeze protection to -37°C (-34°F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations.

• Is formulated with a quality nitrite-free additive package. • Provides cylinder liner cavitation protection according to •

The following engine coolants are preferred:

either the John Deere Cavitation Test Method or a fleet study run at or above 60% load capacity Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion

• John Deere COOL-GARD™ II Premix • John Deere COOL-GARD II PG Premix

The additive package must be part of one of the following coolant mixtures:

Use John Deere COOL-GARD II PG Premix when a non-toxic coolant formulation is required.

• ethylene glycol or propylene glycol base prediluted

Additional Recommended Coolants

(40—60%) heavy duty coolant

• ethylene glycol or propylene glycol base heavy

duty coolant concentrate in a 40—60% mixture of concentrate with quality water

The following engine coolant is also recommended:

• John Deere COOL-GARD II Concentrate in a 40–60% mixture of concentrate with quality water.

John Deere COOL-GARD II Premix, COOL-GARD II PG Premix, and COOL-GARD II Concentrate coolants do not require use of supplemental coolant additives. Other Coolants John Deere COOL-GARD II and COOL-GARD II PG coolants might not be available in the geographical area where service is performed.

Water Quality Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate. IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives.

If these coolants are unavailable, use a coolant concentrate or prediluted coolant intended for use with heavy duty diesel engines and with a minimum of the following chemical and physical properties:

Do not mix ethylene glycol and propylene glycol base coolants. Do not use coolants that contain nitrites.

COOL-GARD is a trademark of Deere & Company DX,COOL3 -19-14APR11-1/1

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Fuels and Lubricants

John Deere COOL-GARD™ II Coolant Extender Some coolant additives will gradually deplete during engine operation. For John Deere COOL-GARD™ II Premix, COOL-GARD II PG Premix, and COOL-GARD II Concentrate, replenish coolant additives between drain intervals by adding John Deere COOL-GARD II Coolant Extender.

IMPORTANT: Do not add a supplemental coolant additive when the cooling system is drained and refilled with any of the following:

John Deere COOL-GARD II Coolant Extender should not be added unless indicated by coolant testing.

The use of non-recommended supplemental coolant additives may result in additive drop-out, gelation of the coolant, or corrosion of cooling system components.

John Deere COOL-GARD II Coolant Extender is a chemically matched additive system for use with all John Deere COOL-GARD II coolants. John Deere COOL-GARD II Coolant Extender is not intended for use with nitrite-containing coolants.

• John Deere COOL-GARD II • John Deere COOL-GARD II PG

Add the recommended concentration of John Deere COOL-GARD II Coolant Extender. DO NOT add more than the recommended amount.

COOL-GARD is a trademark of Deere & Company DX,COOL16 -19-20APR11-1/1

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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 components: ethylene glycol (EG) or propylene glycol (PG) antifreeze, inhibiting coolant additives, and quality water. Coolant Specifications John Deere COOL-GARD™ II Premix either EG or PG, are fully formulated coolants that contain all three components in their correct concentrations. DO NOT add an initial charge of John Deere COOL-GARD II Coolant Extender to COOL-GARD II Premix. DO NOT add any other supplemental coolant additive or water to COOL-GARD II Premix. John Deere COOL-GARD II Concentrate contains both ethylene glycol and inhibiting coolant additives. Mix this product with quality water, but DO NOT add an initial charge of John Deere COOL-GARD II Coolant Extender or any other supplemental coolant additive.

Avoid Automotive-type Coolants Never use automotive-type coolants (such as those meeting ASTM D3306). These coolants do not contain the correct additives to protect heavy-duty diesel engines. Do not treat an automotive engine coolant with supplemental coolant additives because the high concentration of additives can result in additive fallout. Water Quality Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate.All water used in the cooling system should meet the following minimum specifications for quality:

Replenish Coolant Additives Some coolant additives will gradually deplete during engine operation. Periodic replenishment of inhibitors is required, even when John Deere COOL-GARD II Premix or COOL-GARD II Concentrate is used. Follow the recommendations in this manual for the use of John Deere COOL-GARD II Coolant Extender.

<40 mg/L

Sulfates

<100 mg/L

Total dissolved solids

<340 mg/L

Total hardness

<170 mg/L

pH

5.5 to 9.0

Freeze Protection The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit.

Why use John Deere COOL-GARD II Coolant Extender? Operating without proper coolant additives will result in increased corrosion, cylinder liner erosion and pitting, and other damage to the engine and cooling system. A simple mixture of ethylene glycol or propylene glycol and water will not give adequate protection. 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 Premix and COOL-GARD II Concentrate and to provide optimum protection for up to six years or 6000 hours of operation.

Chlorides

Ethylene Glycol

Freeze Protection Limit

40%

-24°C (-12°F)

50%

-37°C (-34°F)

60%

-52°C (-62°F)

Propylene Glycol

Freeze Protection Limit

40%

-21°C (-6°F)

50%

-33°C (-27°F)

60%

-49°C (-56°F)

DO NOT use a coolant-water mixture greater than 60% ethylene glycol or 60% propylene glycol.

COOL-GARD is a trademark of Deere & Company DX,COOL17 -19-20APR11-1/1

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Fuels and Lubricants

Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol base engine coolants.

IMPORTANT: Water may be used as coolant in emergency situations only.

Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required.

Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation will occur when water is used as the coolant, even when coolant conditioners are added.

John Deere COOL-GARD™ II Premix is available in a concentration of 50% ethylene glycol. However, there are situations in warm temperature climates where a coolant with lower glycol concentration (approximately 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).

Drain cooling system and refill with recommended glycol base engine coolant as soon as possible.

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, replenish coolant additives between drain intervals by adding a supplemental coolant additive as determined necessary by coolant testing. John Deere Liquid Coolant Conditioner is recommended as a supplemental coolant additive for nitrite-containing coolants. John Deere Liquid Coolant Conditioner is not designed for use with John Deere COOL-GARD™ II Premix, COOL-GARD II PG Premix, or COOL-GARD II Concentrate.

• John Deere COOL-GARD II • John Deere COOL-GARD II PG If other coolants are used, consult the coolant supplier and follow the manufacturer's recommendation for use of supplemental coolant additives. The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant. Add the manufacturer's recommended concentration of supplemental coolant additive. DO NOT add more than 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

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Fuels and Lubricants

Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing, corrosion, and cylinder liner erosion and pitting. Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating. Coolant Test Strips

Add only the recommended concentration of John Deere COOL-GARD II Coolant Extender. DO NOT add more than the recommended amount. When Using Nitrite-Containing Coolants Compare the test strip results to the supplemental coolant additive (SCA) chart to determine the amount of inhibiting 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 method to check the freeze point and additive levels of your engine coolant.

Add only the recommended concentration of John Deere Liquid Coolant Conditioner. DO NOT add more than the recommended amount.

When Using John Deere COOL-GARD II

Coolant Analysis

John Deere COOL-GARD II Premix™ , COOL-GARD II PG Premix and COOL-GARD II Concentrate are maintenance free coolants for up to six years or 6000 hours of operation, provided that the cooling system is topped off using only John Deere COOL-GARD II Premix or COOL-GARD II PG premix. Test the coolant condition annually with coolant test strips designed for use with John Deere COOL-GARD II coolants. If the test strip chart indicates that additive is required, add John Deere COOL-GARD II Coolant Extender as directed.

For a more thorough evaluation of your coolant, perform a coolant analysis. The coolant analysis can provide critical data such as freezing point, antifreeze level, pH, alkalinity, nitrite content (cavitation control additive), molybdate content (rust inhibitor additive), silicate content, corrosion metals, and visual assessment. Contact your John Deere dealer for more information on coolant analysis.

COOL-GARD is a trademark of Deere & Company DX,COOL9 -19-11APR11-1/1

TM100419 (02APR13)

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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:

TS1416 —UN—31JAN94

• API Service Classification GL-5 • Military Specification MIL-L-2105C

PW66162,00007FC -19-21FEB13-1/1

SAE 10W30

Other oils may be used if they meet one of the following specifications: API Service CF-4/SH, MIL-L-2140C, MIL-L-2140CD, OR MIL-L-2140B.

50ºC

122ºF

40ºC

104ºF

30ºC

86ºF

20ºC

68ºF

10ºC

50ºF

0ºC

32ºF

-10ºC

14ºF

-20ºC

-4ºF

-23ºC

-10ºF

CQ284935 —UN—23DEC11

The standard hydraulic oil is SAE 10W30, super high performance. ISO 68 hydraulic oil is optionally available.

SAE 15W40

Hydraulic Oil

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

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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 TS1673 —UN—31OCT03

IMPORTANT: Some types of grease thickeners are not 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 lubricant recommendations different from those printed in this manual.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic lubricants.

Some John Deere brand coolants and lubricants may not be available in your location.

Re-refined base stock products may be used if the 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

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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 tune-up will restore operating efficiency. When there is doubt, the following preliminary tests will help determine if the engine can be tuned up. If the condition is satisfactory, proceed with the tune-up. Choose from the following procedures only those necessary to restore the harvester.

hydraulic cooler, and charge air cooler.

• Check radiator cap. • Inspect all hoses.

Cylinder Head and Valves:

• Set valve clearance.

Preliminary Engine Testing

Fuel System:

Test for engine compression (minimum readings at cranking speed). It is very important that all cylinder pressures be approximately alike. There should be less than 172 kPa (1.72 bar) (25 psi) difference between cylinder pressures. Engine Tune-Up

• Check fuel tank for water and drain off, if necessary. • Check fuel tank and lines for leaks or restrictions. • Check electric fuel pump pressure. • Bleed fuel system. • Check injection pump timing. • Replace fuel filter. • Replace water separator.

Air Intake System:

Electrical System

• Check system for leaks.

• Clean and tighten battery cables and connections. • Check alternator belt for wear and damage. • Check alternator output. • Check neutral safety start switch operation. • Check safety seat switch operation. • Check starter draw. • Check battery voltage. • Inspect all wiring.

Exhaust System:

• Check system for leaks. or exhaust pipe.

Crankcase Vent:

• Check for restrictions.

Check for restricted muffler

Cooling System: PW66162,0000918 -19-18JAN13-1/1

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Tune-Up and Adjustments

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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

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Contents

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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

P15127 —UN—10JAN08

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

TP40492,000109E -19-13SEP12-1/1

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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

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.

RXA0073092 —UN—09JAN04

a. Check to see if tensioning arm (A) is against free arm stops (B). Replace belt if this condition is seen.

a. Release tension on belt using a long-handle 1/2 in. drive tool. Remove belt from alternator pulley.

C

c. Rotate tension arm (A) slowly using a 1/2 in. drive 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.

RXA0074277 —UN—29MAR04

b. Release tension on tension arm (A).

D

Belt Tensioner Mounting Cap Screw—Torque......................................................................35 N·m (26 lb.-ft.) A—Tension Arm B—Free Arm Stops

C—Metal-to-Metal Contact Between Arm and Spring Case D—Metal-to-Metal Contact Between Arm and End Cap

RXA0073094 —UN—09JAN04

Specification

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

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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.

Specification Radiator Cap—Test Pressure................................................................................... 103.4 kPa (1.03 bar) (15 psi)

R26406N —UN—29NOV88

Pressurize cap and relief should occur close to specification.

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. PW66162,000091A -19-18JAN13-1/1

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Cooling System

Test Surge Tank Cap SPECIAL TOOLS NEEDED:

• Cooling System Pressure Pump

R26406N —UN—29NOV88

•

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

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

RW4517 —UN—15NOV88

•

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

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 radiator does not maintain pressure to specification. To test surge tank, use JDG10539 Surge Tank Pressure Test Adapter Kit1. Pressurize tank to specifications using JDG10539-1 Adapter1 along with coolant leak off hose plug. Repair or replace as necessary.

Surge Tank—Test Pressure...................................................................................... 103 kPa (1.3 bar) (15 psi)

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

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Cooling System

Thermostat Repair—Use CTM

P15127 —UN—10JAN08

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

TP40492,000108F -19-11SEP12-1/1

Engine Water Pump Repair—Use CTM

P15127 —UN—10JAN08

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

TP40492,0000134 -19-17APR09-1/1

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Cooling System

TM100419 (02APR13)

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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.

T8130000256 —UN—23JAN13

CAUTION: Avoid personal injury. Fins on condenser-fuel cooler are sharp. Use 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 B—Fuel Hoses (2 used) C—Cap Screw (2 used)

Lower bracket is not removable from condenser-fuel cooler. 4. Loosen hose clamps and disconnect fuel hoses (B). Cap and plug hoses and fittings. 5. Remove nut (F) and cap screw from lower bracket. 6. Remove nut (A) and cap screw from upper bracket.

D—Refrigerant Hoses E—Latch F— Nut

9. Repair or replace as needed. (See Repair Condenser in Section 90, Group 10.) 10. Install in reverse order of removal using these special instructions:

7. Pull latch (E) downward and remove air conditioning condenser-fuel cooler. 8. If necessary, remove cap screws (C) and upper bracket from condenser-fuel cooler.

• If removed, install upper bracket. • Charge air conditioning. (See Charge Air

Conditioning System in Section 90, Group 05.) PW66162,0000937 -19-23JAN13-1/1

TM100419 (02APR13)

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Auxiliary Coolers

TM100419 (02APR13)

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Contents

Section 30 Fuel and Air

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)

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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.) 592 (LOCTITE®)

Pipe Sealant

Used to seal threads.

Loctite is a trademark of Henkel Corporation PW66162,0000943 -19-31JAN13-1/1

John Deere Fuel System Repair—Use CTM

P15127 —UN—10JAN08

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

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

X9811 —UN—23AUG88

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. 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 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.

High Pressure Fluids

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. RG14250 —UN—06JUN05

Avoid fire hazard from spilled fuel. Use appropriate container and materials to catch and 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 B—Primary Filter Drain Valve C—Water-In-Fuel Sensor Connector D—Primary Filter Canister E—Primary Filter Element F— Packing

Remove and Install Primary and Final Fuel Filter Elements 1. Park machine on level surface, shut off engine, and remove key.

G—Canister Lip H—Header Lip I— Final Filter Header J— Drain Valve K—Final Filter L— Filter Packing

2. Thoroughly clean primary filter header (A) and surrounding area. 10. Place new primary filter element (E) in canister (D) with tangs on bottom going into canister.

3. Connect a fuel drain line to primary filter drain valve (B) on bottom of filter and drain all fuel from primary filter canister (D).

11. Screw canister (D) into filter header (A), turn clockwise. Tighten until canister lip (G) snugly mates with header lip (H).

4. Disconnect water-in-fuel sensor connector (C). 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 sealing surfaces. Clean as required.

14. Thoroughly clean final filter header (I) and surrounding 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

TM100419 (02APR13)

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=70

Diesel Fuel System

17. Inspect final filter header sealing surface and clean as required. 18. Install drain valve and tighten to specification. Specification Final Fuel Filter Drain Valve—Torque........................................................................ 3.4—4 N·m (30—35 lb.-in.)

19. Install new filter packing (L) on filter.

21. Screw final filter clockwise into final filter header. Tighten until final filter snugly mates with final filter header. 22. Turn filter additional 3/4 turn after seal contact with header. NOTE: If necessary, turn key off and on again to repeat priming procedure before starting engine. 23. Turn ignition key to ON for 60 seconds to prime the fuel system before starting engine.

20. Apply a thin film of fuel on filter packing.

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.

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 B—Cover

C—Filter Element

T8120002634 —UN—07JAN13

NOTE: If necessary, turn key off and on again to repeat priming procedure before starting engine.

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

Bleed Fuel System—Use CTM

P15127 —UN—10JAN08

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

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. T8130000253 —UN—22JAN13

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

T8130000254 —UN—22JAN13

7. Open valve and drain fuel. Close valve. 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 B—Clamp C—Drain Plug

D—Hose E—Valve

Continued on next page

TM100419 (02APR13)

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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). C—Front Lower Cooling Package Shield D—Fuel Level Sensor Electrical Connector

T8130000262 —UN—29JAN13

T8130000261 —UN—29JAN13

A—Upper Cap Screw (2 used) B—Side Cap Screw (6 used)

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). C—Platform Plate

T8130000263 —UN—29JAN13

A—Cap Screw (5 used) B—Left-Hand Ladder

Continued on next page

TM100419 (02APR13)

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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. T8130000264 —UN—29JAN13

18. Remove cap screws (H) and support (I). 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. F— Cap Screw (2 used) G—Locking Nut (2 used) H—Cap Screw (4 used) I— Support J— Cap Screw (4 used)

T8130000265 —UN—29JAN13

A—Alarm B—Electrical Connectors (2 used) C—Nut D—Air Cleaner Shield E—Cap Screw (2 used)

Continued on next page

TM100419 (02APR13)

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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.

T8130000269 —UN—30JAN13

24. Loosen clamps and remove railing (B). CAUTION: Approximate weight of platform is 29 kg (64 lb.). 25. Remove cap screws (D) and platform (C). 26. Remove cap screws (E). D—Cap Screw (12 used) E—Cap Screws (2 used)

T8130000266 —UN—30JAN13

A—Lift Point Cover B—Railing C—Platform

Continued on next page

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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. T8130000267 —UN—30JAN13

29. Remove nuts (D) and cap screws. 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).

T8130000268 —UN—30JAN13

33. Pull upper platform support (I) outward and remove. 34. Disconnect fuel return hose (J). Cap and plug hose and fitting. F— U-Bolt G—Clamp Base H—Fitting I— Upper Platform Support J— Fuel Return Hose

T8130000456 —UN—30JAN13

T8130000270 —UN—30JAN13

A—Charge Air Cooler Tube B—U-Bolt C—Nut (2 used) D—Nuts (2 used) E—Nuts (2 used)

Continued on next page

TM100419 (02APR13)

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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).

A—Cap Screw (6 used) B—Center Platform

T8130000457 —UN—30JAN13

37. Remove cap screws (D) and lower platform support (C). C—Lower Platform Support 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.

T8130000459 —UN—01FEB13

CAUTION: Approximate weight of fuel tank is 43 kg (95 lb.). 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

43. Install fuel tank in reverse order of removal using the following special instructions:

B—Fuel Tank Strap

• Be sure to route all hoses and harnesses free from

• Apply PM37397 Pipe Sealant to fuel tank fittings. • Turn key switch to the ON position for 60 seconds

• Clean and inspect fuel tank supports.

• Operate machine for 3 minutes and check for leaks.

pinch points and without twists or binds. Repair or replace as necessary.

before starting engine to prime fuel system.

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

Remove and Install Fuel Cooler Fuel cooler is integrated into the air conditioning system condenser. (See Remove and Install Air Conditioning

Condenser-Fuel Cooler in Section 20, Group 20 for removal and installation of air conditioning condenser-fuel cooler.) 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. T8130000460 —UN—31JAN13

Primary and secondary air filters are located 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. E58856 —UN—02AUG10

Cleaning Dusty Filter 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

When tapping filter does not remove dust, clean filter with compressed air. Hold nozzle next to inner surface and move up and down pleats. IMPORTANT: Do not direct air against outside of filter, this forces dirt through to inside.

B—Secondary Air Filter

Ensure gasket is in good condition. Replacing Air Filter Replace primary air filter after one year of service, six cleanings, or when air filter restriction warning light remains on. Replace damaged filters immediately.

Repeat procedure to remove additional dirt. Inspect air filter before reinstalling. 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. T8130000461 —UN—31JAN13

IMPORTANT: Do not allow moisture or debris to 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. D—Air Cleaner Inlet Assembly E—Clamp (2 used)

T8130000462 —UN—31JAN13

A—Clamp B—Elbow C—Screen

PW66162,0000941 -19-31JAN13-1/1

Turbocharger Repair—Use CTM

P15127 —UN—10JAN08

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

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

Contents

Section 40 Electrical

Page Page

Group 05—Batteries Specifications ................................................ 40-05-1 Servicing Battery ........................................... 40-05-1 Checking Battery Fluid Level......................... 40-05-2 Preventing Battery Damage .......................... 40-05-2 Charging Battery............................................ 40-05-3 Battery Disconnect Switch............................. 40-05-4 Remove and Install Batteries......................... 40-05-5

Remove and Install Hydraulic Oil Temperature Sensor .................................. 40-20-4 Remove and Install Hydraulic Reservoir Level Switch .............................. 40-20-5 Remove and Install Crop Divider Position Sensor (If Equipped).................... 40-20-6 Remove and Install Air Filter Restriction Switch ...................................... 40-20-7

Group 10—Electrical Harness and Connectors Use Electrical Insulating Compound ................................................. 40-10-1 Electrical System Visual Inspection .................................................. 40-10-1 Basic Electrical Component Handling / Precautions for Vehicles Equipped with Computer Controlled Systems................... 40-10-1 Electrical Connector / Wiring Harness Handling and Repair ................... 40-10-2 Repair Procedure R-A ................................... 40-10-3 Repair Procedure R-B ................................... 40-10-6 Repair Procedure R-C ................................... 40-10-9 Repair Procedure R-D ................................. 40-10-12 Repair Procedure R-E ................................. 40-10-14 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 30—Fuses and Relays Replacing Fuses............................................ 40-30-1 Fuse and Relay Panel Location..................... 40-30-1 Fuse and Relay Identification ........................ 40-30-2 Group 40—Charging System Remove and Install Alternator ....................... 40-40-1 John Deere Engine Accessories—Alternator Repair ........................................................ 40-40-1 Group 45—Starting System Remove and Install Starting Motor ......................................................... 40-45-1 John Deere Starting Motor Repair.................. 40-45-1

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)

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=1

Contents

TM100419 (02APR13)

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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

TS204 —UN—23AUG88

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: 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.

N36877 —UN—07OCT88

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 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 (+) terminal of battery and battery ground cable to negative (-) terminal of battery. Reversed

polarity in battery or alternator may result in permanent damage to electrical system. 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.

TS203 —UN—23AUG88

IMPORTANT: Fluid level cannot be accurately checked with battery tilted. 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

TS204 —UN—23AUG88

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: 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.

Be sure that alternator connections are correct before cables are connected to battery. Carefully observe polarity when attaching booster battery. DO NOT operate the engine with alternator or battery disconnected. DO NOT short across battery or alternator terminals, or allow battery positive (+) cable or alternator wire to become grounded.

Disconnect battery cables before using an electric welder on the machine. Store batteries below 26 °C (80 °F) for maximum shelf life. Check voltage after storage, and recharge as needed as recommended by battery manufacturer. DO NOT store batteries in discharged state, or stack batteries on top of each other.

PW66162,00005D5 -19-29AUG12-1/1

TM100419 (02APR13)

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Batteries

Charging Battery CAUTION: DO NOT charge a frozen battery. Warm to 16 °C (60 °F) before charging.

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. Keep battery fully charged, especially during cold weather. CAUTION: Never charge a frozen battery. Thaw at room temperature before connecting to battery charger. Only charge batteries in a well ventilated area. Disconnect both cables from battery terminals when charging batteries in machine. Disconnect both battery cables and connect charger positive cable to “+” terminal and charger negative cable to “-” terminal.

DO NOT use battery charger as a booster if battery has a 1.15 specific gravity reading or lower. NOTE: Attach a ground strap to negative “-” battery post so ground connection can be made away from the battery. If a unit has more than one battery, each battery must be charged separately. IMPORTANT: DO NOT connect or disconnect live circuits. Turn off charger and connect ground cable last, away from battery. Stop or cut back charging rate if battery cable feels hot, or is venting electrolyte. Battery temperature must not exceed 52 °C (125 °F).

Follow instructions provided with charger or reference the charging chart below. Always charge batteries with a 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 31 126—180 Minutes

Reserve Capacity Charger Output (Amperes) Battery Voltage (Specific Gravity)a

2

10

% State of Charge

15

30

40

60

Charging Time In Hours

12.4—12.6V (1.225)

75%

19

6

5

4

4

4

12.2—12.4V (1.190)

50%

35

9

7

5

5

4

12.0—12.2V (1.155)

25%

51

13

9

6

5

5

11.7—12.0V (1.120)

0%

67

16

12

7

6

5

<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

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Batteries

Battery Disconnect Switch

T8120001101 —UN—30AUG12

IMPORTANT: Avoid damage to electrical components of machine. Battery disconnect switch must be in OFF position prior to welding on machine. NOTE: Battery disconnect switch (A) is located on right side of machine inside pump service door. Switch Position

Harvester Status

Rotated Clockwise (when viewed from face of switch)

Power ON

Rotated Counterclockwise (when viewed from face of switch)

Power OFF

Rotate switch to OFF position before leaving machine unattended.

A—Battery Disconnect Switch

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

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Batteries

Remove and Install Batteries

T8120002612 —UN—04JAN13

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

T8120002613 —UN—04JAN13

Cut tie bands as necessary. 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) B—Battery Cover C—Insulator D—(-) Battery Cable Clamp

6. Loosen (+) battery cable nut and disconnect positive battery cable.

E—Forward Battery F— Rearward Battery G—Nut (2 used each battery)

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

9. Inspect, test, and replace battery as necessary.

• Tighten battery cable clamp nuts to specification.

in Section 40, Group 05.)

10. Install battery in reverse order of removal using the following special instructions:

• Clean battery, battery posts, and cable clamps. (See

Specification Battery Cable Clamp Nut—Torque....................................................................................7 N·m (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

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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 harnesses and components for the following items can significantly reduce diagnostic time: • Mechanical damage to the wiring harness covering or harness itself • Disconnected or damaged connectors • Bare wires and/or shorts to ground

• Loose wires and/or open circuits • Poor/corroded connections • Battery condition (terminal corrosion, voltage, cold cranking amperage capacity, electrolyte level)

• Alternator condition (dirty, belt tension) • Overheated or discolored components

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 interrupting a computer program while it is running and electrical voltage spikes that are produced can damage electronic components.

on and the engine is running. Why: This can cause electrical voltage spikes that can damage electronic components.

• Do not connect jumper cables while the key switch is on. Why: This can cause electrical voltage spikes that can damage electronic components.

• Do not apply power or ground to any component as a

test unless specifically instructed to do so. Why: Connecting the wrong voltage to the wrong point of an electronic system can cause electronic component failures.

• Disconnect batteries prior to recharging (if possible)

Why: Electrical loads in the machine can slow the recharging process. Battery chargers can cause electrical voltage spikes that can damage electronic components.

• When welding on the machine, make sure to connect

• Never jump start the machine with a voltage higher than the machine is designed to operate on Why: This can damage electronic components

• Do not connect or disconnect electrical connectors

ground lead to the parts being welded. For maximum protection disconnect all electronic controllers before welding. Why: The high currents associated with welding can damage wiring harnesses that are involved in the ground path. Welding can also cause electrical voltage spikes that can damage electronic components.

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

un-mated. Why: The connectors have been designed to be mated easily. If you have to use tools or excessive force you may be doing something wrong. Prying on or forcing connectors may cause permanent damage to the locking mechanism, contacts or both.

action may not be readily visible, but may prevent new terminals from being properly retained and cause replacement of the connector body.

• When installing a new terminal on a wire make sure the

proper crimping tools is used. Why: Each part of the electrical terminal is designed for a specific purpose, failure to properly crimp the terminal can result in future electrical or mechanical problems. Terminal crimping tools are available through SERVICEGARD. It is important to make sure the insulation and wire crimps on each terminal are made properly. Soldering terminals is not recommended. See repair procedures in the Connector Repair Procedures Group

• When working on connectors make sure you are

working on the correct terminal! Why: Measuring diagnostic values at the wrong connector terminal can lead to unnecessary part replacement. The male and female halves of an electrical connector are mirror images of each other and it is easy to confuse terminal locations. Look for the terminal identifier info on the connector body.

• Use proper terminals for any connector repairs.

• Soldering splices is not recommended.

Why: In some connectors different terminal materials are used (to carry different currents). If improper terminals or terminal materials are used future electrical problems may occur from corrosion or current carrying capacity.

• When removing terminals from a connector body it

is very important to use the proper extraction tool 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

Why: Any repairs to wires in the harness should not allow moisture to come in contact with the actual copper conductor. Soldering a wire splice is not recommended because a portion of stranded wire will become solid and can cause it to break in the future, especially if it is subject to movement. When repairing a broken wire in a wiring harness, use "Heat-Shrinkable" butt splices. Be careful not to place a splice in any section of the harness subject to motion or flexing.

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 Open secondary lock (C) by gently prying locking tabs (A) off locking studs (B). C—Secondary Lock

H74027 —UN—19FEB03

A—Locking Tab B—Locking Stud

H74026 —UN—19FEB03

1.

Continued on next page

TM100419 (02APR13)

40-10-3

PW66162,00006C8 -19-23OCT12-1/6

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=91

Electrical Harness and Connectors

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 Extractor B—Locking Tabs

C—Mating Face D—Wire Entry

H74028 —UN—29APR03

2.

B

H74011 —UN—19FEB03

D

C

H74029 —UN—29APR03

B

B

B

D

H74012 —UN—19FEB03

C

WEATHER PACK is a trademark of Packard Electric 1

Included in JT07195B Electrical Repair Kit Continued on next page

TM100419 (02APR13)

40-10-4

PW66162,00006C8 -19-23OCT12-2/6

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.

A—Wire

H74030 —UN—19FEB03

2. Insert wire (A) through seal (B) and position as shown. 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. C—Wire Crimp D—Contact

H74034 —UN—19FEB03

H74032 —UN—19FEB03

H74031 —UN—19FEB03

A—Wire and Seal B—Seal Crimp

Continued on next page

TM100419 (02APR13)

40-10-5

PW66162,00006C8 -19-23OCT12-4/6

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=93

Electrical Harness and Connectors

IMPORTANT: Make sure contact is fully seated and locked. Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place. H74033 —UN—19FEB03

4.

PW66162,00006C8 -19-23OCT12-5/6

NOTE: If secondary lock is difficult to close, contact may not be properly seated or locked. Close secondary lock (C) until locking tabs (B) securely lock over locking studs (A). A—Locking Stud B—Locking Tab

C—Secondary Lock

H74035 —UN—19FEB03

5.

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

Repair Procedure R-B Remove Contact from Connector Body WZ290900997 —UN—01DEC09

1. If applicable, remove screws (A) and clamps (C).

• 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) B—Grommet

C—Clamp (2 used) D—Rear Connector Assembly

1

Included in JDG359 DEUTSCH Electrical Repair Tool Kit Continued on next page

TM100419 (02APR13)

40-10-6

PW66162,00006C9 -19-23OCT12-1/4

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. H75297 —UN—24FEB03

4. Slide extractor tool along wire into connector body until 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

H75296 —UN—24FEB03

B

H75290 —UN—24FEB03

B

Continued on next page

TM100419 (02APR13)

40-10-7

PW66162,00006C9 -19-23OCT12-2/4

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.

H75295 —UN—24FEB03

2. Adjust selector (A) on JDG360 Crimper for correct wire size. 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.

H75294 —UN—24FEB03

IMPORTANT: If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures. 7. Inspect contact to be certain all wires are in crimped barrel. D—Contact E—Cover F— Wire

H75292 —UN—24FEB03

H75293 —UN—24FEB03

A—Selector B—Lock Nut C—Adjusting Screw

1

Included in JDG155 Electrical Repair Tool Kit Continued on next page

TM100419 (02APR13)

40-10-8

PW66162,00006C9 -19-23OCT12-3/4

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.

10. If removed, install rear connector assembly in reverse order of removal.

H75291 —UN—24FEB03

9. Pull on wire slightly to be certain contact is locked in place.

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

Repair Procedure R-C 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 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. C—Seal D—Lock

H74117 —UN—19FEB03

A—Slot B—Lock

H74116 —UN—19FEB03

Remove Contact from Connector Body

1

Included in JDG359 DEUTSCH Electrical Repair Tool Kit Continued on next page

TM100419 (02APR13)

40-10-9

PW66162,00006CA -19-23OCT12-1/5

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. C—Mating Face H74118 —UN—19FEB03

A—Locking Tab B—Seal

B

H74013 —UN—19FEB03

A

H74119 —UN—19FEB03

C

B

C

H74014 —UN—06NOV02

A

1

Included in JDG359 DEUTSCH Electrical Repair Tool Kit Continued on next page

TM100419 (02APR13)

40-10-10

PW66162,00006CA -19-23OCT12-2/5

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=98

Electrical Harness and Connectors Install New Contact

2. Place wire (A) in contact (D) as shown and crimp both the wire crimp (C) and insulation crimp (B) using JDG144 Crimping Pliers1. C—Wire Crimp D—Contact

H74121 —UN—19FEB03

H74122 —UN—19FEB03

A—Wire B—Insulation Crimp

H74120 —UN—19FEB03

1. Remove contact and strip wire using JDG145 Electrician's Pliers1.

1

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

IMPORTANT: Make sure contact is fully seated and locked.

H74123 —UN—19FEB03

3. Insert contact in connector body in appropriate socket. Slide contact in until locking tabs click into place.

Continued on next page

TM100419 (02APR13)

40-10-11

PW66162,00006CA -19-23OCT12-4/5

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.

H74125 —UN—19FEB03

H74124 —UN—19FEB03

A—Secondary Lock

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

Repair Procedure R-D Remove Contact From Connector Body

H75319 —UN—26FEB03

Insert JDG777 Terminal Extraction Tool1 into connector body socket from mating face (C) as shown and depress locking tab (B).

2. Gently pull contact out in the direction of arrow. A—JDG777, Terminal Extraction Tool B—Locking Tab

C—Mating Face

C B

H75303 —UN—27FEB03

1.

1

Included in JT07195B Electrical Repair Kit Continued on next page

TM100419 (02APR13)

40-10-12

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

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=100

Electrical Harness and Connectors Install New Contact

2.

Place wire in contact as shown and crimp both wire crimp (C) and insulation crimp (B) using JDG144 Crimping Pliers1. C—Wire Crimp D—Contact

H75321 —UN—26FEB03

A—Wire B—Insulation Crimp

H75320 —UN—26FEB03

1. Remove contact and strip wire using JDG145 Electrician's Pliers1.

1

Included in JDG155 Electrical Repair Tool Kit PW66162,00006CB -19-23OCT12-2/3

IMPORTANT: Make sure contact is fully seated and locked. Install contact in connector body in appropriate socket. Slide contact in until locking tab clicks into place. H75322 —UN—26FEB03

3.

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 Remove secondary lock (A) by gently prying locking tabs (B) off locking studs (C). A—Secondary Lock B—Locking Tabs

H75324 —UN—26FEB03

1.

C—Locking Studs

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

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 Extraction Tool B—Locking Tab

C—Mating Face H75325 —UN—26FEB03

2.

C

H75312 —UN—26FEB03

B

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.

A—Wire

H75326 —UN—26FEB03

2. Insert wire (A) through seal (B) and position as shown. B—Seal

1

Included in JDG155 Electrical Repair Tool Kit Continued on next page

TM100419 (02APR13)

40-10-14

PW66162,00006CC -19-23OCT12-3/6

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. C—Wire Crimp D—Contact

H75328 —UN—26FEB03

H75327 —UN—26FEB03

A—Seal B—Seal Crimp

1

Included in JDG155 Electrical Repair Tool Kit PW66162,00006CC -19-23OCT12-4/6

IMPORTANT: Make sure contact is fully seated and locked. Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place. H75329 —UN—26FEB03

4.

Continued on next page

TM100419 (02APR13)

40-10-15

PW66162,00006CC -19-23OCT12-5/6

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. Install secondary lock (A) by aligning with connector body and wires and pushing down until locking tabs (B) lock on locking studs (C). A—Secondary Lock B—Locking Tabs

H75324 —UN—26FEB03

5.

C—Locking Studs

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

Repair Procedure R-F Remove Contact From Connector Body Remove secondary lock (A) by gently prying locking tabs (B) off locking studs (C). A—Secondary Lock B—Locking Tabs

H75333 —UN—26FEB03

1.

C—Locking Studs

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

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 Extraction Tool B—Locking Tab

C—Mating Face H75334 —UN—27FEB03

2.

C

H75314 —UN—26FEB03

B

1

Included in JT07195B Electrical Repair Kit Continued on next page

TM100419 (02APR13)

40-10-16

PW66162,00006CD -19-23OCT12-2/6

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.

A—Wire

H75335 —UN—26FEB03

2. Insert wire (A) through seal (B) and position as shown. 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. C—Wire Crimp D—Contact

H75337 —UN—26FEB03

H75336 —UN—26FEB03

A—Seal B—Seal Crimp

1

Included in JDG155 Electrical Repair Tool Kit Continued on next page

TM100419 (02APR13)

40-10-17

PW66162,00006CD -19-23OCT12-4/6

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=105

Electrical Harness and Connectors

IMPORTANT: Make sure contact is fully seated and locked. Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place. H75338 —UN—26FEB03

4.

PW66162,00006CD -19-23OCT12-5/6

NOTE: If secondary lock is difficult to install, contact may not be properly seated or locked. Install secondary lock (A) by aligning with connector body and wires and pushing down until locking tabs (B) lock on locking studs (C). A—Secondary Lock B—Locking Tabs

H75333 —UN—26FEB03

5.

C—Locking Studs

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

2.

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

1.

Gently push contact out in the direction of arrow. A—”T” Pin B—Locking Tab

C—Mating Face

B

H75429 —UN—06MAR03

C

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

Install New Contact

2.

Place wire (A) in contact (D) as shown and crimp both wire crimp (C) and insulation crimp (B) using JDG144 Crimping Pliers1. C—Wire Crimp D—Contact

H75467 —UN—05MAR03

A—Wire B—Insulation Crimp

H75466 —UN—05MAR03

1. Remove contact and strip wire using JDG145 Electrician's Pliers1.

1

Included in JDG155 Electrical Repair Tool Kit Continued on next page

TM100419 (02APR13)

40-10-19

PW66162,00006CE -19-23OCT12-2/3

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=107

Electrical Harness and Connectors

IMPORTANT: Make sure contact is fully seated and locked

3.

H75468 —UN—05MAR03

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

H75460 —UN—05MAR03

1.

2. Gently push contact out in the direction of arrow. A—JDG777, Terminal Extraction Tool B—Locking Tab

C—Mating Face

C B

H75430 —UN—06MAR03

B

1

Included in JT07195B Electrical Repair Kit Continued on next page

TM100419 (02APR13)

40-10-20

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

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=108

Electrical Harness and Connectors Install New Contact

2.

Place wire in contact as shown and crimp both wire crimp (C) and insulation crimp (B) using JDG144 Crimping Pliers1. C—Wire Crimp D—Contact

H75462 —UN—05MAR03

A—Wire B—Insulation Crimp

H75461 —UN—05MAR03

1. Remove contact and strip wire using JDG145 Electrician's Pliers1

1

Included in JDG155 Electrical Repair Tool Kit PW66162,00006CF -19-23OCT12-2/3

IMPORTANT: Make sure contact is fully seated and locked

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.

H75463 —UN—05MAR03

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.

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 Remove secondary lock (A) by gently prying locking tabs (B) off locking studs (C). A—Secondary Lock B—Locking Tabs

H73987 —UN—19FEB03

1.

C—Locking Studs

Continued on next page

TM100419 (02APR13)

40-10-22

PW66162,00006D0 -19-23OCT12-1/6

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=110

Electrical Harness and Connectors

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 B—Wire Entry

C—Mating Face H73988 —UN—19FEB03

2.

Placement of Extraction Tool Small Contact

C

H73972 —UN—01NOV02

B

A

H73989 —UN—19FEB03

Cross Section View Small Contact

Placement of Extraction Tool Large Contact

B

C

H73971 —UN—01NOV02

A

Cross Section View Large Contact 1

Included in JT07195B Electrical Repair Kit Continued on next page

TM100419 (02APR13)

40-10-23

PW66162,00006D0 -19-23OCT12-2/6

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.

A—Wire

H73990 —UN—19FEB03

2. Insert wire (A) through seal (B) and position as shown. B—Seal

H73991 —UN—19FEB03

Large Contact Seal

Small Contact Seal 1

Included in JDG155 Electrical Repair Tool Kit Continued on next page

TM100419 (02APR13)

40-10-24

PW66162,00006D0 -19-23OCT12-3/6

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. C—Wire Crimp D—Contact H73992 —UN—19FEB03

A—Wire and Seal B—Seal Crimp

H73993 —UN—19FEB03

H73994 —UN—19FEB03

Large Contact

H73995 —UN—19FEB03

Small Contact

1

Included in JDG155 Electrical Repair Tool Kit Continued on next page

TM100419 (02APR13)

40-10-25

PW66162,00006D0 -19-23OCT12-4/6

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=113

Electrical Harness and Connectors

IMPORTANT: Make sure contact is fully seated and locked. Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place. H73996 —UN—19FEB03

4.

H73997 —UN—19FEB03

Large Contact

Small Contact PW66162,00006D0 -19-23OCT12-5/6

NOTE: If secondary lock is difficult to install, contact may not be properly seated or locked. Install secondary lock (A) by aligning with connector body and wires and pushing down until locking tabs (B) lock on locking studs (C). A—Secondary Lock B—Locking Tabs

H73998 —UN—19FEB03

5.

C—Locking Studs

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 Insert JDG140 Terminal Extraction Tool1 (A) in connector body over contact to depress locking tabs (C).

H73956 —UN—19FEB03

1.

2. While holding extraction tool firmly in place, depress plunger (B) and push contact out of connector body. C—Locking Tabs

H73955 —UN—19FEB03

A—JDG140, Contact Extraction 1 Tool B—Plunger

D

C

H73953 —UN—31OCT02

E

1

Included in JT07195B Electrical Repair Kit Continued on next page

TM100419 (02APR13)

40-10-27

PW66162,00006D1 -19-23OCT12-1/3

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=115

Electrical Harness and Connectors Install New Contact

2.

Place wire (A) in contact (D) and crimp both wire crimp (C) and insulation crimp (B) using JDG783 Crimping Tool. C—Wire Crimp D—Contact

H73981 —UN—19FEB03

H73958 —UN—19FEB03

A—Wire B—Insulation Crimp

H73957 —UN—19FEB03

1. Remove contact and strip wire using JDG145 Electrician's Pliers1.

1

Included in JDG155 Electrical Repair Tool Kit PW66162,00006D1 -19-23OCT12-2/3

IMPORTANT: Make sure contact is fully seated and locked.

H73982 —UN—19FEB03

3. Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place.

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 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). C—Door Type Secondary Lock

H73858 —UN—19FEB03

A—Slide Type Secondary Lock B—Teeth

H73857 —UN—19FEB03

Remove Contact From Connector Body

PW66162,00006D2 -19-23OCT12-1/5

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. C—Wire Entry D—Mating Face

H73765 —UN—01NOV02

A—Locking Tab B—Secondary Lock

H73879 —UN—19FEB03

2.

1

Included in JT07195B Electrical Repair Kit Continued on next page

TM100419 (02APR13)

40-10-29

PW66162,00006D2 -19-23OCT12-2/5

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. Place wire (A) in contact (D) and crimp both wire crimp (C) and insulation crimp (B) using JDG144 Crimping Pliers1. C—Wire Crimp D—Contact

H73983 —UN—19FEB03

H73922 —UN—19FEB03

A—Wire B—Insulation Crimp

H73921 —UN—19FEB03

2.

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.

H73978 —UN—19FEB03

3. Install contact in connector body in appropriate socket. Slide contact in until the lock clicks into place.

Continued on next page

TM100419 (02APR13)

40-10-30

PW66162,00006D2 -19-23OCT12-4/5

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.

H73858 —UN—19FEB03

H73977 —UN—19FEB03

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.

PW66162,00006D2 -19-23OCT12-5/5

Repair Procedure R-N Remove Contact From Connector Body Open secondary lock doors (A) by gently prying locking tabs (B) off locking studs (C). C—Locking Studs

H75454 —UN—05MAR03

A—Secondary Lock Door B—Locking Tabs

H75453 —UN—05MAR03

1.

Continued on next page

TM100419 (02APR13)

40-10-31

PW66162,00006D3 -19-23OCT12-1/5

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=119

Electrical Harness and Connectors

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 Extraction Tool B—Locking Tab

C—Mating Face H75455 —UN—05MAR03

2.

B

H75431 —UN—06MAR03

C

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. Place wire in contact as shown and crimp both wire crimp (C) and insulation crimp (B) using JDG144 Crimping Pliers1. C—Wire Crimp D—Contact

H75457 —UN—05MAR03

A—Wire B—Insulation Crimp

H75456 —UN—05MAR03

2.

1

Included in JDG155 Electrical Repair Tool Kit Continued on next page

TM100419 (02APR13)

40-10-32

PW66162,00006D3 -19-23OCT12-3/5

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=120

Electrical Harness and Connectors

IMPORTANT: Make sure contact is fully seated and locked. Install contact in connector body in appropriate socket. Slide contact in until locking tab clicks into place. H75458 —UN—05MAR03

3.

PW66162,00006D3 -19-23OCT12-4/5

NOTE: If secondary lock door is difficult to close, contact may not be properly seated or locked. Close secondary lock door (A) until locking tabs (B) are securely locked over locking studs (C). A—Secondary Lock Door B—Locking Tabs

H75454 —UN—05MAR03

4.

C—Locking Studs

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

2. Cut a length of shrink wrap material long enough to 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.

CM073510484 —UN—21SEP07

1. Strip 7 mm (3/8”) of insulation from end of wires (A) to be spliced.

A—Wires B—Connector

CM073510485 —UN—21SEP07

5. Center shrink wrap over splice and use a heat gun or hair dryer to heat shrink wrap. C—Shrink Wrap

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

2

47 29

43

30

48 3

46

41

32

5

4

44

42

31

1

45

49

40

58

39 38

57

36 37

56

6 59

50

35

33

7

34 53

54 55

20 19

8

51

9

21

10

22

52

11

18 12

17 15

14

13

T8130000169 —UN—06FEB13

16

23 28

27

24 26

25

Continued on next page

TM100419 (02APR13)

40-15-1

CG01926,000031D -19-08FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=123

Wire Harness Routings 1— X242—Right Speaker 2— X243—Left Speaker 3— X269—Left Wiper Motor 4— X282—Left Horn 5— X283—Left Horn 6— X284—Left Outside Road Lamp 7— X285—Left Field Lamp 8— X286—Left Inside Road Lamp 9— X288—GPS Receiver 10— X091—GPS Receiver-toGround 11— X287—Beacon Light 12— X289—Right Inside Road Lamp 13— X290—Right Field Lamp 14— X291—Right Outside Road Lamp 15— X280—Right Horn 16— X279—Right Horn

17— X249—Primary Display Unit J1 18— X250—Park Brake 19— X254—Right Wiper Motor 20— X252—AUTEQ Alarm 21— X253—AUTEQ Alarm 22— X251—AutoTrac Display 23— X292—Universal AutoTrac 24— X293—Universal AutoTrac 25— X112—Cab Harness-to-Cab Load Center Harness 26— X113—Cab Harness-to-Cab Load Center Harness 27— X070—Ground 28— X060—Ground 29— X244—Panel Lamp 30— X245—Panel Lamp 31— X246—Dome Lamp 32— X247—Dome Lamp

33— X248—Dome Lamp Switch 34— X276—Wiper Timer N.C. 35— X275—Wiper Timer N.O. 36— X274—Wiper Timer 2 37— X273—Wiper Timer 1 38— X272—Wiper Timer C 39— X124—Cab Harness-toFlasher Relay Harness 40— X258—Secondary Extractor Switch 41— X257—Primary Extractor Switch 42— X256—Knockdown Roller Tilt Switch 43— X259—Reversing Cooling Fan 44— X268—Beacon Light Switch 45— X267—Engine Work Light Switch 46— X266—Field Light Switch

47— X265—Road Light Switch 48— X264—Hazard Light Switch 49— X270—Camera 50— X281—Terminating Resistor 51— X271—Center Wiper Motor 52— X255—AUTEQ Display 53— X397—Center Wiper Switch 54— X398—Side Wiper Switch 55— X399—Wiper Diode 56— X262—High-Low Switch 57— X261—Transport Switch 58— X260—Positrac Switch 59— X120—Cab Harness-toFlasher Module Harness

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 K

G

E

F

H J

I B

D C

F

A

L M

N F

O

P

Q

R S T T8130000170 —UN—06FEB13

U X V W

A—X221—Neutral Switch B—X217—Throttle Switch C—X216—Right Side Knife On-Off Switch D—X215—Left Side Knife On-Off Switch E—X214—Elevator Forward-Reverse Switch F— X213—Elevator Up-Down Switch G—X210—Basecutter Forward-Reverse Switch

H—X211—Left Crop Divider Tilt Switch I— X212—Right Crop Divider Tilt Switch J— X209—Hydraulic Reset Switch K—X438—Secondary Display Unit L— X200—Topper Left-Right Switch M—X201—Primary Hood Rotate Switch

N—X202—Crop Divider Float Switch O—X203—Secondary Hood Rotate Switch P—X220—Elevator Diode Q—X204—Ground Drive Position Sensor R—X223—Left Elevator Swing Pedal S—X222—Right Elevator Swing Pedal T— X224—Elevator On-Off Switch

U—X225—Resume Switch V—X226—Hi-Low Switch W—X102—Armrest Harness-to-Steering Column Harness X—X100—Armrest Harness-to-Cab Load Center Harness

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

3

2

10

9

4

5

6 7 8

28 21

22

23 27 25

29

26

30

31

11

24 20 19

12

18 17 16

13 15

T8130000168 —UN—07FEB13

14

Continued on next page

TM100419 (02APR13)

40-15-4

CG01926,000031C -19-05FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=126

Wire Harness Routings 1— X107—Cab Load Center Harness-to-Engine Harness 31 #1 2— X110—Cab Load Center Harness-to-Engine Harness 14 3— X108—Cab Load Center Harness-to-Mainframe Harness 4— X111—Cab Load Center Harness-to-Engine Harness Ground Plug 5— X109—Cab Load Center Harness-to-Engine Harness 18 6— X106—Cab Load Center Harness-to-Engine Harness 31 #2

7— X030—Ground 8— X090—Ground 9— X080—Ground 10— X040—Ground 11— X108—Mainframe Harness-to-Cab Load Center Harness 12— X115—Mainframe Harness-to-Engine Harness 13— X103—Cab Load Center Harness-to-Air Conditioning Harness 14— X116—Mainframe Harness-to-Main Track Harness 15— X101—Cab Load Center Harness-to-Automatic Base Cutter Harness

16— X104—Cab Load Center Harness-to-Automatic Base Cutter Harness 17— X233—Multi-function Control Lever 18— X232—Multi-function Control Lever 19— X230—Operators Presence Switch 20— X229—Crop Divider Diode 21— X099—Load Center 22— X228—Light Switch 23— X227—Elevator Diode 24— X100—Cab Load Center Harness-to-Armrest Harness

25— X237—CAN Diagnostic 26— X236—Propulsion Steering Control J1 27— X235—Propulsion Steering Control J2 28— X234—Propulsion Steering Control J3 29— X105—Cab Load Center Harness-to-Auxiliary Power Strip Harness 30— X112—Cab Load Center Harness-to-Cab Harness 31— X113—Cab Load Center Harness-to-Cab 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

12

6

11 7 8 18 17

9 10

14

15

16 19

27

20 23 22 26

25 24 21

29

30

31 32 33

46

34

45

35

36

37

44

42 41

38 40

Continued on next page

TM100419 (02APR13)

40-15-6

39

T8130000166 —UN—06FEB13

43

CG01926,0000316 -19-08FEB13-1/3

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=128

Wire Harness Routings 1— X126—Engine Harness-toPositive Terminal Battery Harness 2— X298—Transfer Pump Fuse 3— X437—ECU Fuse 4— X320—Vehicle Control Unit Fuse 5— X321—Vehicle Control Unit Fuse 6— X353—Topper Right-Left Solenoid 7— X354—Left Side Knife Solenoid 8— X355—Right Side Knife Solenoid 9— X356—Topper Collector Solenoid 10— X130—Engine Harness-toEngine Extension Harness

11— X361—Basecutter Up Solenoid 12— X364—Basecutter Down Solenoid 13— X362—Door Switch 14— X363—Left Crop Divider Float Solenoid 15— X346—Left Height Sensor 16— X360—Knock-Down Roller Tilt Solenoid 17— X358—Left Side Crop Divider Tilt Solenoid 18— X357—Right Side Crop Divider Tilt Solenoid 19— X350—CAN Terminator 20— X351—Engine Control Unit J2 21— X352—Basecutter Pressure Sensor

22— X316—Left Ground Drive Pump 23— X317—Chopper Pump Solenoid 24— X318—Chopper Transducer 25— X313—Basecutter Pump Solenoid 26— X314—Right Ground Drive Pump 27— X315—Primary Extractor Pump 28— X050—Ground 29— X308—Starter Relay 30— X310—Starter Relay 31— X311—Starter Relay 32— X309—Starter Relay 33— X301—Vehicle Control Unit 34— X300—Vehicle Control Unit

Continued on next page

TM100419 (02APR13)

40-15-7

35— X405—Right Crop Divider Float Solenoid 36— X347—Right Height Sensor 37— X299—Vehicle Control Unit 38— Row Sense 39— Row Sense 40— X303—Unloading Solenoid 41— X302—Basecutter Pump Solenoid 42— X304—Topper Up-Down 43— X305—Primary Hood Rotate 44— X306—Right Crop Divider 45— X297—Left Crop Divider 46— X307—Elevator Swing

CG01926,0000316 -19-08FEB13-2/3

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=129

Wire Harness Routings Engine: Rear Left Side 10 11

9

2

8 1 4

5

7

12

6 13 14

15

3

16

17 18

19

37

36

38 40

23

20

39

21 22

35

24 32

34

27

T8130000167 —UN—06FEB13

33

26 25

28 31 30

1— X390—Left Turn Signal 2— X391—Right Turn Signal 3— X296—Steering Input Device 4— X295—Engine Work Light 5— X121—Turn Signal Harness-to-Engine Harness 6— X121—Engine Harness-toTurn Signal Harness 7— X109—Engine Harness 18-to-Cab Harness 8— X106—Engine Harness 31 #2-to-Cab Harness 9— X110—Engine Harness 14-to-Cab Harness 10— X107—Engine Harness 31 #1-to-Cab Harness

11— X115—Engine Harness-toMainframe Harness 12— X294—Pressure Sensors 13— X331—Park Break Solenoid 14— X330—Positrac Solenoid 15— X328—Variable Speed Solenoid 16— X327—High-Low Solenoid 17— X344—Reverse Coil (Top) Solenoid 18— X343—Proportional Coil (Right) Solenoid 19— X119—Engine Harness-toRear Frame Harness 20— X118—Engine Harness-toRear Frame Harness

21— X114—Cooling Harness-to-Engine Harness 22— X470—Auxiliary Power 23— X340—Fuel Sensor 24— X322—Feed Roller Forward-Reverse Solenoid 25— X093—Engine Ground 26— X336—Starter “S” Motor 27— X010—Engine Ground 28— X061—Engine Ground 29— X337—Starter Motor Positive 30— X337—Starter Motor Positive 31— X337—Starter Motor Positive 32— X339—Air Conditioning High Pressure Switch

29

33— X342—Front Washer Motor 34— X341—Side Washer Motor 35— X338—Compressor 36— X348—Air Filter Restriction Switch 37— X326—Hydraulic Oil Filter Restriction Pressure Sensor 38— X329—Brake Pressure Sensor 39— X323—Hydraulic Oil Temperature Sensor 40— X324—Hydraulic Oil Level 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

E

F

T8130000165 —UN—07FEB13

H

G

A—X456—Battery Negative Terminal B—X455—Battery Positive Terminal C—X458—Battery Negative Terminal

D—X457—Battery Positive Terminal E—X459—Battery Disconnect Switch F— X439—Battery Disconnect Switch

G—X359—Primary Tachometer Sensor H—X126—Positive Terminal Battery Harness-to-Engine Harness 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 A

B C

D E L G

F

T8130000164 —UN—07FEB13

K

J I A—X401—Primary Extractor Speed Sensor B—X128—Rear Frame Harness-to-Primary Extractor Harness C—X402—Primary Extractor

D—X240—Engine Coolant Level Low Sensor E—X239—Left Side Light F— X389—Reverse Alarm G—X388—License Plate Light

H

H—X114—Cooling Harness-to-Engine Harness I— X118—Rear Frame Harness-to-Engine Harness J— X119—Rear Frame Harness-to-Engine Harness

K—X387—Flap Beater L— X241—Right Side Light

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 A

C

B

J D

H

F

E

T8130000163 —UN—07FEB13

G

I

A—X116—Main Track Harness-to-Mainframe Harness B—X366—Right Height Sensor

C—X371—Left Height Sensor D—X372—Left Speed Sensor E—X370—Left Tail Light

F— X369—Reverse Light J— X365—Right Speed Sensor G—X368—Reverse Light H—X367—Right Tail Light 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 B D

C

A

E

F

G

M N O

H

L

T8130000162 —UN—07FEB13

K

I

J

A—X377—Secondary Hood Rotate SV2 B—X379—Elevator Up-Down SV3 C—X380—Elevator Forward-Reverse SV6 D—X376—Elevator Unload SV5

E—X381—Secondary Extractor SV1 F— X378—Bin Flap SV4 G—X375—Elevator Speed Solenoid H—X374—Left Beacon Light I— X373—Left Elevator Light

J— X117—Elevator N—X385—Elevator Diode Module Harness-to-Main Track 1 Harness O—X386—Elevator Diode Module K—X382—Right Beacon Light 2 L— X383—Right Elevator Light M—X384—Elevator Diode Module 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 Control Rod

Length

210 mm (8.25 in.)

Air Filter Restriction Switch

Torque

11 N·m (97 lb.-in.) PW66162,000098E -19-13FEB13-1/1

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

Replace Engine Sensors and Switches—Use CTM

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 T8120002614 —UN—07JAN13

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

A—Engine Access Door Switch

B—Electrical Harness 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.

Sensor cannot be repaired. If defective, 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).

T8130000255 —UN—28JAN13

NOTE: Surround fuel level sensor mounting area with disposable cloth or paper to minimize fuel spill.

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:

Specification Fuel Level Sensor Cap Screws—Torque................................................................ 1.0—1.47 N·m (9—13 lb.-in.) F— Cap Screw (5 used) G—Upper Cap Screw (2 used) H—Side Cap Screw (6 used) I— Front Lower Cooling Package Shield J— Electrical Connector

T8130000260 —UN—28JAN13

A—Fuel Tank Fill Neck B—Platform Plate C—Cap Screw (5 used) D—Fuel Level Sensor E—Rear of Cab

T8130000259 —UN—28JAN13

• Use a new gasket between tank and sensor. • Tighten sensor cap screws to specification.

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.).

T8120002615 —UN—07JAN13

Sensor cannot be repaired. If defective, it must be replaced. 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 Sensor

6. If necessary, replace sensor O-ring and sensor. 7. Lubricate O-ring, install sensor, and tighten to specification.

B—Connector

8. Connect harness connector.

Specification Hydraulic Temperature Sensor—Torque............................................................................32 N·m (24 lb.-ft.)

9. Fill hydraulic reservoir. (See Hydraulic Oil in Section 10, Group 15 for recommended oil.) 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. T8120002616 —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. 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 B—Hydraulic Reservoir Level Switch

5. Clean hydraulic reservoir level switch (B) and surrounding area.

C—Electrical Connector

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: hydraulic level switch and adapter bushing before installation.

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.)

T8120002272 —UN—26NOV12

• Apply Pipe Sealant with TEFLON® to threads of

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.) T8130000596 —UN—08FEB13

5. Clean crop divider position sensor and surrounding 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.

T8130000597 —UN—08FEB13

11. Install in reverse order using the following special instructions.

• 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 Crop Divider Position Sensor Control Rod—Length............................................................................... 210 mm (8.25 in.)

A—Control Rod B—Lever C—Electrical Connector

D—Cap Screw (2 used) E—Distance F— Nuts (2 used)

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. T8130000258 —UN—28JAN13

3. Disconnect electrical connector (B). 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 B—Electrical Connector

C—Intake Tube

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

Replacing Fuses IMPORTANT: Do not replace original fuse with higher rated fuse or machine damage can occur. All electrical circuits are protected by fuses. Amperage rating is marked on each fuse and fuses are color coded to ensure proper replacement.

Color

5 Amp

Tan

10 Amp

Red

15 Amp

Blue

20 Amp

Yellow

25 Amp

Natural (White)

30 Amp

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

Fuse and Relay Panel Location

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). D—Fuse and Relay Panel E—Fuse and Relay Identification Decal

T8120002113 —UN—21FEB13

A—Storage Bin B—Knob C—Seat Back Cushion

N56385 —UN—22MAR01

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

PW66162,0000837 -19-21FEB13-1/1

TM100419 (02APR13)

40-30-1

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=143

TM100419 (02APR13)

40-30-2

Continued on next page

1

2

24V IGNITION ECU

K27

24V COMPRESSOR A/C

K26

PRIMARY PUMP

K25

2

4

HAZARD LIGHTS

F2

F3

1

3

20A

FRONT FIELD LIGHTS

20A F43

20A F45 F46

30A F32

FAN MOTOR

F18

F4

4

1

2

INNER ELEVATOR WORK FIELD ROAD LIGHTS LIGHTS LIGHTS 20A 20A 20A

10A F44

3

F6

3

20A

OUTER ROAD LIGHTS

F47

15A

HORN

20A F33 10A F34

4

10A

KEY SWITCH

F48

10A

AUTO TRAC BATT

2

F7

F36

1

BASECUTTER FWD/REV 10A

2

SIDE KNIFE FWD/REV ON/OFF 10A 10A F50 F49 ELEVATOR

5A F35

F22

F8

HARVESTING

1

PARK BRAKE PROPULSION

K21

K13

4

5A F52

ALTERNATOR

F24 TILT OPTIONS 15A F38

F10

3

VALVE 5A

4

5A

RESET

DISCHARGE PARK BRAKE

ELEVATOR PROPULSION

5A F51

HARVESTING FUNCTIONS

F37

F23

F9

ACCESSORY

3

PARK BRAKE PROPULSION RESET

2

F26

F12

IGNITION

5A F27

VCU SWITCH

F13

3

F28

F14

24V BAT

4

LOWER ROAD LIGHTS

K24

QUICK STOP LAMP

K16

HORN

F

G

H

J

A

B

C

D

E

F

G

H

J

1

5A

GAUGES

2

CYLINDER

IGNITION FUNCTION ECU 15A 15A F53 F54

24V COMPRE SSOR A/C

C

D

3

10A

F55

4

10A

A

5A F56 B 24V PSC-PTP ECU POWER IGNITION

10A

AUTO TRAC ING

24V VCU JOYSTICK IGNITION PRIMARY F25 PUMP E 5A 10A 5A F41 F42 F39 F40

F11 ABC 5A

1

WIPERS

K23

TURN SIGNAL

SIDE FIELD LIGHTS K22

K15

HARVESTING FUNCTIONS

K4RELAY BLOCK 4 K7 K8

K14

ENGINE WORK LIGHT

RELAY BLOCK 3 K5 K6

F20 F21 TRANS- EXTRACTOR LIGHT MISSION SWITCH CONTROLLER FANS

F5 LOWER ROAD LIGHTS 20A F19

4

PROPULSION ENABLE

K20

BIN FLAP (IN)

K12

BIN FLAP (OUT)

BATTERY BLOCK 2

2

ACCESSORY BLOCK

K19

ELEVATOR (RESET)

K11

ELEVATOR (FWD/REV)

RELAY BLOCK 2 K3 K4

20A F15 F16 F17 ACC BATTERY PRESS POWER POWER MOTOR OUTLET OUTLET 10A 10A 15A F29 F30 F31 SIDE ACC 12V WIPER FIELD BATTERY LIGHTS

F1

BATTERY BLOCK 1

3

IGNITION BLOCK

1

K18

12V A/C COMPRESSOR

REVERSE LIGHT

HARVESTING FUNCTIONS RESET K17

K10

K9

CROP DIVIDER RESET

RELAY BLOCK 1 K2

ACC POWER OUTLET

K1

CQ291883 —UN—03AUG12

A

B

C

D

E

F

G

H

J

A

B

C

D

E

F

G

H

J

FRONT FIELD LIGHTS

K31

OUTER ROAD LIGHTS

K30

INNER ROAD LIGHTS

K29

ELEVATOR FIELD LIGHTS

K28

Fuses and Relays

Fuse and Relay Identification

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

3520 and 3522 Sugar Cane Harvester Repair 040213

PN=144

Fuses and Relays K1—Accessory Power Outlet Relay K2—Crop Divider Reset Relay K3—Elevator Relay (forward and reverse) K4—Bin Flap Relay (Out) K5—(blank) K6—Engine Work Light Relay K7—Harvesting Functions Relay K8—Horn Relay K9—Hydraulic Functions Reset Relay K10— Reverse Light Relay K11— Elevator Reset Relay K12— Bin Flap Relay (In) K13— (blank) K14— Side Field Lights Relay K15— Turn Signal Relay K16— Quick Stop Lamp Relay K17— 12 V Air Conditioning Compressor Relay K18— Ignition Block Relay K19— Accessory Block Relay K20— Propulsion Enable Relay K21— Park Brake Relay K22— Park Brake Relay Reset K23— Wipers Relay K24— Lower Road Lights Relay

K25— Primary Pump Relay K26— 24 V Air Conditioning Compressor Relay K27— 24 V Ignition ECU Relay K28— Elevator Field Lights Relay K29— Inner Road Lights Relay K30— Outer Road Lights Relay K31— Front Field Lights Relay F1— (blank) F2— Hazard Lights Fuse (20 Amp) F3— (blank) F4— (blank) F5— Lower Road Lights Fuse (20 Amp) F6— (blank) F7— (blank) F8— (blank) F9— (blank) F10— (blank) F11— Automatic Base Cutter Fuse (5 Amp) F12— (blank) F13— VCU Switch Fuse (5 Amp) F14— (blank) F15— Battery Power Outlet Fuse (10 Amp) F16— Accessory Power Outlet Fuse (10 Amp) F17— Pressure Motor Fuse (15 Amp) F18— Recirculation Fan Motor Fuse

F19— Light Switch Fuse (20 Amp) F20— Propulsion Controller Battery Fuse (10 Amp) F21— Extractor Fans Fuse (5 Amp) F22— (blank) F23— (blank) F24— Tilt Options Fuse (15 Amp) F25— (blank) F26— Multi-Function Lever Fuse (5 Amp) F27— VCU Ignition Fuse (10 Amp) F28— 24 V Fuel Primary Pump Fuse (5 Amp) F29— Side Field Lights Fuse (20 Amp) F30— Cigarette Lighter Fuse (10 Amp) F31— Wiper Fuse (20 Amp) F32— Blank F33— Horn Fuse (15 Amp) F34— AutoTrac Battery Fuse (10 Amp) F35— Elevator Fuse (Forward and Reverse) (10 Amp) F36— Side knife Fuse (On and Off) (10 Amp) F37— Harvesting Functions Fuse (5 Amp) F38— Alternator Fuse (5 Amp) F39— Ignition ECU Fuse (15 Amp)

F40— Cylinder Function Fuse (15 Amp) F41— AutoTrac Ignition Fuse (10 Amp) F42— 24 V Air Conditioning Compressor Fuse (5 Amp) F43— Front Field Lights Fuse (20 Amp) F44— Inner Road Lights Fuse (20 Amp) F45— Elevator Fields Lights Fuse (20 Amp) F46— Work Lights Fuse (20 Amp) F47— Outer Road Lights (20 Amp) F48— Key Switch (10 Amp) F49— Base Cutter Fuse (Forward and Reverse) (10 Amp) F50— (blank) F51— Elevator Unload Fuse (5 Amp) F52— Park Brake Reset Fuse (5 Amp) F53— Displays Fuse (5 Amp) F54— (blank) F55— Propulsion Ignition Fuse (10 Amp) F56— 24 V Ignition ECU Fuse (10 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. T8130000463 —UN—31JAN13

5. Slide and position insulators (F and G) to expose wire 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.) 9. Install in reverse order using the following special instructions:

A—Alternator B—Cap Screw C—Cap Screw D—Belt

E—Tensioner Arm F— Insulator G—Insulator

• Check condition of belt for wear or damage. Replace as necessary.

• After wires are connected, be sure to position insulators over wire connectors.

• Ensure that belt is fully engaged into grooves of each grooved belt pulley.

PW66162,000083A -19-31JAN13-1/1

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

John Deere Engine Accessories—Alternator Repair

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).

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 B—Negative Cable (4 used) C—Positive Booster Cable

D—Solenoid Wire E—Cap Screw (2 used) F— Positive Cables (4 used)

T8130000464 —UN—01FEB13

4. Tag and disconnect cables (F), positive booster cable (C), and solenoid wire (D).

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

John Deere Starting Motor Repair

P15127 —UN—10JAN08

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

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

Contents

Section 50 Power Train

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.) TY9473 (Canadian) 242 (LOCTITE®)

Thread Lock and Sealer (Medium Strength)

To seal and retain threads.

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

CM002500287 —UN—26SEP07

Pump Drive Gear Case Exploded View

Continued on next page

TM100419 (02APR13)

50-05-2

PW66162,00008A4 -19-12NOV12-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=154

Pump Drive Gear Case 1— Housing 2— Ball Bearing 3— Spur Gear 4— Spline Coupling 5— Adapter Plate 6— Cap Screw

7— O-ring 8— Adapter Plate 9— Socket Head Screw 10— Ball Bearing 11— Gear 12— Bearing

13— Shaft 14— Bearing 15— Housing 16— Seal 17— Pipe Plug 18— Cap Screw 19— Fitting

20— Pipe Bushing 21— Tube 22— Pipe Plug 23— Pipe Plug

PW66162,00008A4 -19-12NOV12-2/2

Remove and Install Pump Drive Gear Case

CM073510558 —UN—03MAR08

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

CM073510559 —UN—24MAR08

7. Remove bolts from flywheel housing located on rear of pump drive.

PW66162,00007CF -19-01MAR13-2/6

8. Remove bolts (B), located on each side of pump drive, that are securing rear engine mount.

CM073510558 —UN—03MAR08

NOTE: Coupling and drive shaft may stay with either the engine or pump drive. 9. Carefully slide pump drive outward and away from engine.

Continued on next page

TM100419 (02APR13)

50-05-3

PW66162,00007CF -19-01MAR13-3/6

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=155

Pump Drive Gear Case

CM073510560 —UN—03MAR08

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

PW66162,00007CF -19-01MAR13-4/6

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

CM073510561 —UN—24MAR08

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.

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

13. Install pump drive on flywheel housing by meshing rubber coupling spline with aluminum ring bolted to engine flywheel. The pilot, located on pump drive shaft, must go into the support bearing located in center of flywheel.

CM073510562 —UN—24MAR08

12. Install pump drive shaft (13) into pump drive housing. Be careful not to damage seal (16).

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 CM073510563 —UN—24MAR08

Disassemble 1. Position pump drive with hydraulic adapter plates (5 and 8) facing upward.

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

CM073510564 —UN—24MAR08

2. Remove bolts (6 and 9), and adapter plates from pump drive housing (1).

Continued on next page

TM100419 (02APR13)

50-05-5

PW66162,00007E4 -19-01MAR13-2/11

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.

CM073510566 —UN—03MAR08

CM073510565 —UN—27SEP07

3. Remove gears (3), spline adapters (4), and bearings (2) from pump drive housing.

Continued on next page

TM100419 (02APR13)

50-05-6

PW66162,00007E4 -19-01MAR13-3/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=158

Pump Drive Gear Case

CM073510568 —UN—03MAR08

CM073510567 —UN—03MAR08

4. Bearings are press fit to gear hubs. It may be necessary to tip gear slightly to clear pinion gear bearing pocket.

PW66162,00007E4 -19-01MAR13-4/11

CM073510569 —UN—24MAR08

5. After all gears and bearings have been removed, remove breather parts (19, 20, and 21).

Continued on next page

TM100419 (02APR13)

50-05-7

PW66162,00007E4 -19-01MAR13-5/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=159

Pump Drive Gear Case

CM073510571 —UN—03MAR08

CM073510570 —UN—03MAR08

6. Turn gear case over so adapter housing (15) is facing upward. Remove bolts (18) and lift adapter housing from pump drive housing.

Continued on next page

TM100419 (02APR13)

50-05-8

PW66162,00007E4 -19-01MAR13-6/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=160

Pump Drive Gear Case

CM073510573 —UN—27SEP07

CM073510572 —UN—24MAR08

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

Continued on next page

TM100419 (02APR13)

50-05-9

PW66162,00007E4 -19-01MAR13-7/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=161

Pump Drive Gear Case

CM073510575 —UN—03MAR08

CM073510574 —UN—24MAR08

8. Remove bearings (2, 10, and 12) from hubs of gears (3 and 11) using a gear puller or arbor press.

Continued on next page

TM100419 (02APR13)

50-05-10

PW66162,00007E4 -19-01MAR13-8/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=162

Pump Drive Gear Case

CM073510577 —UN—03MAR08

CM073510576 —UN—24MAR08

9. Remove oil seal (16) by driving outward or pulling outward toward engine side of adapter housing (15).

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.

5. Prior to installation, lubricate all seals with O-ring lube 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.

CM073510578 —UN—24MAR08

4. Check around splines and chamfered area of shaft for burrs, nicks, or sharp edges that can damage seals when reassembling.

Specification Pump Gear Case Cap Screws—Torque..........................................................................271 N·m (200 lb.-ft.) Continued on next page

TM100419 (02APR13)

50-05-11

PW66162,00007E4 -19-01MAR13-10/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=163

Pump Drive Gear Case

CM073510581 —UN—06MAR08

CM073510580 —UN—03MAR08

9. Replace oil seal (16). Lubricate and install oil seal towards engine side of adapter housing (15). Rubber lip of oil seal must point toward inside of pump drive as shown.

CM073510579 —UN—03MAR08

NOTE: When a repair is made to pump drive, the oil seal should be replaced.

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

TM100419 (02APR13)

50-05-12

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=164

Contents

Section 55 Track

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)—Exploded 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

CM002500182 —UN—24MAR08

Track Component Identification

1— Idler Assy-Front 2— Spring Assy-Recoil

3— Rail Assy-Link 4— Bushing 5— Pin 6— Roller Assy-Carrier

7— Roller Assy-Track 8— Sprocket Assembly

9— Track Shoe

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

TM100419 (02APR13)

55-05-1

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=167

Track

CM053510242 —UN—27JUL05

Track Alignment

A—Sprocket B—Carrier Roller

F— Hydraulic Track Adjuster G—Track Roller

C—Track Shoe D—Idler E—Rear Axle Cover

One of the most important factors to check for obtaining a good service life is correct track alignment. All the rollers should be central to a line from the sprocket tooth center to the front idler center. Another vital check is that all bottom track rollers are level. Misalignment from wear, bearing failure, or a distortion in track frame causes uneven distribution of the uncorrected uneven load distribution. A new bottom roller should never be used along with worn ones.

A simple field test to check the load distribution is to walk the machine on a hard surface for about 1 km (5/8 mile). Check the rollers for correct oil level prior to this test. Feel each roller with your hand and note the temperature of each one. Any rollers that feel hotter than others would indicate that they are carrying more than their share of the load.

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

Roller Lubrication The track, carrier, and idler rollers are filled with a SAE 30 engine oil, which has a red dye additive. This allows for easy detection of leakage, if a leak occurs. A periodic visual inspection should be made for signs of leakage. Since these are “lifetime” rollers, it is not normally necessary to refill them until the shells are due for replacement. However, in cane harvester applications, the lubrication level should be checked on an annual basis. To check, use the following procedure: 1. Position the harvester on level ground. 2. Remove the shaft plug and screw in the lubrication fitting.

NOTE: If oil flowing from around the fitting is dirty or mixed with water, keep filling until flowing oil is absolutely clean. 3. Attach a lubrication gun nozzle and pump oil in until it comes out from around the fitting. 4. This indicates correct level. Quickly remove the nozzle and refit the plug. An alternative way to lubricate is to place the machine on an angle away from the filler plug at approximately 20°. Oil 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.

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 CM002500195 —UN—23MAY00

Idler is filled with SAE 30 engine oil, which has a red 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 idler. Tread wear is determined by measuring, with a broad based depth gauge, from the idler center flange to the tread surface. The depth gauge should be positioned so that the ruler is aimed, as closely as possible, toward the center of the idler. The ruler’s base should be flat on the center flange and parallel to the idler shaft. The greatest error in measuring idler wear is caused by any wear located on top of the center flange; this alters the reference point. Abrasive packing conditions usually cause the greatest amount of center flange wear. If this wear is suspected, some attempt to compensate should be made when the reading is taken. Remember, idler tread wear occurs and decreases as center flange wear occurs.

top flange. It is also caused by the links jumping out of thread and running on the center flange. If the track is too loose or snaky, the chances of link damage is increased. This can reduce the wear measurement distance and the resulting measurement accuracy.

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 most worn to least worn is greater than 1.5 to 1 and the average percentage worn is less than 60%.

To remedy, clean the packed material away from the area behind the idler and correct the problem causing the link to jump track. Top flange wear is not normally critical, but if wear is extreme, rebuild. Flange Side Wear This is caused by side-hill operation or misalignment. This reduces link life and makes idler rebuilding questionable.

Idlers Percentage Wear Chart

Check Idler Flange Wear Examine the idler flanges for excessive wear. Wear on just one side may mean the idler is off center. Correct with a shim adjustment. Excessive wear on both sides may indicate that the wear strips or shims are worn out. The problem may be corrected by adding shims. But new wear strips may be needed. Another possible cause of this type of wear is that the roller frame could be out of alignment or if there is continuous side-hill operation.

Inches

mm

% Worn

0.669

17.00

0

0.701

17.80

25

0.740

18.80

50

0.787

20.00

75

0.866

22.00

100

Inches

mm

% Worn

1.031

26.00

0

1.046

26.80

25

1.043

27.80

50

1.140

29.00

75

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 040213 PN=169

Track

Track Shoes

Wear Limits — Service & Destruction

Tighten The following is the proper procedure for torquing the track hardware. The initial torque draws the parts together tightly, an additional 1/3 turn gives the bolt a stretch for good retention. Stretching stresses the bolt until some permanent deformation occurs, this deformation ensures that the bolts maximum clamping force is used. 1. Lubricate the bolt threads.

Wear limits for all shoes are based on three criteria, in the following order: 1. Remaining beam or bending resistance strength for the standard width shoe. 2. Remaining grouser base available for regrousering purposes. 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 N·m (300 lb-ft).

Depending on the nature of the shoe and its expected use, both high and low impact wear limits have been established.

Inspection Torque Inspection procedure for loose bolts should be as follows: 1. Mark bolt head and the adjacent surface of the track shoe. 2. Loosen bolt approximately 1/8 of a turn (45°). 3. Tighten bolt until the two marks align.

As the degree of impact increases, a shoe is more subject to bending. Shoes may require re-grousering before the high impact wear limit is reached to help avoid bending. The shoe grouser base is generally less evenly worn, thus reducing its re-grouseability. The shoe will need more penetration to grip a hard surface and it may require re-grousering before the wear limit is reached.

Track Shoe Problems

The service point is represented by 100% worn. The destruction point is represented by 120% worn, meaning destruction will be reached in 20% more hours than it takes to reach the service limit of 100%. Destruction is the complete loss of grouser and/or if the shoe bends or breaks.

Grouser Wear Measurement

Grouser Wear

Grouser height wear is measured with a broad based depth gauge. Set the base across two adjacent grousers and use the gauge to measure down to the plate. The position of the depth gauge should be 1/3 of the way in from the outer edge of the shoe; this eliminates a problem in measuring in cases of uneven outer-to-inner grouser wear. The depth gauge should be perpendicular to the plate in order to get the most accurate reading. Measurements should be made to the closest 0.01" (0.25 mm).

This is caused by sliding contact with the surface underfoot. It can be accelerated by weight, horsepower, speed, impact, abrasiveness, terrain, and all operating variables that cause nonproductive slippage, turning or sliding. This causes a loss of traction, bending strength and the re-grouserability when wear limits are reached or exceeded.

4. Read the torque at this point. If the torque is below 400 N·m (300 lb-ft), loosen all four bolts and retighten by the torque-turn method. If the torque is higher, it is acceptable.

To remedy this, reduce or eliminate controllable accelerator variables, particularly slippage and unnecessary turning.

Continued on next page

TM100419 (02APR13)

55-05-4

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

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=170

Track

CM002500197 —UN—23MAY00

CM002500196 —UN—23MAY00

PW66162,00006DF -19-23OCT12-2/6

This is caused by sliding contact with the surface underfoot. It can be accelerated by weight, horsepower, speed, impact, abrasiveness, terrain, and all operating 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.

CM053510243 —UN—24MAR08

Plate Wear and Leading/Training Edge Wear

PW66162,00006DF -19-23OCT12-3/6

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 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

TM100419 (02APR13)

55-05-5

CM002500199 —UN—23MAY00

Bolt Hole Wallowing Out

PW66162,00006DF -19-23OCT12-4/6

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=171

Track Self-Locking Track Nut

CM002500200 —UN—23MAY00

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.

Item

Measurement

Specification

Bolts

Torque

400 N·m (300 lb-ft) PW66162,00006DF -19-23OCT12-5/6

CM053510244 —UN—29JUL05

Sprocket Chain Roller Alignment

Sprocket Chain Roller Alignment — Segment Sprocket: 2.19 inches Solid Sprocket: 2.25 PW66162,00006DF -19-23OCT12-6/6

TM100419 (02APR13)

55-05-6

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=172

Track

Sprocket Tightening

2. Tighten segment nuts and disc bolts to specification.

1. Apply Thread Lock and Sealer (High Strength) to the bolts.

Specification Segment Nuts—Torque...............................................................278 N·m (205 lb.-ft.) Disc Bolts—Torque......................................................................529 N·m (390 lb.-ft.)

NOTE: Ensure threads are free of oil. Do not use air tools to install them. Clean bolts and holes in final drive to ensure they are free from grease.

PW66162,00006E1 -19-08MAR13-1/1

Rear Axle Maintenance Every 250 hours of operation service the rear axle. Remove rear axle cover. Tighten inner nut to specification Specification Inner Nut—Torque.......................................................................815 N·m (600 lb.-ft.)

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.

Specification Outer Nut Locking Bolts—Torque................................................................................50 N·m (35 lb.-ft.)

Pack bearings with grease. Coat the inner cavity walls with grease. Be sure to use silicone to properly seal when putting the cover back on.

PW66162,00006E2 -19-08MAR13-1/1

CM992500057 —UN—24MAR08

Adjust Track Tension

A—Track Pin (2 used)

B—Carrier Roller (2 used)

C—Track Frame D—Relief Valve

NOTE: Track adjustment procedure should be performed under similar conditions in which the machine is used. Thoroughly clean track assembly to achieve an accurate measurement and adjustment.

3. Proper track tension is achieved when the distance between track chain and track frame (C) is approximately 1-1/4” to 1-1/2”.

1. Clean track assembly of all debris.

4. If track chain is too tight, loosen relief valve (D) until grease escapes (compressing the track adjuster.)

2. Move harvester forward a distance of approximately 20 m (65 ft.). Allow harvester to come to a complete stop when one of the track pins (A) is centered over a carrier roller (B).

5. If track chain is too loose, add grease to the relief valve (D) until the proper measurement is reached.

PW66162,00006E3 -19-23OCT12-1/1

TM100419 (02APR13)

55-05-7

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=173

Track

Recoil Spring Repair and Adjust Repair CM002500186 —UN—24MAR08

NOTE: Although recoil spring is serviceable, it does not 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. 1— Nut 2— Flange 3— Cylinder 4— Spring

3. Rubber seals and all contact surfaces must be clean and dry at assembly. Put a thin layer of oil on the surfaces of the metal seals. 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”). 5. Tighten nut (1) until both pin holes, located on cylinder (3) and the nut are aligned. Insert the pin into the holes and relieve the pressure placed on the flange. Adjust The recoil springs are normally in compression. They are held between brackets and stops on the track roller frames. Normally, the force of the springs is not against the tracks. The force against the track for the correct setting of track curve is controlled by the mechanism for track adjustment. Track adjustment is made by the hydraulic mechanism for track adjustment. Pressurized grease is sent to a cavity through a fill valve. This moves recoil rod and front idler toward the front of machine. Movement of recoil rod and front idler tightens the track. The tension on the track is released by a relief valve.

5— Seal 6— Seal 7— Piston

NOTE: Never visually inspect the vent holes or valves to see if grease or oil is coming out of them. Make sure that the vent holes are clean before the tension is released on the track. Watch the cylinder to see that it moves. If rocks or debris get between the track and the rollers, idlers or sprocket, the recoil rod will move toward the rear of the machine. The movement of the recoil rod tightens the track. Since the grease in the cavity cannot be put in compression, the piston and bolt move toward the rear of the machine. The bolt pushes the pilot toward the rear of the machine. The pilot pushes on the spring, this puts the spring in a compressed state. The movement of the pilot and the compression of the spring prevents too much tension on the track. Nut (1) is used to keep the recoil spring in compression.

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 040213 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

3.70

94.00

16.00

3.68

93.50

24.00

3.66

93.00

32.00

3.64

92.50

40.00

3.62

92.00

46.00

3.60

91.50

52.00

3.58

91.00

58.00

3.56

90.50

64.00

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

The only measurable wear position on the link is rail (top) wear. It is measured with a broad base depth gauge from the rail surface to the track shoe plate. This dimension is the rail height. The correct location for track link measurement is outside of the links at the end of the track pin. Position the depth gauge as close to the end of the pin as possible, making sure link and shoe surfaces are clean. Ensure the gauge is flat against the link rails and perpendicular to the shoe surface. Measure to the closest 0.25 mm (0.01").

PW66162,00006E6 -19-23OCT12-1/1

TM100419 (02APR13)

55-05-9

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=175

Track

Sealed Track Bushings & Pins Bushing and Pin Wear CM002500187 —UN—22MAY00

Since the successful turn-ability and total life of sealed 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 sufficient strength to resist cracking after the turn. This remaining strength is largely affected by wear before the turn. The sealed track bushing receives most of its load in the later part of its wear life, at the same position where maximum wear occurs. Wear Limits — Service and Destruction Wear limits for sealed track bushings are determined not only on the basis of remaining strength before and after the turn, but also upon the external wear in later hours. The “high impact” allowable wear to the service point is 3.1 mm (0.12"). The “low impact” allowable wear to the service point is 4.8 mm (0.19"). Destruction or break through, is expected to occur within 20% of any additional hours if the condition continues to exist. Wear limits should always be chosen on the basis of the degree of expected impact, not on the basis of abrasiveness or desired life.

Wear charts for sealed track bushings have the built-in effect of approximately double the expected wear rate after the bushing case depth is worn through. The chart has a faster, yet expected wear rate (approximately three times), after a significant amount of internal wear. The chart further accelerates wear, due to greater interference loads and relative motion, between the bushing and the sprocket. The percentage worn charts translate direct component measurements into the percent worn. All percent worn figures shown are based on the percent of time used. This allows the charts to be used to directly calculate or project the total potential time, or remaining life, until the service limit is reached. In most cases, service limit projections made from less than 30% worn cannot be considered accurate. However, such projections can be used to determine the subsequent dates for remeasuring wear. PW66162,00006E8 -19-23OCT12-1/1

TM100419 (02APR13)

55-05-10

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=176

Track

Track Bushing Allowable Wear Chart mm

Inches

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 040213 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. 2. Locate the calibrated side of the tape along an imaginary line which connects the pin centers. 3. Take the reading from one side of a pin to the same side of the fifth pin away (which includes 4 track sections). 4. The hook located on the tape end should not be used. The mark at an even increment of inches or millimeters should be placed at the 5th pin, leaving the end of the tape free to measure the fractional part of the total length. 5. This measurement should be taken at least three sections away from any one-piece type master link joint. It should be repeated at least twice, over different sections of the track, on both sides of the machine. Detrimental Effects of Excessive Pinch 1. Counter-bore depth and elongation wear accelerates wear rates and prevents adequate resealing after the turn. It also shortens after turn or replacement, pin and bushing life.

3. There is a tendency of users to overtighten tracks to compensate for the snakiness of an excessive pitch extended track. This, in effect, acts upon bushings, sprockets, and other components. 4. When the forward drive side external wear is critical, there is a loss of strength to the internal bushing walls. This contributes to bushings cracking on the forward drive side, before the pins are turned. There is also a loss of wall strength of the forward drive side after turn, when the rear drive side external wear was critical before the turn. Allowable Wear The internal wear is affected by the impact conditions. When low impact conditions exist, the bushing and pin wear can extend beyond 100 percent. The following lists the percentage worn with its corresponding measurement: 0% — 686 mm (27 inches) 100% — 698.5 mm (27.5 inches) 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 040213 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

CM002500189 —UN—24MAR08

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 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

TM100419 (02APR13)

55-05-13

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

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=179

Track

Percentage Worn mm

% Worn

8.00

203.00

0.00

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

If lubricant is added, when the roller is removed from the machine, shaft must be in a horizontal position. The slot located in the end, where the nozzle is installed, must be pointing downward.

7.78

197.50

40.00

7.76

197.00

43.00

7.74

196.50

46.00

7.72

196.00

49.00

The lubricant is sent into center passage (5) through the nozzle. The lubricant fills tank (4) in the rollers. When the tanks are full, the pressure of the oil causes the air and extra lubricant to exit through the relief threads located on the nozzle.

7.70

195.50

52.00

7.68

195.00

55.00

7.66

194.50

58.00

7.64

194.00

61.00

7.62

193.50

64.00

When the lubricant is bubble free, remove the nozzle and install the plug.

7.60

193.00

67.00

7.58

192.50

70.00

7.56

192.00

73.00

7.54

191.50

76.00

1. Rubber toric seals, and all surfaces in contact with them, must be clean and dry at assembly.

7.52

191.00

79.00

7.50

190.50

82.00

2. Apply a thin layer of oil on the surfaces of all contacting metal seals just before installation.

7.48

190.00

85.00

7.46

189.50

88.00

7.44

189.00

91.00

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

CM002500190 —UN—24MAR08

Inches

Seal Assembly

3. Apply lubricant on all other seals at assembly.

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

TM100419 (02APR13)

55-05-14

PW66162,00006EC -19-23OCT12-2/3

3520 and 3522 Sugar Cane Harvester Repair 040213 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 040213 PN=181

Track

Carrier Roller

CM002500191 —UN—24MAR08

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 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 2— Metal Seal 3— Bearings

Lubricant is sent through the nozzle and into the center of end cover (4). The lubricant fills the cavity between 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. When the lubricant is bubble free, remove the nozzle and install the plug. Torque the plug to 150-190 N·m (110140 lb-ft).

4— End Cover 5— Plug

3. Just before installation, apply a thin layer of oil on the surfaces of all contacting metal seals. 4. Apply lubricant to all other seals at assembly.

Assembly

5. Assemble the ground face of the plate to the end of the shaft and bearing.

1. Assemble the shaft flush with the back of the bracket. Make an adjustment, if necessary, for track alignment.

6. Before installation, apply lubricant to the inside of the 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

TM100419 (02APR13)

55-05-16

PW66162,00006F0 -19-23OCT12-1/2

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 Wear is caused by dirt packing in the sprocket teeth or 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.

CM002500194 —UN—23MAY00

Sprocket 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 Thread wear is caused by normal usage, and will cause the roller flange to hit the pin boss of the links. To remedy this, rebuild before the flange hits the pin boss. Flange wear is caused by side-hill operation, misalignment, snaky track, or the flange striking the link pin boss. It will reduce the link life, and make rebuilding the roller questionable. To remedy this, install or maintain the track guiding guards, realign the roller frame, adjust the track to reduce snakiness, or rebuild the rollers.

How to Measure Roller Wear Using large calipers, gauge the diameter of the roller thread. Place the calipers against a steel ruler to find the diameter measurement. Compare the worn diameter to the “Percentage Worn Chart” to determine the roller assembly’s wear. Wear Specifications

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 Flange to Boss Measurement If the track roller guards make the pin-boss-to-roller flange measurement difficult to obtain, you can acquire it by subtracting the link wear plus the roller wear, from the clearance, when the parts are new. For example, if the

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 Boss Clearance = 17.55 mm - (3.8 + 4.6) = 17.5 mm - 8.4 mm = 9.1 mm 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 perform the job correctly. Some tools may be available from local suppliers or may be fabricated.

NOTE: Order tools from the SERVICEGARD™ Catalog. 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

N64174 —UN—03OCT03

Track

TB90758,0000295 -19-04MAR13-3/8

Torque Multiplier ................................................. JDG1455

Track TB90758,0000295 -19-04MAR13-4/8

Torque Multiplier ................................................. JDG1782

N64173 —UN—03OCT03

Track

Continued on next page

TM100419 (02APR13)

55-10-1

TB90758,0000295 -19-04MAR13-5/8

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=187

Final Drive Repair

Seal Installer....................................................... JDG1785

N64177 —UN—03OCT03

Track

TB90758,0000295 -19-04MAR13-6/8

Bearing Installer.................................................. JDG1786

N64175 —UN—03OCT03

Track

TB90758,0000295 -19-04MAR13-7/8

Safety Plate ........................................................ JDG1787

N64178 —UN—03OCT03

Track

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

15

10 10 9

7

11

14

13

12 8

11 9

7

9

10

6 21 1 22 22 3

20

2

21

19 4

5

28

3 2

18

17 29 16

28 29 28 29 28 29 28 29 28

25 11

24

27 36

24 35 23 33

26 32 25 31 24

30

24 23

Continued on next page

TM100419 (02APR13)

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N89787 —UN—27OCT10

34

TB90758,0000250 -19-25FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=190

Final Drive Repair 1— Socket Head Cap Screw (24 used) 2— Plug (2 used) 3— O-Ring (2 used) 4— Plug 5— O-Ring 6— Cover 7— O-Ring (2 used) 8— Ring Gear 9— Retaining Ring 10— Spur Gear (3 used)

11— Bronze Bushing (3 used) 12— Sun Gear 13— Retaining Ring 14— Planet Pinion Gear 15— Sun Gear 16— Lock Nut 17— Spacer 18— Bearing 19— Hub 20— Wheel Studs (10 used)

21— O-Ring (2 used) 22— Mechanical Face Seal (2 used) 23— Retaining Ring (4 used) 24— Secondary Gear (4 used) 25— Spacer (4 used) 26— Housing 27— Coupler 28— Steel Disk (6 used)

29— Fiber Disk (5 used) 30— O-Ring 31— Piston 32— Inner Spring (12 used) 33— Outer Spring (12 used) 34— O-Ring 35— Spring Retainer 36— Retaining Ring

TB90758,0000250 -19-25FEB13-2/2

Disassemble Final Drive (S.N. 120701— ) 1. Remove hydrostatic drive motor. 2. Remove final drive from machine. N64115 —UN—02OCT03

3. Before disassembly, clean final drive thoroughly. 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 ring (C).

A—Disk 1 B—Bar

1

C—Retaining Ring

6. Slowly remove screw to release spring tension. Remove tool. 1

Included in JDG1451 Spring Compressor For further information, see SERVICEGARD online tool catalog or your John Deere dealer. 2

Continued on next page

TM100419 (02APR13)

55-10-5

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=191

Final Drive Repair

7. Remove spring retainer (A) and springs (B). B—Spring (12 inner and 12 outer used)

N89860 —UN—01NOV10

N64116 —UN—02OCT03

A—Retainer

TB90758,0000251 -19-05MAR13-2/16

8. Remove brake shaft (A) and brake piston (B) using an inside puller. B—Brake Piston

N89861 —UN—01NOV10

A—Brake Shaft

Continued on next page

TM100419 (02APR13)

55-10-6

TB90758,0000251 -19-05MAR13-3/16

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. B—Brake Disk (6 steel and 5 fiber used)

N89758 —UN—22OCT10

A—O-Ring

TB90758,0000251 -19-05MAR13-4/16

11. Turn final drive hub over and remove socket head cap screws (A) and end cover (B). B—End Cover

N89759 —UN—22OCT10

A—Socket Head Cap Screw (24 used)

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). B—First Stage Reduction Assembly N89760 —UN—27OCT10

A—First Stage Sun Gear

Continued on next page

TM100419 (02APR13)

55-10-7

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=193

Final Drive Repair

14. Remove retaining rings (A) from second reduction assembly planet gears.

N64128 —UN—02OCT03

A—Retaining Ring (4 used)

TB90758,0000251 -19-05MAR13-7/16

15. Remove second reduction assembly planet gears (A) using D01302AA Internal 2 Jaw Puller1 or equivalent.

N64129 —UN—02OCT03

A—Second Reduction Planet Gear (4 used)

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.

N64130 —UN—02OCT03

A—Spacer (4 used)

Continued on next page

TM100419 (02APR13)

55-10-8

TB90758,0000251 -19-05MAR13-9/16

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). C—Spacer Ring

N89762 —UN—22OCT10

N89761 —UN—26OCT10

A—Ring Gear B—Hub

Continued on next page

TM100419 (02APR13)

55-10-9

TB90758,0000251 -19-05MAR13-10/16

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. N70774 —UN—16AUG05

b. Drill two additional holes (D) as shown. 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. C—Stake Mark D—Holes

N70757 —UN—12AUG05

N70773 —UN—16AUG05

A—Electric Drill B—Threaded Ring Nut

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.

N90933 —UN—03JAN11

g. Remove two halves of threaded ring. A—Cold Chisel

Continued on next page

TM100419 (02APR13)

55-10-10

TB90758,0000251 -19-05MAR13-12/16

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). B—Flanged Hub

N89765 —UN—27OCT10

A—Hub Housing

TB90758,0000251 -19-05MAR13-13/16

21. Remove first half-seal assembly (A).

N64143 —UN—02OCT03

A—Half-Seal Assembly

TB90758,0000251 -19-05MAR13-14/16

22. Remove second half-seal assembly (A) by prying lightly with a screwdriver.

N64138 —UN—02OCT03

A—Half-Seal Assembly

Continued on next page

TM100419 (02APR13)

55-10-11

TB90758,0000251 -19-05MAR13-15/16

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).

N89786 —UN—26OCT10

IMPORTANT: Ensure all foreign material is out of bearing assembly, or premature bearing failure can occur. 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. N70948 —UN—26AUG05

Inspect all parts for excessive wear and damage, replace 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. A—Threaded Ring Nut

The unit must be cleaned as thoroughly as possible. Remove all dirt and debris to prevent final drive failure. Assemble unit on a bench in clean work area free of dust and dirt. 1. Before beginning assembly procedure, do the following: a. Clean threads of spindle to remove any thread lock material. b. Inspect threads of spindle. Repair any damaged threads using a thread file.

B—Spindle

correctly, torque multiplier can be used to turn nut on and off several times. c. Screw new threaded ring nut (A) onto spindle (B) by hand. Threaded ring nut must turn on by hand for correct assembly. d. Remove threaded ring nut. e. Clean spindle and threaded ring nut in clean solvent to remove any foreign material. Blow dry using compressed air.

IMPORTANT: Threaded ring nut can easily be cross threaded. Ensure nut is started correctly. If nut cannot be started correctly, or will not thread on at least two threads by hand once started, replace ring nut.

f. Repeat Sub-step (c) to ensure threaded ring nut threads all of the way onto spindle by hand.

IMPORTANT: If threaded ring nut can only be turned on a few threads and it is started Continued on next page

TM100419 (02APR13)

55-10-12

TB90758,0000252 -19-04MAR13-1/27

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=198

Final Drive Repair

IMPORTANT: If seals are to be reused, keep seal rings together as a matched set with seal ring faces together.

A 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). C

b. Sealing area must be uniform and concentric with ID and OD of seal ring (A).

B

c. Sealing area must not be chipped, nicked, or scratched. D—Outer Half of Seal Ring Face E—Sealing Area (Dark Line)

C

D

N75868 —UN—24APR07

A—Seal Ring B—Worn Area (Shaded Area) C—Seal Ring Face

D

TB90758,0000252 -19-04MAR13-2/27

A—Seal Ring B—Worn Area (Shaded Area)

C—Inner Half of Seal Ring Face D—Sealing Area (Dark Line)

Continued on next page

TM100419 (02APR13)

55-10-13

T85080 —UN—05DEC96

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.

TB90758,0000252 -19-04MAR13-3/27

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=199

A

B

F

F

C

C

E

E

D

D

A—Seat B—Seat C—O-Ring (2 used)

D—Sealing Surfaces E—Half Seal (2 used)

F— Half Seal Surfaces

the half seals. Any Moly on surfaces that contact O-rings (C) MUST be cleaned and dried before installing half seals. On half seals that are reused, a thin film of oil on sealing surfaces during assembly will be sufficient.

3. Before installing half seals, do the following: a. Carefully clean surfaces (A, B, and F), if necessary, metal brushes or solvent can be used. Surfaces in contact with O-rings (C) MUST be perfectly clean and dry. b. Ensure sure sealing surfaces (D) of half seals are free from scratches, nicks or foreign substances, metal ring surfaces MUST be perfectly clean and dry. c. Carefully clean sealing surface of half seals to remove dust and fingerprints. If new seals are used, lubricate with Moly from tube that is supplied with seal, taking care not to get any Moly on the rest of

4. Seal rings, O-rings, and housings must be clean and free of any oil film, dust, or other foreign matter. Use a solvent that evaporates quickly, leaves no residue, and is compatible with the rubber O-rings. (Follow all safety guidelines for use of the solvent.) Seal ring and housing should be wiped clean. Use a solvent-soaked cloth or paper towel that are lint free.

Continued on next page

TM100419 (02APR13)

N54714 —UN—11AUG00

Final Drive Repair

55-10-14

TB90758,0000252 -19-04MAR13-4/27

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=200

Final Drive Repair

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 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 B—O-Ring C—Correct O-Ring Seating

D—Twisted O-Ring E—Incorrect O-Ring Seating

N55266 —UN—05OCT00

5.

C

E

N75869 —UN—24APR07

D

TB90758,0000252 -19-04MAR13-5/27

6. Position flanged hub (B) on press and install bearing (A). B—Flanged Hub

N89855 —UN—29OCT10

A—Bearing

Continued on next page

TM100419 (02APR13)

55-10-15

TB90758,0000252 -19-04MAR13-6/27

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). N64144 —UN—02OCT03

C—JDG1785 Seal Installer

N64145 —UN—02OCT03

A—O-Ring B—Steel Ring

1

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

9. Install half-seal assembly on hub housing until JDG1785 Seal Installer1 bottoms out on housing. Remove installer ring.

A

A

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 around the circumference of the ring. If the seal does 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.

N75873 —UN—24APR07

TB90758,0000252 -19-04MAR13-7/27

A—Stand-Out Height Dimension

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

TM100419 (02APR13)

55-10-16

TB90758,0000252 -19-04MAR13-8/27

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). N64144 —UN—02OCT03

C—JDG1785 Seal Installer

N64145 —UN—02OCT03

A—O-Ring B—Steel Ring

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. N64146 —UN—02OCT03

A—JDG1785 Seal Installer

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. Continued on next page

TM100419 (02APR13)

55-10-17

TB90758,0000252 -19-04MAR13-10/27

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=203

Final Drive Repair

14. Lightly lubricate surface of steel ring (A) with clean oil.

N64148 —UN—02OCT03

A—Steel Ring

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. C—Hub Housing N89856 —UN—29OCT10

A—JDG1786 Bearing Installer B—Flanged Hub

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.

N89857 —UN—29OCT10

A—JDG1787 Safety Plate

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. Continued on next page

TM100419 (02APR13)

55-10-18

TB90758,0000252 -19-04MAR13-13/27

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=204

Final Drive Repair

19. Install ring nut (B).

IMPORTANT: Output of torque multiplier turns in opposite direction of input. Tighten ring nut by 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.)

N89763 —UN—22OCT10

20. Align dowel pins in JDG1782 Torque Multiplier1 (C) with holes (A) in ring nut (B).

22. Remove JDG1782 Torque Multiplier1 (C) and JDG1787 Safety Plate1 (D). A—Hole B—Ring Nut

C—JDG1782 Torque Multiplier D—JDG1787 Safety Plate

N89764 —UN—28OCT10

Specification Final Drive Ring Nut—Torque (Torque Multiplier Output).......................................................................3078 N·m (2278 lb.-ft.)

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. Continued on next page

TM100419 (02APR13)

55-10-19

TB90758,0000252 -19-04MAR13-14/27

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.

N64158 —UN—02OCT03

N64157 —UN—02OCT03

A—Seats

TB90758,0000252 -19-04MAR13-15/27

NOTE: Align holes on ring gear and hub. 24. Install spacer ring (C).

C—Spacer Ring

N89762 —UN—22OCT10

A—Ring Gear B—Hub

N89761 —UN—26OCT10

25. Install new O-rings onto ring gear (A) and install onto hub (B).

Continued on next page

TM100419 (02APR13)

55-10-20

TB90758,0000252 -19-04MAR13-16/27

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=206

Final Drive Repair

26. Install spacers (A), as shown, with bevel facing down.

N64159 —UN—02OCT03

A—Spacers

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. B—Inner Bearing Race

N64160 —UN—02OCT03

A—Planet Gear (4 used)

Continued on next page

TM100419 (02APR13)

55-10-21

TB90758,0000252 -19-04MAR13-18/27

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=207

Final Drive Repair

28. Install retaining rings (A).

N64128 —UN—02OCT03

A—Retaining Ring (4 used)

TB90758,0000252 -19-04MAR13-19/27

29. Install first stage reduction assembly (B). 30. Install first stage sun gear (A). B—First Stage Reduction Assembly

N89760 —UN—27OCT10

A—First Stage Sun Gear

Continued on next page

TM100419 (02APR13)

55-10-22

TB90758,0000252 -19-04MAR13-20/27

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).

Specification Cover Cap Screws—Torque............................................................................76 N·m (56 lb.-ft.) A—Socket Head Cap Screw (18 used)

B—Cover

N89759 —UN—22OCT10

32. Install socket head cap screws (A). Tighten to specification.

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. B—Brake Disks N64161 —UN—02OCT03

A—Brake Shaft

Continued on next page

TM100419 (02APR13)

55-10-23

TB90758,0000252 -19-04MAR13-22/27

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). C—O-Ring

N89859 —UN—01NOV10

N89858 —UN—29OCT10

A—O-Ring B—Piston

TB90758,0000252 -19-04MAR13-23/27

37. Install brake piston (A) and springs (B). B—Spring (12 inner and 12 outer used)

N89862 —UN—01NOV10

A—Brake Piston

Continued on next page

TM100419 (02APR13)

55-10-24

TB90758,0000252 -19-04MAR13-24/27

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=210

Final Drive Repair

38. Install spring retainer (A).

N64116 —UN—02OCT03

A—Spring Retainer

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).

A—Disk 1 B—Bar

1

N64115 —UN—02OCT03

40. Slowly remove screw to release spring tension. Remove tool. C—Retaining Ring

2

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. Included in JDG1451 Spring Compressor

1

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.

N64182 —UN—07OCT03

Specification Mounting Flange-to-Drive Coupler—Depth............................................................ 111.4—112.2 mm (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 as required. IMPORTANT: Overfilling of final drive can cause premature bearing failure.

A—Mounting Flange

B—Brake Shaft

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

22

21

20

23 24 25

1

18

26

29

3

2

27 28

30 4

31 5 6

14

8 9

10 T8130000874 —UN—05MAR13

11

7

12 32

13 15

17

1— Socket Head Cap Screw 2— Seal 3— Plug 4— Plug 5— Seal 6— End Cover 7— O-Ring Seal 8— Line Up Pin 9— 1st Stage Sun Gear 10— 1st Reduction

16

11— Spacer 12— 2nd Reduction 13— Spacer 14— Spacer 15— Ring Nut 16— Gear Case Housing 17— 1st Half Seal and 2nd Half Seal 18— O-Ring Seal

19— Flanged Hub 20— Spacer Ring 21— Brake Shaft 22— Brake Disc Unit 23— Brake Disc Unit 24— Spacer Ring 25— O-Ring Seal 26— O-Ring Seal

27— Brake Piston 28— Spring 29— Spring Retainer Disc 30— Circlip 31— O-Ring Seal 32— Cap Screw

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. T8130000845 —UN—25FEB13

2. Install JDG1451 Spring Compressor1 (B) on flanged hub (C). 3. Turn cap screw (A) until it contrasts the force of internal springs. A—Cap Screw B—JDG1451 Spring Compressor

C—Flanged Hub

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

T8130000846 —UN—25FEB13

A—Circlip

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).

T8130000847 —UN—25FEB13

A—Spring Retainer Disc

Continued on next page

TM100419 (02APR13)

55-10-27

TB90758,0000273 -19-05MAR13-3/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=213

Final Drive Repair

6. Remove springs (A) from brake piston (B). B—Brake Piston

T8130000848 —UN—25FEB13

A—Spring

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). T8130000849 —UN—05MAR13

B—Brake Shaft

A

Continued on next page

TM100419 (02APR13)

55-10-28

B

T8130000850 —UN—05MAR13

A—Brake Piston

TB90758,0000273 -19-05MAR13-5/23

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). B—Spacer

T8130000851 —UN—05MAR13

A—Brake Shaft

B

T8130000852 —UN—05MAR13

A

TB90758,0000273 -19-05MAR13-6/23

9. Remove O-ring seal (A) from flanged hub.

T8130000853 —UN—25FEB13

A—O-Ring Seal

Continued on next page

TM100419 (02APR13)

55-10-29

TB90758,0000273 -19-05MAR13-7/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=215

Final Drive Repair

10. Remove spacer ring (A).

T8130000854 —UN—25FEB13

A—Spacer Ring

TB90758,0000273 -19-05MAR13-8/23

11. Remove O-ring seal (A) from spacer ring (B). B—Spacer Ring

T8130000855 —UN—25FEB13

A—O-Ring Seal

TB90758,0000273 -19-05MAR13-9/23

12. Remove brake disc unit (A—B). B—Brake Disc Unit

T8130000856 —UN—25FEB13

A—Brake Disc Unit

Continued on next page

TM100419 (02APR13)

55-10-30

TB90758,0000273 -19-05MAR13-10/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=216

Final Drive Repair

13. Remove spacer ring (A).

T8130000857 —UN—25FEB13

A—Spacer Ring

TB90758,0000273 -19-05MAR13-11/23

14. Remove socket head cap screws (A), and remove end cover.

T8130000858 —UN—25FEB13

A—Sock Head Cap Screw

TB90758,0000273 -19-05MAR13-12/23

15. Remove O-ring seal (A) from end cover groove (B). B—End Cover Groove

T8130000859 —UN—25FEB13

A—O-Ring Seal

Continued on next page

TM100419 (02APR13)

55-10-31

TB90758,0000273 -19-05MAR13-13/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=217

Final Drive Repair

16. Remove 1st reduction (B) from gear case housing (A). B—1st Reduction T8130000860 —UN—05MAR13

A—Gear Case Housing

B

T8130000861 —UN—05MAR13

A

TB90758,0000273 -19-05MAR13-14/23

NOTE: This operation should be done only when necessary to replace sun gear.

A—1st Stage Sun Gear

T8130000862 —UN—25FEB13

17. Remove 1st stage sun gear (A) from 1st reduction (B). B—1st Reduction

Continued on next page

TM100419 (02APR13)

55-10-32

TB90758,0000273 -19-05MAR13-15/23

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). B—2nd Reduction T8130000863 —UN—25FEB13

A—Circlip

TB90758,0000273 -19-05MAR13-16/23

19. Using a puller, remove planet assemblies of 2nd reduction (A).

T8130000864 —UN—25FEB13

A—2nd Reduction

TB90758,0000273 -19-05MAR13-17/23

20. Remove spacer (A).

T8130000865 —UN—25FEB13

A—Spacer

Continued on next page

TM100419 (02APR13)

55-10-33

TB90758,0000273 -19-05MAR13-18/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=219

Final Drive Repair

21. Using JDG1455 Torque Multiplier1 (A), loosen ring nut (B). B—Ring Nut T8130000866 —UN—05MAR13

A—JDG1455 Torque Multiplier

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).

T8130000867 —UN—25FEB13

A—Ring Nut

TB90758,0000273 -19-05MAR13-20/23

23. Using a press, remove flanged hub (A) from gear case housing (B). B—Gear Case Housing T8130000868 —UN—25FEB13

A—Flanged Hub

Continued on next page

TM100419 (02APR13)

55-10-34

TB90758,0000273 -19-05MAR13-21/23

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.

T8130000869 —UN—25FEB13

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. 25. Remove first half seal (B). 26. Using a flat head screwdriver, remove second half seal (C). C—2nd Half Seal

T8130000871 —UN—25FEB13

T8130000870 —UN—25FEB13

A—Cap Screws B—1st Half Seal

Continued on next page

TM100419 (02APR13)

55-10-35

TB90758,0000273 -19-05MAR13-22/23

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.

C—Bearing Balls

T8130000873 —UN—25FEB13

A—Gear Case Housing B—Inner Ring

T8130000872 —UN—25FEB13

29. Gear case disassembly ends with above operation. Repair or replace parts as necessary.

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

•

C

2. Fit lower ball row (D) in gear case housing, holding inner raceway (C) with spacers (A) and (B). A—Spacer B—Spacer

A

C—Inner Raceway D—Lower Ball Row

B

Continued on next page

TM100419 (02APR13)

55-10-36

T8130000875 —UN—05MAR13

•

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 themselves and on O-rings. Always replace components that seem to be damaged or have excessive wear, with original spare parts.

TB90758,0000276 -19-02APR13-1/31

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 B—Spacer

C—Lower Ball Row D—Inner Raceway

D

A B

T8130000881 —UN—05MAR13

C

TB90758,0000276 -19-02APR13-2/31

4. Support gear case housing (B) and lower flanged hub (A) inside gear case. B—Gear Case Housing T8130000931 —UN—04MAR13

A—Flanged Hub

Continued on next page

TM100419 (02APR13)

55-10-37

TB90758,0000276 -19-02APR13-3/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=223

Final Drive Repair

CM073510528 —UN—03MAR08

5. Using a press and stopper, push flanged hub against shoulder of gear case housing until assembly of unit is complete.

TB90758,0000276 -19-02APR13-4/31

6. Install ring nut (A).

T8130000932 —UN—04MAR13

A—Ring Nut

TB90758,0000276 -19-02APR13-5/31

Specification Ring Nut—Torque......................................................................6249 N·m (4609 lb.-ft.)

CM073510530 —UN—03MAR08

7. Using JDG1455 Torque Multiplier1 , tighten ring nut to specification.

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. Continued on next page

TM100419 (02APR13)

55-10-38

TB90758,0000276 -19-02APR13-6/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=224

Final Drive Repair

CM073510532 —UN—03MAR08

8. Staking detail.

TB90758,0000276 -19-02APR13-7/31

9. Install spacers (A) on pins (B) of flanged hub. B—Pins T8130000933 —UN—04MAR13

A—Spacers

TB90758,0000276 -19-02APR13-8/31

10. Place planet gears (A) on pins of flanged hub (B), checking that groove is toward end cover. B—Flanged Hub T8130000934 —UN—04MAR13

A—Planet Gears

Continued on next page

TM100419 (02APR13)

55-10-39

TB90758,0000276 -19-02APR13-9/31

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. B—Flanged Hub T8130000935 —UN—04MAR13

A—Planet Gears

TB90758,0000276 -19-02APR13-10/31

12. Install circlips (B) in flanged hub groove (A). B—Flanged Hub Groove T8130000936 —UN—04MAR13

A—Circlips

TB90758,0000276 -19-02APR13-11/31

13. Install 1st reduction (A).

T8130000937 —UN—04MAR13

A—1st Reduction

Continued on next page

TM100419 (02APR13)

55-10-40

TB90758,0000276 -19-02APR13-12/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=226

Final Drive Repair

14. Using a rubber hammer, install 1st stage sun gear (A).

T8130000938 —UN—04MAR13

A—1st Stage Sun Gear

TB90758,0000276 -19-02APR13-13/31

15. Install O-ring (B) into end cover groove (A) B—O-Ring T8130000939 —UN—04MAR13

A—End Cover Groove

TB90758,0000276 -19-02APR13-14/31

Specification End Cover Socket Head Cap Screws—Torque....................................................................25 N·m (18 lb.-ft.) A—Socket Head Cap Screws

Continued on next page

TM100419 (02APR13)

55-10-41

T8130000940 —UN—04MAR13

16. Attach end cover to gear case housing using socket head cap screws (A), tighten to specification.

TB90758,0000276 -19-02APR13-15/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=227

Final Drive Repair

17. Turn gear case upside down, install spacer (A).

T8130000941 —UN—04MAR13

A—Spacer

TB90758,0000276 -19-02APR13-16/31

18. Using a rubber hammer, tap spacer (A) against shoulder inside brake shaft (B). B—Brake Shaft T8130000942 —UN—04MAR13

A—Spacer

TB90758,0000276 -19-02APR13-17/31

19. Install brake shaft (A).

T8130000943 —UN—04MAR13

A—Brake Shaft

Continued on next page

TM100419 (02APR13)

55-10-42

TB90758,0000276 -19-02APR13-18/31

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. T8130000944 —UN—04MAR13

A—Brake Disc Unit

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. T8130000945 —UN—04MAR13

B—Brake Disc Unit

TB90758,0000276 -19-02APR13-20/31

22. Lubricate seal seat inside flanged hub groove (A) with oil and install O-ring (B). B—O-Ring T8130000946 —UN—04MAR13

A—Flanged Hub Groove

Continued on next page

TM100419 (02APR13)

55-10-43

TB90758,0000276 -19-02APR13-21/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=229

Final Drive Repair

23. Install O-ring (A) into brake spacer inner groove (B). B—Inner Groove T8130000947 —UN—04MAR13

A—O-Ring

TB90758,0000276 -19-02APR13-22/31

24. Install brake spacer ring (A) inside flanged hub.

CQ280020 —UN—27JUN07

T8130000948 —UN—04MAR13

A—Brake Spacer Ring

Continued on next page

TM100419 (02APR13)

55-10-44

TB90758,0000276 -19-02APR13-23/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=230

Final Drive Repair

NOTE: Lubricate grooves already fitted.

A—O-Ring Seal

T8130000949 —UN—04MAR13

25. Install O-ring seal (A) into seat in flanged hub groove (B). 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.

T8130000950 —UN—04MAR13

A—Brake Piston

TB90758,0000276 -19-02APR13-25/31

27. Install springs (B) in seats in brake piston (A). B—Spring T8130000951 —UN—04MAR13

A—Brake Piston

Continued on next page

TM100419 (02APR13)

55-10-45

TB90758,0000276 -19-02APR13-26/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=231

Final Drive Repair

28. Install spring retainer disc (A).

T8130000952 —UN—04MAR13

A—Spring Retainer Disc

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. C—Flanged Hub

T8130000953 —UN—04MAR13

A—JDG1451 Spring 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

T8130000954 —UN—04MAR13

A—Circlip

1

For further information, see SERVICEGARD, online tool catalog or your John Deere dealer. Continued on next page

TM100419 (02APR13)

55-10-46

TB90758,0000276 -19-02APR13-29/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=232

Final Drive Repair

Specification Fill Plug—Torque...........................................................................30 N·m (22 lb.-ft.) A—Plug

T8130000955 —UN—04MAR13

31. Install plug (A) into filler hole and tighten socket head cap screws to specification.

TB90758,0000276 -19-02APR13-30/31

Specification Level Plug—Torque.........................................................................8 N·m (71 lb.-in.)

33. Fill with appropriate oil. (See Final Drive Gear Oil in Section 10, Group 15.) A—Plug

T8130000956 —UN—04MAR13

32. Install plug (A) into level hole and tighten to specification.

TB90758,0000276 -19-02APR13-31/31

TM100419 (02APR13)

55-10-47

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=233

Final Drive Repair

A—Seat B—Seat

A

B

C

C

D

D

E

E

F

F

D—O-Ring E—Metal Ring

T8130000882 —UN—05MAR13

Assemble Lifetime Seal (S.N. —100986)

F— Sealing Surface

1. Carefully clean seats (A) and (B) using, if necessary, metal brushes or solvent (surfaces in contact with O-ring (D) must be perfectly clean and dry).

3. Carefully clean lapped surface of metal ring and remove dust or finger prints. Apply a thin oil film, 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.

T8130000957 —UN—05MAR13

A—Half Seal

Continued on next page

TM100419 (02APR13)

55-10-48

TB90758,0000278 -19-05MAR13-2/5

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=234

Final Drive Repair

5. Assemble half seal (A) on gear case housing (B). B—Gear Case Housing T8130000958 —UN—05MAR13

A—Half Seal

TB90758,0000278 -19-05MAR13-3/5

6. Using same tool, install other half seal (B) onto flanged hub (A). B—Half Seal T8130000959 —UN—05MAR13

A—Flanged Hub

TB90758,0000278 -19-05MAR13-4/5

7. Clean metallic faces of seal (A) and apply thin film of oil.

T8130000960 —UN—05MAR13

A—Half Seal

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

Contents

Section 57 Wheel

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

Use jack locations (A and B) to lift harvester. B—Front Jack Locations (2 used)

CQ280288 —UN—27MAR08

A—Rear Jack Locations (2 used)

CQ280287 —UN—27MAR08

IMPORTANT: Do NOT support machine weight with lifting device. Position blocks or stands under machine after lifting.

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.

• Apply Anti-Seize Lubricant to wheel cap screws

For some applications, tires can be filled with fluid. Use suitable equipment when handling wheel assemblies to avoid injury.

before installation.

• Start wheel cap screws by hand to prevent thread damage.

1. Loosen wheel cap screws before lifting harvester off the ground. 2. Raise machine with an appropriate lifting device. Support machine with blocks or stands. (See Jack Locations in Section 57, Group 05.) 3. Place wheel assembly lift under wheel and attach a safety chain around the upper portion of tire.

• Tighten wheel cap screws to specification. Specification Front Wheel Cap Screw—Torque............................................................................230 N·m (170 lb.-ft.) Rear Wheel Cap Screw—Torque............................................................................529 N·m (390 lb.-ft.)

4. Remove three evenly spaced wheel cap screws and install threaded dowels in their place. Remove remaining wheel cap screws and pull wheel assembly outward and away from machine.

• Check tire air pressure. (See Operators Manual for recommended tire air pressure.)

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

CM002500247 —UN—26MAR08

1. Remove front wheel. (See Remove and Install Wheel Assembly in Section 57, Group 05.)

1— Dust Cap 2— Cotter Pin 3— Spindle Nut

4— Washer 5— Outer Bearing Cone 6— Outer Bearing Cup

7— Hub 8— Inner Bearing Cup 9— Inner Bearing Cone Continued on next page

TM100419 (02APR13)

57-05-3

10— Seal PW66162,00009E1 -19-02APR13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=241

Wheel IMPORTANT: Seal must be replaced when removed. Each bearing cone and cup must be replaced as a set.

9. Pack both bearing cones with grease. 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 (5) as hub is removed.

12. Slide hub onto spindle. Install outer bearing cone, washer, and spindle nut.

3. Pull hub (7) outward and remove with washer and outer bearing cone. 4. Remove and discard seal (10). 5. Remove inner bearing cone (9). 6. Inspect bearing cones and bearing cups (6 and 8) for wear or damage. Replace as necessary.

13. Tighten spindle nut to specification. Specification Front Wheel Spindle Nut—Torque..................................................................................47 N·m (35 lb.-ft.)

NOTE: If necessary, loosen spindle nut the minimum amount required to insert cotter pin in spindle.

NOTE: To aid in removal, position a punch in the cut out area of hub to drive out bearing cups.

14. Install cotter pin.

7. If necessary remove and replace bearing cups.

16. Install dust cap.

8. If removed, use an appropriate tool to install new bearing cups into hub. Ensure that each bearing cup is driven against hub shoulders.

17. Install front wheel. (See Remove and Install Wheel Assembly in Section 57, Group 05.)

15. Rotate hub by hand to ensure that hub spins smoothly.

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.

CM19989999022 —UN—02NOV99

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. 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. Over inflation can cause the tire to explode. If possible, use a safety cage.

8. Install valve stem cap.

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

CM053510256 —UN—08AUG05

Steering Valve Exploded View (Wheel Harvester)

1— Cap Screw 2— End Cap 3— O-ring 4— Gerotor 5— Spacer Plate

6— Drive 7— Housing Valve 8— Sleeve Spool 9— Centering Pin 10— Spring Spacer

11— Centering Spring 12— Retainer Spring 13— Bearing Race 14— Needle Thrust Bearing

15— Seal 16— Dust Seal

PW66162,0000851 -19-21FEB13-1/1

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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 these parts last after reassembly.

Cleanliness is extremely important when repairing a steering control unit. Work in a clean area. Before disconnecting lines, clean port area of unit thoroughly. Use a wire brush to remove foreign material and debris from around exterior joints of the unit.

1. Clamp unit in a vise, meter end up. Clamp lightly on the edges of port face sides. Use protective material on vise jaws. Housing distortion could result if jaws are over tightened.

Although not all drawings show the unit in a vise, we recommend that you keep the unit in a vise during disassembly and reassembly. Follow the clamp procedures.

2. Carefully disassemble the steering control unit in the vertical position. If it is not kept vertical, the pin that links the sleeve, spool and drive could possibly slip and dead bolt; it will lock these parts in the housing before it is completely out.

NOTE: Notice placement of check ball and roll pin (manual steering check valve), the cap screw

PW66162,0000852 -19-06NOV12-1/1

Reassembly Requirements

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.

CM073510467 —UN—19MAR08

Assure that all parts are free from rust, other contaminants, nicks and burrs at time of reassembly.

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

TM100419 (02APR13)

60-10-3

PW66162,0000853 -19-06NOV12-1/4

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=247

CM073510468 —UN—19MAR08

Steering Valve

4. Insert spring spacers (10) and springs (11) one at a time in sequence noted by reference numbers 2-9 (A — Standard Torque), 2-8 (B — Medium Torque),

then position spring retainer (12) correctly over all these parts. Adjust alignment of spring parts with a small screwdriver. Continued on next page

TM100419 (02APR13)

60-10-4

PW66162,0000853 -19-06NOV12-2/4

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=248

CM073510469 —UN—20SEP07

Steering Valve

1— Gerotor Meter Star Valley Align with Mark on Drive Spline

2— Drive Marked Parallel with Pin 3— Pin Location Reference Align 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

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60-10-5

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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.

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 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.

CM053510258 —UN—08AUG05

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).

PW66162,0000853 -19-06NOV12-4/4

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=250

Steering Valve

Troubleshooting Most steering problems can be corrected if the problem is properly defined. The entire steering system should be evaluated before removing any components. Usually the

steering control valve is not the cause of most problems. The following is a list of steering problems and their possible cause along with suggested corrections.

Symptom

Problem

Solution

Slow Steering, Hard Steering or Loss of Power Assist

Worn or Malfunctioning Pump

Repair or replace pump.

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 from Operator directed course

Air in system due to low oil level, Check the system and add system 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. Non-Operator directed course:

Repair or replace linkage and align front end.

Slip - When a slow movement of steering wheel fails to cause any movement of steered wheels: Erratic Steering

Replace piston seals.

Spongy or Soft Steering

Free Wheeling, (Steering Wheel turns freely with no feeling of pressure and no action on steered wheels.)

Leakage of cylinder piston seals.

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.

Air in system due to low oil level, cavitating pump, loose fittings, kinked hose, etc. Air in hydraulic system. (Most likely air is trapped in cylinders or lines.) Low oil level.

Check system for the above and add system fluid to correct.

Steering column upper shaft is loose or damaged.

Tighten steering wheel nut, repair or replace column.

Lower splines of column may be disengaged or broken.

Repair or replace column.

Continued on next page

TM100419 (02APR13)

60-10-7

Bleed air from system. Add oil and check for leaks.

PW66162,0000854 -19-06NOV12-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=251

Steering Valve Symptom

Problem

Solution

Steering valve gerotor is low on oil. (This can happen on start-up, after repair, or after long periods of non-use.) No flow to steering unit caused by low oil.

Starting engine will usually cure this problem.

Internal steering valve damaged due to thermal shock.

Repair or replace the valve.

Add oil and check for leaks or ruptured hose.

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 increase pressure.

Specification Steering Relief Valve—Pressure..................................................................... 17 237 kPa (172 bar) (2500 psi)

Rotate hex head screw counterclockwise to decrease pressure. 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

CM053510260 —UN—26MAR08

NOTE: Right-hand side shown. Left-hand side is similar.

Continued on next page

TM100419 (02APR13)

60-15-2

PW66162,000088B -19-13FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=254

Steering Arms and Pivots 1— Grease Fitting (4 used) 2— Grease Fitting 3— Cotter Pin 4— Washer 5— Seal 6— Snap Ring 7— Bearing

8— Trunnion Assembly 9— Cap Screw (4 used) 10— Ball Bushing (4 used) 11— Strut Assembly 12— Wheel Hub 13— Nut (4 used)

14— Nut-SL 15— Dust Cap 16— Steering Cylinder 17— Washer 18— Bushing 19— Ball Joint 20— Nut-SL 21— Cotter Pin

22— Nut 23— Cylinder Extension 24— Nut-SL 25— Cotter Pin 26— Ball Joint

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 ToeIn—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.) C—Rear Dimension D—Front Dimension

N42173UX —UN—15JAN97

A—Line B—Center Line

PW66162,000088C -19-08NOV12-1/1

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Steering Arms and Pivots

Adjust Front Axle Toe-In 2. Position both front wheels straight forward. Check wheel position by obtaining the same measurement from front (B) and rear (A) of the tire at center line (C) to the side wall of harvester (D). C—Center Line D—Side Wall of Harvestor

CM053510263 —UN—09AUG05

A—Rear B—Front

CM053510262 —UN—09AUG05

1. Park machine on a firm and level surface.

Continued on next page

TM100419 (02APR13)

60-15-4

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=256

CM053510261 —UN—09AUG05

Steering Arms and Pivots

A—Fittings (2 used)

B—Jam Nut C—Adjustment Cylinder Assembly

3. Disconnect hydraulic hoses from fittings (A) on steering cylinder.

7. Repeat procedure for the opposite front wheel.

4. Loosen jam nut (B).

8. Repeat adjustment procedure until toe-in is to specification. (See Check Front Axle Toe-In in Section 60, Group 15.)

5. Rotate adjustment cylinder assembly (C) clockwise 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

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60-15-5

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=257

Steering Arms and Pivots

TM100419 (02APR13)

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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 Drain Hydraulic Reservoir.............................. 70-05-1 Remove and Install Hydraulic Filter Assemblies ................................................ 70-05-2

Disassemble and Assemble Base Cutter Lift Cylinders (Track Harvester)................................................ 70-20-28 Remove and Install Knockdown Tilt Cylinder (Optional)................................... 70-20-31 Remove and Install Crop Divider Tilt Cylinders (Optional) ........................... 70-20-33 Disassemble and Assemble Knockdown Tilt and Crop Divider Tilt Cylinder (Optional) ............................. 70-20-35 Remove and Install Elevator Lift Cylinders.................................................. 70-20-39 Disassemble and Assemble Elevator Lift Cylinders.............................. 70-20-41 Remove and Install Elevator Discharge Flap Cylinder .......................... 70-20-46 Disassemble and Assemble Elevator Discharge Flap Cylinder ................................................... 70-20-47

Group 10—Hydraulic Pumps Specifications ................................................ 70-10-1 Multiple Gear Pump Repair ........................... 70-10-2 Piston Pump ................................................ 70-10-27 Group 15—Hydraulic Valves Specifications ................................................ 70-15-1 Remove and Install Floating Crop Divider Valves ............................................ 70-15-2 Remove and Install Improved Height Control Valve .................................. 70-15-4 Repair Control Valve...................................... 70-15-5 Repair Steering Priority Valve (Wheel Harvester) ................................... 70-15-10 Remove and Install Elevator Valve ........................................................ 70-15-15

Group 25—Hydraulic Motors Other Material................................................ 70-25-1 Specifications ................................................ 70-25-1 Remove and Install Topper Gathering Disk Motor (Whole Topper) ...................................................... 70-25-2 Disassemble and Assemble Topper Gathering Disk, Scroll, Side Knife, Butt-Lifter, Feed Roller, and Elevator Motors .................................. 70-25-3 Remove and Install Chopper Motor ....................................................... 70-25-11 Disassemble and Assemble Chopper Motor......................................... 70-25-15 Topper Severing Disk (Whole Topper) and Secondary Extractor Fan Motors Exploded View...................... 70-25-29 Disassemble and Assemble Topper Severing Disk (Whole Topper) and Secondary Extractor Fan Motors...................................................... 70-25-30 Repair Base Cutter and Primary Extractor Motors ...................................... 70-25-41 Cooling Package Motor ............................... 70-25-58 Disassemble and Assemble Secondary Extractor Rotate Motor ....................................................... 70-25-65 Repair Fixed Displacement Ground Drive Motor (Track Harvester) ................. 70-25-84

Group 20—Hydraulic Cylinders Specifications ................................................ 70-20-1 Other Material................................................ 70-20-1 Remove and Install Topper Cylinder ..................................................... 70-20-2 Remove and Install Cab Tilt Cylinder ..................................................... 70-20-3 Remove and Install Elevator Swing Cylinders.................................................... 70-20-5 Disassemble and Assemble Topper, Cab Tilt, and Elevator Swing Cylinders—Use CTM ...................... 70-20-6 Remove and Install Steering Cylinders (Wheel Harvester) ..................... 70-20-7 Disassemble and Assemble Steering Cylinders (Wheel Harvester).................................................. 70-20-8 Remove and Install Crop Divider Lift Cylinders............................................ 70-20-11 Disassemble and Assemble Crop Divider Lift Cylinders................................ 70-20-13 Remove and Install Base Cutter Lift Cylinders (Wheel Harvester) ................... 70-20-17 Disassemble and Assemble Base Cutter Lift Cylinders (Wheel Harvester)................................................ 70-20-20 Remove and Install Base Cutter Lift Cylinders (Track Harvester)..................... 70-20-26

Continued on next page

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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 Cap Screws

Torque

35 N·m (25 lb.-ft.) PW66162,0000933 -19-22JAN13-1/1

Drain Hydraulic Reservoir 2. Lower topper boom, adjustable knockdown roller, base cutter, and elevator. Lower crop divider to ground. 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.

T8120002629 —UN—22JAN13

1. Park machine on level surface.

NOTE: Approximate capacity of hydraulic reservoir is 397 L (105 gal.).

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

T8120002630 —UN—22JAN13

Hydraulic reservoir is vented. However, removing reservoir vent (A) allows oil to drain easier.

B—Drain Plug

PW66162,00009E2 -19-02APR13-1/1

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70-05-1

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=261

Hydraulic Reservoir

IMPORTANT: Avoid hydraulic system contamination. Clean filter assembly cover and surrounding 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.

T8120002629 —UN—22JAN13

Remove and Install Hydraulic Filter Assemblies

3. Remove cap screws (B) and lift cover (C) from reservoir.

5. Place cover over opening to prevent contaminants from entering reservoir. 6. Remove lower spring assembly (E) from filter assembly. 7. Slide filter element (F) from assembly rod. Discard element.

T8130000252 —UN—22JAN13

4. Carefully lift filter assemblies (D) out of tank.

8. Clean all contaminates from magnet (G).

10. Install new filter element on assembly rod and install lower spring assembly. Tighten nut until it stops. Do NOT tighten further. 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.

T8130000251 —UN—22JAN13

9. Inspect filter seal (H) and replace as necessary.

Specification Hydraulic Filter Assembly Cover Cap Screws—Torque............................................................................35 N·m (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 B—Cap Screw (8 used) C—Cover D—Filter Assembly (3 used)

E—Lower Spring Assembly F— Filter Element G—Magnet H—Seal

T8120002372 —UN—29NOV12

14. Install cover and tighten cap screws to specification.

PW66162,0000930 -19-13FEB13-1/1

TM100419 (02APR13)

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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 Screws

Torque

9.5 N·m (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

CM073510081 —UN—20AUG07

Multiple Gear Pump Repair

Continued on next page

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=264

Hydraulic Pumps 1— Seal 2— Cover 3— Plug 4— Bushing 5— Seal 6— Plate 7— Gear 8— Seal 9— Dowel Pin 10— Gear Housing

11— Housing 12— Shaft 13— Gear 14— Housing 15— Housing 16— Housing 17— Washer 18— Bolt 19— Nut 20— Gear

31— Housing 32— Housing 33— Shaft 34— Seal 35— Nut 36— Gear Case 37— Gear 38— Gear Case

21— Gear 22— Housing 23— Washer 24— Stud 25— Shaft 26— Plate 27— Seal 28— Seal 29— Dowel Pin 30— Bushing

Service instructions familiarize you with multiple pumps, their component parts, position of parts, method of disassembly and assembly, and pump care.

14. Bushing Installation Tool

To facilitate the repair of these pumps, and before any work is done, we suggest you first read all of the repair steps.

16. Small screwdriver

15. Scale (1/32 or 1/64 inch graduations)

17. Torque Wrench

The first requirement for good maintenance of hydraulic equipment is cleanliness. Make sure that you perform all repair work in a clean area.

18. Vise with 6 in. minimum open spread 19. Seal Installation Tool from kit D01045AA

It is important to air blast all parts and wipe them with a clean, lintless cloth before assembly.

20. Special Steel Sleeve (0290244683) 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 it is was built, otherwise the pressure blows shaft seal.

• If it is necessary to pry off sections, take extreme care

Check all replacement parts before installation. Suggested Tools

•

1. Arbor Press

•

2. 1-1/2 in. diameter steel ball. 3. Bearing Puller

•

4. Bushing Removal Tool from kit D01045AA.

not to mar or damage machined surfaces. Excessive force while prying can result in misalignment and component damage. If parts are difficult to install during assembly, tap gently with a soft-headed hammer. Never use a metal hammer. 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. Never hammer bushings into bores, use an arbor press.

Bushing and Seal Removal Tools

5. Clean lintless cloths 6. Deburring tool (an old file with cutting teeth ground off) 7. Machinist Hammer 8. Soft Hammer

Remove bushings in double and triple pumps from their bores by using a bushing removal tool. The seal removal tool can be easily made from an old 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 12. Snap Ring Pliers

The seal installation tool (0290244684) is used to install the lip seal into the housing.

13. Prick Punch Continued on next page

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=265

Hydraulic Pumps

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 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.

CM073510082 —UN—06MAR08

Disassemble

NOTE: Marked line on pump sections aids in assembly. 2. Mark a line across all pump sections. PW66162,00009B5 -19-11MAR13-3/62

CM073510083 —UN—06MAR08

3. Remove four hex nuts (19), washer (17), stud bolts (18), hex nuts (35), stud bolts (24) and washers (23).

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. CM073510084 —UN—06MAR08

Do not remove dowel pins (29). Pins can remain 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

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=266

Hydraulic Pumps

NOTE: If prying is necessary, take care not to damage machine surfaces.

22— Housing

CM073510085 —UN—06MAR08

6. Remove gear housing (31) from housing (22). 31— Gear Housing

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NOTE: Label and retain gearset together. Gears are a matched set.

CM073510086 —UN—06MAR08

7. Remove the two gears (20) from housing (22).

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NOTE: Do not remove dowel pins (29). Pins can remain in either housing (22) or gear housing.

CM073510087 —UN—06MAR08

8. Carefully lift or pry housing (22) from gear housing (32).

Continued on next page

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Hydraulic Pumps

CM073510088 —UN—06MAR08

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.

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NOTE: Do not remove dowel pins (9). Pins can remain in either gear housing or housing (14).

CM073510089 —UN—06MAR08

10. Carefully lift or pry gear housing (32) from housing (14).

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CM073510090 —UN—06MAR08

11. Remove thrust plate (26) and connector shaft (25).

Continued on next page

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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.

CM073510091 —UN—06MAR08

12. Remove housing (14) from gear housing (36).

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CM073510092 —UN—06MAR08

13. Remove thrust plate (6) and gearset (37) from gear housing (36).

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NOTE: Do not remove dowel pins (9). Pins can remain in gear housing or housing (15).

CM073510093 —UN—06MAR08

14. Remove gear housing (36) from housing (15).

Continued on next page

TM100419 (02APR13)

70-10-7

PW66162,00009B5 -19-11MAR13-14/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=269

Hydraulic Pumps

CM073510094 —UN—06MAR08

15. Remove thrust plate (6) and connector shaft (12) from housing (15).

PW66162,00009B5 -19-11MAR13-15/62

NOTE: Do not remove dowel pins (9). Pins can remain in housing (15) or gear housing.

CM073510095 —UN—06MAR08

16. Remove housing (15) from gear housing (10).

PW66162,00009B5 -19-11MAR13-16/62

CM073510096 —UN—06MAR08

17. Remove thrust plate (6) and gearset (13) from gear housing (10).

Continued on next page

TM100419 (02APR13)

70-10-8

PW66162,00009B5 -19-11MAR13-17/62

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).

CM073510097 —UN—06MAR08

18. Remove gear housing (10) from housing (11).

PW66162,00009B5 -19-11MAR13-18/62

CM073510098 —UN—06MAR08

19. Remove thrust plate (6) and connector shaft (12) from housing (11).

PW66162,00009B5 -19-11MAR13-19/62

NOTE: Do not remove dowel pins (9). Pins can remain in either housing (11) or gear housing.

CM073510099 —UN—06MAR08

20. Remove housing (11) from gear housing (38).

Continued on next page

TM100419 (02APR13)

70-10-9

PW66162,00009B5 -19-11MAR13-20/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=271

Hydraulic Pumps

CM073510100 —UN—06MAR08

21. Remove thrust plate (6), gear housing (38), gear assembly (7) and remaining thrust plate (6) from cover (2).

CM073510101 —UN—06MAR08

PW66162,00009B5 -19-11MAR13-21/62

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

TM100419 (02APR13)

70-10-10

PW66162,00009B5 -19-11MAR13-22/62

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.

CM073510102 —UN—06MAR08

24. Insert a seal removing tool into the notch between lip seal and front cover. Remove and discard lip seal (1). 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.

2. Where cutout is moderate, 0.13 mm (0.005 in.) or less, the gear housing is in good condition and can be reused. 3. Gears which exhibit any scoring on the gear hub must be replaced. Any scoring, grooving, or burring of the outer tooth diameter requires replacement. Nicking, grooving, or fretting of teeth surfaces requires gear replacement.

T5921AH —UN—25OCT88

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 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.

4. Drive shaft (7) must be replaced if any wear is detectable in seal area or at drive coupling. Maximum allowable wear is 0.05 mm (0.002 in.). Wear in the shaft seal area indicates oil contamination. Wear or damage to splines requires shaft replacement.

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. 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

TM100419 (02APR13)

70-10-11

CM073510103 —UN—06MAR08

PW66162,00009B5 -19-11MAR13-24/62

PW66162,00009B5 -19-11MAR13-25/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=273

Hydraulic Pumps

CM073510104 —UN—06MAR08

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 dowel pin in hole, or improper pin-to-hole fit.

PW66162,00009B5 -19-11MAR13-26/62

CM073510105 —UN—06MAR08

8. Bushings (4) and (30) must be replaced if gears are replaced. Bushings fit into bore with a “heavy” press fit.

PW66162,00009B5 -19-11MAR13-27/62

CM073510106 —UN—06MAR08

9. All sealing parts: lip seal (1), channel seals (5), and square seals (8) and (28) must be replaced.

Continued on next page

TM100419 (02APR13)

70-10-12

PW66162,00009B5 -19-11MAR13-28/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=274

Hydraulic Pumps

CM073510107 —UN—06MAR08

10. Examine check assembly (3) located in front cover (2). Ensure that it is in the proper position and tightly seated.

PW66162,00009B5 -19-11MAR13-29/62

Assembly

CM073510108 —UN—06MAR08

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 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 bushings into drive bores (bores which do not house the connector shafts) with bushing groove facing toward the bottom of the pump (six o’clock). NOTE: Bushings must be pressed into the bores flush with housing face. 4. If removed, install bushings using JDG11606 Bushing Installer. Be sure that the grooves are positioned, as

specified in step 3. Be sure to support the housings so they are square and level. 5. Repeat step 1. 6. After installing the bushings in all housings, ensure that the dowel pins are in position. Examine all dowel pins and before inserting, make certain the hole is clean and free from burrs. Gently start pin (9) straight into the hole and tap lightly with a soft hammer. PW66162,00009B5 -19-11MAR13-30/62

Do not damage the lip of seal during installation. 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

TM100419 (02APR13)

70-10-13

CM073510109 —UN—06MAR08

NOTE: Before inserting new lip seal (1) into front cover (2), coat outer edge and recess with non-hardening gasket sealant.

PW66162,00009B5 -19-11MAR13-31/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=275

CM073510110 —UN—06MAR08

Hydraulic Pumps

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

CM073510111 —UN—24MAR08

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.

PW66162,00009B5 -19-11MAR13-33/62

NOTE: Flat side of seal must face away from the thrust plate.

CM073510112 —UN—06MAR08

10. Install seal (5) into the grooves in thrust plate (6).

Continued on next page

TM100419 (02APR13)

70-10-14

PW66162,00009B5 -19-11MAR13-34/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=276

Hydraulic Pumps

11. Carefully slip the thrust plate (6) through gear housing (38) and into place onto the shaft end cover (2).

CM073510113 —UN—06MAR08

NOTE: Seal (5) must face shaft end cover (2). Relief groove, located in the thrust plate (6), must face the outlet side of pump.

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).

13. Lightly grease drive shaft from set (7) and insert inside 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).

CM073510114 —UN—06MAR08

Coat steel sleeve tool (0290244683) with grease.

CM073510115 —UN—06MAR08

15. Remove sleeve tool and lubricate gears with clean hydraulic oil.

Continued on next page

TM100419 (02APR13)

70-10-15

PW66162,00009B5 -19-11MAR13-36/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=277

Hydraulic Pumps

CM073510116 —UN—06MAR08

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.

PW66162,00009B5 -19-11MAR13-37/62

18. Line up dowel holes over the dowel pins. With sections aligned, squeeze or alternately tap over each dowel until the sections are together.

Continued on next page

TM100419 (02APR13)

70-10-16

CM073510117 —UN—06MAR08

17. Position housing (11) over gear housing (38) so bushing (6) in housing (11) receives the journals of drive and driven gears (7).

PW66162,00009B5 -19-11MAR13-38/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=278

Hydraulic Pumps

CM073510119 —UN—06MAR08

Position gear housing (10) over housing (11) and dowel pin. Tap it with a soft hammer until it rests tightly against cover. Be careful not to pinch the seal. Be sure that the large round area is located on the inlet side.

CM073510118 —UN—06MAR08

19. Insert connecting shaft (12) into splines of the drive gear from set (7).

PW66162,00009B5 -19-11MAR13-39/62

20. Place thrust plate (6) in gear housing (10).

CM073510121 —UN—06MAR08

CM073510120 —UN—06MAR08

Insert gear assembly (13) into bushings located in housing (11). Make certain gears are in contact with the face of the thrust plate (6).

Continued on next page

TM100419 (02APR13)

70-10-17

PW66162,00009B5 -19-11MAR13-40/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=279

Hydraulic Pumps

CM073510122 —UN—06MAR08

21. Slip thrust plate (6) with seal over gear journal (13) and into gear housing (10).

PW66162,00009B5 -19-11MAR13-41/62

23. Line up the dowel holes over dowel pins. With the sections aligned, squeeze or alternately tap over each dowel until the parts are seated together.

CM073510123 —UN—06MAR08

22. Position housing (15) over gear housing (10) so the bushings receive the journals of the drive and driven gears (13).

PW66162,00009B5 -19-11MAR13-42/62

CM073510124 —UN—06MAR08

24. Insert connecting shaft (12) into the splines of the drive gear from set (13).

Continued on next page

TM100419 (02APR13)

70-10-18

PW66162,00009B5 -19-11MAR13-43/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=280

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

Hydraulic Pumps

PW66162,00009B5 -19-11MAR13-44/62

CM073510126 —UN—06MAR08

26. Place thrust plate (6) into gear housing (36).

PW66162,00009B5 -19-11MAR13-45/62

NOTE: Make certain gears are in contact with the face of thrust plate (6).

CM073510127 —UN—06MAR08

27. Insert gear assembly (37) into bushings located in housing (36).

Continued on next page

TM100419 (02APR13)

70-10-19

PW66162,00009B5 -19-11MAR13-46/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=281

Hydraulic Pumps

CM073510128 —UN—06MAR08

28. Slip thrust plate (6) with seal over gear journal (37) and into gear housing (36).

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 -19-11MAR13-47/62

PW66162,00009B5 -19-11MAR13-48/62

CM073510130 —UN—06MAR08

30. Insert connecting shaft (25) into the splines of the drive gear, from set (37).

Continued on next page

TM100419 (02APR13)

70-10-20

PW66162,00009B5 -19-11MAR13-49/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=282

CM073510131 —UN—06MAR08

Hydraulic Pumps

31. Replace the four hex nuts (19), washer (17) and studs (18). Thread the four studs (18), washers (17) and hex nuts (19) into the front cover (2) and cross tighten.

33. After the fasteners are tight and there is no internal binding, cross torque the nuts (19) to 272 N·m (250 lb.-ft.).

32. Rotate the drive shaft with a wrench to make certain there is no binding in pump. Continued on next page

TM100419 (02APR13)

70-10-21

PW66162,00009B5 -19-11MAR13-50/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=283

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

Hydraulic Pumps

PW66162,00009B5 -19-11MAR13-51/62

CM073510133 —UN—06MAR08

35. Place thrust plate (26) in gear housing (32).

PW66162,00009B5 -19-11MAR13-52/62

NOTE: Make certain gears are in contact with the face of the thrust plate (26).

CM073510134 —UN—06MAR08

36. Insert gear assembly (21) into bushings located in housing (14).

Continued on next page

TM100419 (02APR13)

70-10-22

PW66162,00009B5 -19-11MAR13-53/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=284

Hydraulic Pumps

CM073510135 —UN—06MAR08

37. Slip thrust plate (26) with seal over gear journal (21) and into gear housing (32).

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 -19-11MAR13-54/62

PW66162,00009B5 -19-11MAR13-55/62

CM073510137 —UN—06MAR08

39. Insert connecting shaft (33) into the splines of the drive gear from set (21).

Continued on next page

TM100419 (02APR13)

70-10-23

PW66162,00009B5 -19-11MAR13-56/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=285

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

Hydraulic Pumps

PW66162,00009B5 -19-11MAR13-57/62

CM073510139 —UN—06MAR08

41. Place thrust plate (26) in gear housing (31).

PW66162,00009B5 -19-11MAR13-58/62

NOTE: Make certain gears are in contact with the face of the thrust plate (26).

CM073510140 —UN—06MAR08

42. Insert gear assembly (20) into bushings located in housing (22).

Continued on next page

TM100419 (02APR13)

70-10-24

PW66162,00009B5 -19-11MAR13-59/62

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=286

Hydraulic Pumps

CM073510141 —UN—06MAR08

43. Slip thrust plate (26) with seal over gear journal (20) and into gear housing (31).

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.

Continued on next page

TM100419 (02APR13)

70-10-25

CM073510142 —UN—06MAR08

PW66162,00009B5 -19-11MAR13-60/62

PW66162,00009B5 -19-11MAR13-61/62

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. CM073510143 —UN—06MAR08

46. Rotate the drive shaft with a wrench to make certain 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 prior to removal. 2. Before connecting any hoses to the pump, fill all ports with clean hydraulic oil. 3. After pump installation, operate the pump at least 2 minutes at no load and low rpm (400 minimum). During this break-in period, pump must run free and not develop an excessive amount of heat. If the pump operates properly, speed and pressure can then be increased to normal operating settings. 4. Adjust main relief valve to specification while the pump is running at maximum operating speed. Recommended Test Procedure 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 L/min. (gpm) of pump capacity is required. 2. If only one section of the tandem pump is being tested, make sure that all other sections, not being tested are adequately supplied with oil. If any of the other sections run dry, or if plugs are left in the ports, serious or permanent damage can result.

6. Operate pump at least 2 minutes at no load and moderate speed (not over 1500 rpm). If the pump becomes excessively hot, shut down immediately and locate the problem. 7. Gradually increase pressure on the pump in 34 bar (500 psi) increments until desired test pressure has been reached. This should take about 5 minutes. 8. Delivery should run close to rated performance figures which are averaged from testing several pumps. A 5% lower reading may be used as a rate minimum if new or relatively new parts have been used. When rebuilding a pump with parts from the original pump (which, while worn, appear satisfactory for use) a 10% to 15% lower reading should be used, depending upon the performance expected from the equipment. 9. Measure the outlet at normal operating speed and at zero pressure, then again at 69 bar (1000 psi) (or the operating pressure of the equipment) and allow a volume decrease approximating the list below. It is a suggested reference only which makes allowance for reused parts. At test speeds other than 1800 rpm, L/min. (gpm) delivery will vary almost proportionately, but the same (drop off) figures can be used.

3. Use a good quality hydraulic oil rated at 150 SSU at 38 °C (100 °F) with the oil temperature held at 46° to 52 °C (115° to 125 °F).

100 psi

1000 psi

2000 psi

3000 psi

10—30 gpm

1-1/2 — 3 gpm

2 — 3-1/2 gpm

2-1/2 — 4 gpm

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 than 17 kPa (5 in.) of mercury vacuum near pump inlet. Feed line must provide a feed flow velocity not in excess of 2.4 m per second (eight feet per second).

50—70 gpm

2-1/2 — 3-1/2 gpm

3—5 gpm

3-1/2 — 5-1/2 gpm

6.9 bar

69 bar

138 bar

207 bar

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 to seize. Jog the pump by momentarily starting the driving engine to equalize pump and oil temperatures gradually.

113.6—189 L

7.6—11.4 L

9.5—15.1 L

11.4—17 L

189—265 L

9.5—13.2 L

11.4—18.9 L

13.2—20.8 L

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 Replace gaskets and O-rings when making repairs. All gasket sealing surfaces must be cleaned prior to installation. Lubricate O-rings with clean hydraulic oil prior to assembly.

CM073510144 —UN—23AUG07

IMPORTANT: Absolute cleanliness is essential when working on the hydraulic system. Contamination can result in serious damage or inadequate operation. Clean parts with clean solvent and dry with compressed air.

Continued on next page

TM100419 (02APR13)

70-10-27

PW66162,0000861 -19-22FEB13-1/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=289

Hydraulic Pumps 1— Pressure Relief Valve 2— Cylindrical Roller Bearing 3— Pin 4— Plug 5— Plug 6— Plug 7— Filter 8— Plate 9— Swash Plate 10— Cylinder Block

22— Round Retainer 23— Shim 24— Gasket Kit 25— Nut 26— O-ring 27— Bolt 28— Pressure Relief Valve 29— Spring 30— O-ring 31— Kit

11— O-ring 12— Control 13— O-ring 14— Coupling 15— Valve 16— O-ring 17— Link 18— Dowel Pin 19— Spring 20— Cover 21— Lever

32— O-ring 33— O-ring 34— O-ring 35— Piston 36— O-ring 37— Ring 38— Sway Block 39— Orifice

PW66162,0000861 -19-22FEB13-2/11

Replace Multifunction Valve Cartridges 1. Using a 1-1/4” wrench, remove valve cartridges (28).

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.) 61— Seal

CM073510155 —UN—23AUG07

28— Valve Cartridges (2 used) 30— Seal

CM073510154 —UN—07MAR08

2. Inspect each cartridge for damage.

Continued on next page

TM100419 (02APR13)

70-10-28

PW66162,0000861 -19-22FEB13-3/11

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. CM073510147 —UN—06MAR08

Protect exposed surfaces and cavities on pump 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 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 cap screws. Tighten pump control cap screws to specification.

76— Cap Screws (6 used)

Specification Piston Pump Control Cap Screws—Torque............................................................................16 N·m (142 lb.-in.) PW66162,0000861 -19-22FEB13-4/11

Replace Charge Pressure Relief Valve

CM053510146 —UN—07MAR08

NOTE: Before removing the screw adjustable relief valve plug, mark plug, locknut, and housing to maintain original adjustment when assembling. 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 made at disassembly, and torque the locknut 52 N·m (38 lb.-ft.).

8. Check the charge pressure and adjust, if necessary.

Continued on next page

TM100419 (02APR13)

70-10-29

PW66162,0000861 -19-22FEB13-5/11

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. CM002500137 —UN—07MAR08

Protect exposed surfaces and cavities on the pump 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 spring retainer to hold the orifice check valve in position.

1— Spring Retainer 2— Spring

3— Orifice Check Valve 4— Control Assembly

4. Install control in reverse order of removal. Continued on next page

TM100419 (02APR13)

70-10-30

PW66162,0000861 -19-22FEB13-6/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=292

Hydraulic Pumps Replace Shaft Seal

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.

68— Retainer Plate 69— Cap Screws

CM073510150 —UN—07MAR08

62— Shaft 65— Seal Carrier 66— Seal

CM073510149 —UN—07MAR08

3. Using an arbor press, remove seal (66) from seal carrier. Discard seal.

CM073510148 —UN—07MAR08

NOTE: Refer to pump breakdown in the beginning of this section.

Continued on next page

TM100419 (02APR13)

70-10-31

PW66162,0000861 -19-22FEB13-7/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=293

Hydraulic Pumps

4. Inspect seal carrier for damage and replace as necessary.

CM073510152 —UN—07MAR08

IMPORTANT: Do not damage seal during installation. 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 seal carrier cavity.

62— Shaft 65— Seal Carrier

66— Seal 67— O-Ring PW66162,0000861 -19-22FEB13-8/11

Specification Shaft Seal Retainer Plate Cap Screws—Torque...................................................................9.5 N·m (84 lb.-in.) 68— Retainer Plate

69— Cap Screws

Continued on next page

TM100419 (02APR13)

70-10-32

CM073510153 —UN—07MAR08

10. Install retainer plate (68) and cap screws (69). Tighten retainer plate cap screws to specification.

PW66162,0000861 -19-22FEB13-9/11

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).

CM002500139 —UN—17MAY00

3. Remove cover (9), bushing (8), shaft (4), gerotor (6), pin (5) and key (3). 4. Inspect valve plate, gerotor assembly, shaft spline and bearings for wear, damage, or foreign material. Replace if necessary. 1— End Cap 3— Key 4— Shaft 5— Pin 6— Gerotor 8— Bushing

9— Cover 10— Cover Retainer 11— Cap Screw (6 used) 13— Auxiliary Mounting Pad 15— Cap Screw (4 used)

Continued on next page

TM100419 (02APR13)

70-10-33

PW66162,0000861 -19-22FEB13-10/11

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. CM053510147 —UN—21JUL05

2. Install inner valve plate, gerotor assembly, shaft, key, and outer valve plate into charge pump cavity. Use 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 two different ways. Always install cover with small port 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 of cover during assembly. 6. Install charge pump cover and align pin into previously aligned parts located in cavity.

A—Discharge B—Alignment Pin

C—Inlet

Specification Charge Pump Cover cap Screws—Torque.........................................................................13.5 N·m (119 lb.-in.)

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 Relief Valve

Pressure

17 900 kPa (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

X9811 —UN—23AUG88

IMPORTANT: Absolute cleanliness is essential when working on the hydraulic system. Contamination can result in serious damage or inadequate operation. 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).

T8130000695 —UN—21FEB13

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. Avoid personal injury. Before floating crop divider valve removal, pressure must be relieved with manual bleed valve (D).

A—Shield B—Cap Screws (2 used)

C—Locking Nut D—Manual Bleed Valve

6. Loosen locking nut (C). 7. Rotate manual bleed valve (D) counterclockwise until light resistance is felt. Continued on next page

TM100419 (02APR13)

70-15-2

PW66162,0000945 -19-22FEB13-1/2

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.

13. Install in reverse order of removal using the following special instructions:

• 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 B—Hose C—Cap Screws (2 used) D—Hoses (2 used)

T8130000696 —UN—22FEB13

12. Repair or replace floating crop divider valve as necessary.

E—Hose F— Mounting Plate G—Electrical Connectors (2 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

X9811 —UN—23AUG88

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 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.

T8130000467 —UN—04FEB13

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. 6. Tag and disconnect hoses (C). 7. Cap and plug hoses and fittings. 8. Remove cap screws (A) and improved height control valve. 9. Repair or replace improved height control valve as necessary. 10. Install in reverse order of removal using the following special instructions:

A—Cap Screw (2 used) B—Electrical Connectors (6 used)

C—Hose (10 used) D—Improved Height Control Valve

• Check hydraulic reservoir oil level and fill as

necessary. (See Hydraulic Oil in Section 10, Group 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

CM053510246 —UN—29JUL05

Valve Assembly

1— Valve Assembly 2— Bolt 3— Flange 4— Tube 5— Bolt 6— Washer 7— Spring 8— O-ring 9— Relief Valve

10— Cap 11— Bolt 12— Spool 13— Inlet Section Assembly 14— Body 15— Outlet Section 16— O-ring

17— Tie Rod 18— Hex Nut 19— Tie Rod 20— Hex Nut 21— Relief Cartridge Valve 22— Retainer

Continued on next page

TM100419 (02APR13)

70-15-5

23— O-ring 24— O-ring 25— SAE Plug 26— Plug 27— O-ring

PW66162,0000850 -19-26FEB13-1/11

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 work section with a “B” (for back cap end).

IMPORTANT: All repair work must be performed in a clean area. Mark sections of the valve bank aid in assembly. 1. Clean control valve.

NOTE: Mark relief valves before removal to aid in assembly. Inlet and mid-inlet relief valves are marked with their casting number only. 5. If necessary, remove relief valves from valve bank.

CM073510450 —UN—19MAR08

2. Take a waterproof, quick-drying marker and mark each casting with a sequential number. Start by marking the inlet casting as #1 and finish by marking the outlet with the highest number.

4. Mark the port boss closest to the spool clevis on each work section with an “A” (for spool end).

6. Remove the three tie rods that hold valve bank together. Separate valve sections. PW66162,0000850 -19-26FEB13-2/11

Assemble

CM073510451 —UN—19MAR08

1. Lay out valve components on a clean, flat working surface. The inlet section includes an O-ring.

Continued on next page

TM100419 (02APR13)

70-15-6

PW66162,0000850 -19-26FEB13-3/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=302

Hydraulic Valves

CM073510452 —UN—19MAR08

2. The spool section (14) includes an O-ring (16) and possibly a load check poppet and load check spring.

PW66162,0000850 -19-26FEB13-4/11

CM073510453 —UN—19MAR08

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.

PW66162,0000850 -19-26FEB13-5/11

4. Assemble tie rod nuts to one end of each tie rod with one or two threads showing.

CM073510454 —UN—19MAR08

NOTE: Ensure that the large tie rod (17) passes through top hole of the section. 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

TM100419 (02APR13)

70-15-7

PW66162,0000850 -19-26FEB13-6/11

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). CM073510455 —UN—19MAR08

10. Install load check poppet (nose down) and spring (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

CM073510456 —UN—19MAR08

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 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.

CM053510250 —UN—19MAR08

NOTE: Applying pressure to end sections on a flat surface aligns end sections and spool sections. 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.) Control Valve 3/4 in. Tie Rod Nut—Torque.........................................................................104 N·m (77 lb.-ft.)

18. Install auxiliary valves and plugs and torque to proper specifications.

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

TM100419 (02APR13)

70-15-8

PW66162,0000850 -19-26FEB13-9/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=304

Hydraulic Valves Adjust Relief Settings

2. Adjust inlet section relief valve to specification. Specification Control Valve Inlet Section Relief Valve—Pressure..................................................................... 17 900 kPa (179 bar) (2 600 psi) 13— Inlet Section

CM073510448 —UN—19MAR08

1. The inlet section (13) of the valve has a relief cartridge valve (21).

21— Relief Cartridge Valve

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). A—Locking Jam Nut

CM073510449 —UN—19MAR08

PW66162,0000850 -19-26FEB13-10/11

PW66162,0000850 -19-26FEB13-11/11

TM100419 (02APR13)

70-15-9

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=305

Hydraulic Valves

CM073510457 —UN—18SEP07

Repair Steering Priority Valve (Wheel Harvester)

1— Adjusting Screw 2— Cover 3— Spring

4— Ball Holder 5— Ball 6— Relief Valve

7— O-ring 8— Screen 9— Seat 10— Housing Continued on next page

TM100419 (02APR13)

70-15-10

11— O-ring 12— O-ring

PW66162,0000864 -19-12FEB13-1/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=306

Hydraulic Valves

CM073510458 —UN—18SEP07

1. Remove relief valve (6) from housing (10).

PW66162,0000864 -19-12FEB13-2/11

CM073510459 —UN—18SEP07

2. Inspect the ball (5) seating on the ball holder (4).

Continued on next page

TM100419 (02APR13)

70-15-11

PW66162,0000864 -19-12FEB13-3/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=307

Hydraulic Valves

CM073510460 —UN—18SEP07

3. Inspect the O-ring (7); discard after inspection.

PW66162,0000864 -19-12FEB13-4/11

CM073510461 —UN—18SEP07

4. Inspect seat (9), screen (8) and ring (7) for damage. If damaged, replace the relief.

Continued on next page

TM100419 (02APR13)

70-15-12

PW66162,0000864 -19-12FEB13-5/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=308

Hydraulic Valves

CM073510462 —UN—18SEP07

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).

PW66162,0000864 -19-12FEB13-6/11

CM073510463 —UN—18SEP07

6. Remove cover (2), spring (3), ball holder (4) and ball (5). Inspect for damage; replace the entire relief valve (6) if necessary.

Continued on next page

TM100419 (02APR13)

70-15-13

PW66162,0000864 -19-12FEB13-7/11

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=309

Hydraulic Valves

CM073510464 —UN—18SEP07

7. Inspect ball seat (9) for scratches or debris. Remove any debris; replace entire valve (6) if damaged.

PW66162,0000864 -19-12FEB13-8/11

CM073510463 —UN—18SEP07

8. Install ball (5), ball holder (4), spring (3) and cover (2) into relief valve (6).

PW66162,0000864 -19-12FEB13-9/11

9. Install adjusting screw (1) into relief valve (6).

CM073510465 —UN—18SEP07

Continued on next page

TM100419 (02APR13)

70-15-14

PW66162,0000864 -19-12FEB13-10/11

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.

CM073510466 —UN—18SEP07

Specification Steering Priority Valve Relief Valve—Pressure.......................................................... 17 237 kPa (172 bar) (2500 psi)

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. T8130000468 —UN—04FEB13

3. Shut off engine and remove key. 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

TM100419 (02APR13)

70-15-15

PW66162,0000946 -19-21FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=311

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.

X9811 —UN—23AUG88

Hydraulic Valves

NOTE: Cut tie bands as necessary. 6. Tag and disconnect hoses (A) from elevator valve (B). 7. Cap and plug hoses and fittings.

9. Remove cap screws (C) and elevator valve. 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.) C—Cap Screws (4 used) D—Electrical Connectors (6 used)

T8130000470 —UN—04FEB13

A—Hose (15 used) B—Elevator Valve

T8130000469 —UN—04FEB13

8. Disconnect electrical connectors (D).

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.) 271 (LOCTITE®)

Thread Lock and Sealer (High Strength)

Used to seal and lock threads.

PM37477 (U.S.) 242 (LOCTITE®)

Thread Lock and Sealer (Medium Strength)

Used to seal and lock threads.

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.

X9811 —UN—23AUG88

2. Check that cylinder safety stop (A) is in the upward position. 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.

T8120002359 —UN—03JAN13

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.

A—Safety Stop B—Hose C—Rear Pin

6. Tag and disconnect hose (B).

D—Topper Cylinder E—Front Pin

7. Cap and plug hose and fitting. 11. Install in reverse order of removal using the following special instructions:

CAUTION: Approximate weight of topper cylinder is 35 kg (77 lb.).

• Grease cylinder pins. • Check hydraulic reservoir oil level and fill as

8. Remove nut and front pin (E).

necessary. (See Hydraulic Oil in Section 10, Group 15 for recommended oil.)

9. Remove nut, rear pin (C), and topper cylinder. 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.

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. 2. Shut off engine and remove key. 3. Tilt cab. (See Cab Tilt Procedure in Section 90, Group 20.

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.

4. Clean cab tilt cylinder and surrounding area. CAUTION: Avoid injury or death. Attach lifting device to cab in a manner that allows technician to work safely under cab in the tilted position. 5. Attach an appropriate lifting device and support cab in the tilted position.

Continued on next page

TM100419 (02APR13)

70-20-3

TB90758,000022E -19-02APR13-1/2

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.).

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.)

T8120001396 —UN—11SEP12

8. Remove nut, washers, and lower pin (D) from cable end (B) and cab tilt cylinder (H).

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.) F— Upper Pin G—Cable End H—Cab Tilt Cylinder I— Safety Stop T8120001397 —UN—11SEP12

A—Hose B—Cable End C—Hose D—Lower Pin E—Nut

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.

X9811 —UN—23AUG88

1. Park machine on level surface. 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.

CAUTION: To avoid injury when removing cylinders, use appropriate support device to stabilize elevator to ensure elevator does not move.

T8130000448 —UN—05FEB13

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—Hydraulic Hoses (2 used)

5. Disconnect hydraulic hoses (A) from T-fitting. Cap and plug all openings. Continued on next page

TM100419 (02APR13)

70-20-5

TB90758,000022F -19-28MAR13-1/2

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. T8130000449 —UN—05FEB13

8. Repair or replace cylinder as necessary. (See 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.) D—Cap Screw (5 used) E—Cap Screw (5 used)

T8130000450 —UN—05FEB13

A—Lock Nut B—Pin C—Cap Screw

TB90758,000022F -19-28MAR13-2/2

Disassemble and Assemble Topper, Cab Tilt, and Elevator Swing Cylinders—Use CTM

P15127 —UN—10JAN08

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

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. X9811 —UN—23AUG88

2. Relieve hydraulic pressure. 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. T8130000583 —UN—06FEB13

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. 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).

T8130000584 —UN—06FEB13

7. Remove upper cylinder end by lightly tapping on end 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.) 11. Install in reverse order of removal using the following special instructions:

A—Steering Cylinder B—Cotter Pin and Nut

C—Hoses (2 used) D—Cotter Pin and Nut

• 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

CM073510003 —UN—26MAR08

Disassemble and Assemble Steering Cylinders (Wheel Harvester)

1— Ball Joint Tie Rod 2— Seal 3— Square Wire Wrap

4— Seal 5— Backup Seal 6— O-ring 7— End Cap 8— Rod

9— O-ring 10— Piston 11— Seal 12— Wear Ring 13— Nut Continued on next page

TM100419 (02APR13)

70-20-8

14— Barrel 15— Jam Nut 16— Ball Joint

TB90758,0000233 -19-28MAR13-1/7

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). N61178 —UN—06NOV02

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. 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.

A—Square Wrap Wire

N61179 —UN—06NOV02

7. Remove rod with end cap and piston from barrel. B—End Cap

CM073510004 —UN—03AUG07

TB90758,0000233 -19-28MAR13-3/7

A—Rod B—O-ring

C—Piston D—Lock Nut

NOTE: Install rod end in soft-jawed vise in order to remove lock nut.

E—End Cap

8. Remove lock nut (D), piston (C), O-ring (B), and end cap (E) from rod (A). Continued on next page

TM100419 (02APR13)

70-20-9

TB90758,0000233 -19-28MAR13-4/7

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.

N61182 —UN—06NOV02

C—Seal D—Wear Ring

T8130000619 —UN—13FEB13

A—End Cap B—Wiper Seal

TB90758,0000233 -19-28MAR13-5/7

B

A

12. Replace wear ring (A) and seal (B) on piston head. 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

E

F

E—O-Ring F— Backup Ring G—Wiper Seal

G D

T8130001055 —UN—26MAR13

17. Apply Thread Lock and Sealer (High Strength) to threads of piston end of cylinder rod. A—Wear Ring B—Seal C—O-Ring D—Rod Seal

T8130001054 —UN—26MAR13

11. Inspect cylinder barrel for wear or damage. Nicks, burrs, or rust can be removed using emery cloth, replace as necessary.

Cylinder Head Continued on next page

TM100419 (02APR13)

70-20-10

TB90758,0000233 -19-28MAR13-6/7

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.) N61187 —UN—06NOV02

19. Test cylinder once assembly is complete.

• 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—Pressure................................................................................... 344—861 kPa (3—8.6 bar) (50—125 psi)

• • • • •

test (low) pressure to retract port and check for bypass (rod will creep out if bypassing). With ball/lock valves in locked position, apply test (high) pressure to retract port and check for bypass (rod will creep out if bypassing). While retract test pressure is applied at mid stroke, observe for external leaks. Open ball/lock valves. Fully retract cylinder. Check for bypass at fully retracted position. Cylinder will bypass at fully retracted position. Fully extend cylinder, and check for bypass. Cylinder will bypass in fully extended position.

A—Piston Lock Nut

21. Install cylinder (See Remove and Install Steering Cylinders (Wheel Harvester) in Section 70, Group 20.) onto machine and bleed steering system. 22. Check the toe-in. (See Check Front Axle Toe-In in Section 60, Group 15.) 23. Adjust toe-in if necessary. (See Adjust Front Axle Toe-In in Section 60, Group 15.)

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

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.

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.

2. Relieve hydraulic pressure. 3. Shut off engine and remove key. 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

TM100419 (02APR13)

70-20-11

TB90758,0000230 -19-28MAR13-1/2

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.).

7. Support cylinder and remove pin (B). 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.)

T8130000447 —UN—05FEB13

6. Remove cap screw (C).

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.)

T8130000446 —UN—05FEB13

D—Cap Screw E—Lock Nut

T8130000445 —UN—05FEB13

A—Hydraulic Hoses (2 used) B—Pin C—Cap Screw

TB90758,0000230 -19-28MAR13-2/2

TM100419 (02APR13)

70-20-12

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=324

Hydraulic Cylinders

CM073510006 —UN—26MAR08

Disassemble and Assemble Crop Divider Lift Cylinders

1— Cylinder Rod 2— Barrel 3— Piston 4— Cylinder Head

5— Nut 6— Thrust Washer 7— Grease Fitting 8— Bushing

9— Seal 10— O-Ring 11— O-Ring 12— O-Ring 13— Seal Continued on next page

TM100419 (02APR13)

70-20-13

14— Wear Ring 15— Seal 16— Seal

TB90758,000022A -19-28MAR13-1/9

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=325

Hydraulic Cylinders 1. Remove cylinder from machine. (See Remove and Install Crop Divider Lift Cylinders in Section 70, Group 20.)

CAUTION: Before removing the cylinder from machine for repair, relieve hydraulic pressure.

TB90758,000022A -19-28MAR13-2/9

2. Remove set screw from locking collar. B

A—Cylinder Head

T8130000756 —UN—25FEB13

3. Using spanner wrench, turn cylinder head (A) counterclockwise until threads on head separate from the internal threads in barrel (B). 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 procedure is the same for all three cylinders.

B

4. Remove rod (A) with cylinder head (E), piston (D), washer (C), and nut (B) from barrel. 5. Remove nut, washer, cylinder head, and piston from rod. Inspect components for wear or damage. Replace as needed.

C D

6. Inspect inside cylinder barrel for wear or damage. Nicks, burrs, or rust may be removed with emery cloth. Replace as necessary. NOTE: When removing seals from piston and rod guide, do not damage, mark, or score any surfaces that contact the seals.

E

A—Rod B—Nut C—Washer

T8130000757 —UN—25FEB13

A

D—Cylinder Head E—Piston

7. Remove all seals and rings from piston and rod guide, replace as necessary. Continued on next page

TM100419 (02APR13)

70-20-14

TB90758,000022A -19-28MAR13-4/9

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 seal damage.

B A

A—Seal B—Seal C—Cylinder Head D—O-Ring E—Seal

F— O-Ring G—O-Ring H—Piston I— Seal

C

D

E

F

T8130000758 —UN—25FEB13

G

H I

C

TB90758,000022A -19-28MAR13-5/9

A—Rod

B—Head

A B

T8130000759 —UN—25FEB13

9. Carefully push head (B) onto the rod (A). A soft mallet can be used to tap head onto rod.

TB90758,000022A -19-28MAR13-6/9

10. Install piston (A) onto rod. NOTE: Loctite will not fully cure for 24 hours. C 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 B—Thrust Washer

C—Nut

Continued on next page

TM100419 (02APR13)

T8130000760 —UN—25FEB13

B

11. Apply Thread Lock and Sealer (High Strength) to rod threads.

70-20-15

TB90758,000022A -19-28MAR13-7/9

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 to ease assembly. Line up barrel and rod center lines and push rod assembly into barrel.

C

D—Barrel E—Piston

T8130000761 —UN—25FEB13

A—Cylinder Head B—Rod C—Nut

D

B A

E

TB90758,000022A -19-28MAR13-8/9

14. Push cylinder head (A) into tube until it stops. Push rod (C) fully into barrel (B) to ensure cylinder is fully retracted.

B

15. Using spanner wrench, tighten cylinder head into barrel to specification. Specification Cylinder Head—Torque..................................................... 338—406 N·m (250—300 lb.-ft.)

T8130000762 —UN—25FEB13

A

C

16. Tighten set screw to specification. Specification Set Screw—Torque............................................................. 0.5—1.6 N·m (5—15 lb.-in.) A—Cylinder Head B—Barrel

NOTE: Start with cylinder in retracted position and extend cylinder first to prevent fluid dieseling with large volume of air on retract side of cylinder. Ensure cylinder cycles freely in both directions. 17. Test cylinder once assembly is complete.

• All cylinder testing should be conducted with oil of minimum level of cleanliness of ISO 18/15.

• Cycle cylinder at specified cycling pressure

C—Rod

• Change to specified test stand pressure Specification Test Stand Pressure—Pressure............................................................... 17 236 kPa (172 bar) (2500 psi)

Specification Cycling Pressure—Pressure........................................................................................... 1378 kPa (13.7 bar) (200 psi)

two or three times to fill with oil and remove any trapped air.

•

and fully extend cylinder and pressurize to full pressure for 60 seconds. Check for external leaks. Open lower port on cylinder. Pressurize rod end of cylinder. Watch for fluid running out of lower port. If fluid continues to stream out for more than a few seconds, the piston seal was damaged during 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)

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.

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.

2. Lower base cutter. 3. Relieve hydraulic pressure. 4. Shut off engine and remove key. 5. Clean cylinder and surrounding area.

IMPORTANT: Absolute cleanliness is essential when working on the hydraulic system. Contamination can result in serious damage or inadequate operation. Plug and cap all open hoses and fittings.

6. Engage cylinder safety stop on cylinder not being removed. 7. Remove front wheel. (See Remove and Install Wheel Assembly in Section 57, Group 05.) 8. Remove hub assembly.

NOTE: Remove and install procedure is same for left-hand and right-hand cylinder.

9. Remove lower end of steering cylinder. (See Remove and Install Steering Cylinders (Wheel Harvester) in Section 70, Group 20.)

1. Park machine on level surface. 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

TM100419 (02APR13)

70-20-17

TB90758,0000225 -19-28MAR13-1/3

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). C—Cap Screw and Nut D—Cylinder Pin

T8130000614 —UN—13FEB13

T8130000613 —UN—08FEB13

A—Hose B—Hose

Continued on next page

TM100419 (02APR13)

70-20-18

TB90758,0000225 -19-28MAR13-2/3

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.

16. Replace or repair cylinder as necessary. (See Disassemble and Assemble Base Cutter Lift Cylinders (Wheel Harvester) in Section 70, Group 20.) 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.) B—Cotter Pin and Nut

T8130000618 —UN—13FEB13

A—Dust Cap

T8130000615 —UN—13FEB13

15. Remove cylinder from machine.

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)

CM11475579A1 —UN—06MAR08

Disassemble

Continued on next page

TM100419 (02APR13)

70-20-20

TB90758,000022B -19-28MAR13-1/17

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=332

Hydraulic Cylinders 1— Cylinder Barrel 2— Nut 3— Washer 4— Seal 5— Piston 6— Cylinder Rod

7— Stop Tube 8— Cylinder Cap 9— Ring 10— Washer 11— Cap Screw

12— V-Ring Seal 13— Backup Ring 14— O-ring 15— Wear Ring 16— Seal

1. CAUTION: Before removing cylinder for repair, block up machine and relieve all system pressure. Remove cylinder from machine. (See Remove and Install Base Cutter Lift Cylinders (Wheel Harvester) in Section 70, Group 20.)

17— O-ring 18— Fitting 19— O-ring

3. Clean exterior with solvent and dry to prevent dirt and debris from entering cylinder barrel. IMPORTANT: Clamping cylinder in a vise at middle or end of barrel may damage barrel. Clamp only at cylinder base end. 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 may be forced out of the retract port when the rod is removed from the barrel.

T8130000768 —UN—27FEB13

A

6. Remove cylinder rod assembly from barrel. A—Cap B—Barrel

C—Washer (4 used) 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—Nut

A

Continued on next page

TM100419 (02APR13)

70-20-21

T8130000769 —UN—27FEB13

A—Piston B—Washer

C B

TB90758,000022B -19-28MAR13-4/17

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=333

Hydraulic Cylinders

8. Remove piston (D), stop tube (C), and cylinder cap (B) from cylinder rod (A) with gentle blows from a plastic or hard rubber hammer.

D C

Clean and Inspect CAUTION: Do Not use a flammable solvent to clean cylinder parts. An explosion may occur inside the cylinder, at the moment of pressurization.

T8130000770 —UN—27FEB13

B

A

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 damage. Check for dents and burrs. These may be repaired with light filing and polishing. 2. Clean cylinder parts thoroughly with solvent before repacking and reassembly. Inspect barrel with flashlight for scratches or extreme wear. Light scratches can be removed with 600 grit sandpaper dampened in oil. Other barrel defects will require replacement for optimum seal life. Check ports for accumulations of heavy dirt deposits.

A—Cylinder Rod B—Cylinder Cap

C—Stop Tube D—Piston

3. Clean rod assembly and examine surfaces for dents or scratches. Examine pin bore for wear. Replace bushing, if necessary. Clean threads thoroughly. Clean threads of nut and inspect for damage. Check fit of nut on male rod threads by turning on nut by hand for full engagement. TB90758,000022B -19-28MAR13-5/17

Assemble

B

1. Ensure parts are thoroughly clean before repacking and reassembly. 2. Check all seal widths, lengths, and diameters are same as old ones.

A

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). A—Cylinder Cap

B

T8130000771 —UN—27FEB13

A

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

B—U-Cup Seal

A

B

Continued on next page

TM100419 (02APR13)

70-20-22

T8130000772 —UN—27FEB13

A—Cylinder Cap

TB90758,000022B -19-28MAR13-7/17

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=334

Hydraulic Cylinders

6. Install backup ring (A) on cylinder cap (B). A—Backup Ring

A

B—Cylinder Cap

B

T8130000773 —UN—27FEB13

B

A

TB90758,000022B -19-28MAR13-8/17

7. Install O-ring (A) on cylinder cap (B). A—O-Ring

A

B—Cylinder Cap

B

T8130000774 —UN—27FEB13

B

A

TB90758,000022B -19-28MAR13-9/17

8. Install wear ring (A) onto eye of piston (B). B—Piston

B B

A

A

Continued on next page

TM100419 (02APR13)

70-20-23

T8130000775 —UN—27FEB13

A—Wear Ring

TB90758,000022B -19-28MAR13-10/17

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=335

Hydraulic Cylinders

9. Install expander ring (B) and seal (C) onto piston (A). C—Seal

B A

A

B C

T8130000776 —UN—27FEB13

A—Piston B—Expander Ring

TB90758,000022B -19-28MAR13-11/17

10. Install expander ring (B) on end of piston (A). B—Expander Ring

B A

A

B

T8130000777 —UN—27FEB13

A—Piston

TB90758,000022B -19-28MAR13-12/17

11. Install O-ring (A) into inner groove of piston (B). B—Piston

A

B A B

Continued on next page

TM100419 (02APR13)

70-20-24

T8130000778 —UN—27FEB13

A—O-Ring

TB90758,000022B -19-28MAR13-13/17

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 rod.

T8130000779 —UN—27FEB13

A—Rod

A

B—Cylinder Cap

B

TB90758,000022B -19-28MAR13-14/17

13. Slide stop tube (B) onto rod (A). B—Stop Tube T8130000780 —UN—27FEB13

A—Rod

A B

TB90758,000022B -19-28MAR13-15/17

14. Slide piston (C) onto rod. C

15. Install washer (E) over threaded end of rod (A). E 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 B—Stop Tube C—Piston Continued on next page

TM100419 (02APR13)

70-20-25

T8130000781 —UN—27FEB13

D

B

16. Wipe any excess oil from rod threads. Apply Thread Lock and Sealer (High Strength) to external threads of rod.

D—Lock Nut E—Washer

TB90758,000022B -19-28MAR13-16/17

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 cylinder cap and into cylinder barrel (A). Tighten to specification.

T8130000782 —UN—27FEB13

A

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 B—Washer (4 used)

C—Cap Screw (4 used)

TB90758,000022B -19-28MAR13-17/17

Remove and Install Base Cutter Lift Cylinders (Track Harvester)

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 in Moline, Illinois, U.S.A. IMPORTANT: Absolute cleanliness is essential when working on the hydraulic system. Contamination can result in serious damage or inadequate operation. Plug and cap all open hoses and fittings.

CAUTION: Before removal of cylinder for repair, block up machine and relieve all system pressure. Use cylinder safety stop on cylinder not being removed. 2. Lower base cutter. 3. Relieve hydraulic pressure. 4. Shut off engine and remove key. 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

TM100419 (02APR13)

70-20-26

TB90758,000023A -19-02APR13-1/3

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=338

Hydraulic Cylinders

7. Disconnect upper hose (A). 8. Remove clamp (B).

T8130000620 —UN—13FEB13

9. Disconnect lower hose (C). 10. Cap and plug all openings and fittings. C—Lower Hose

T8130000621 —UN—13FEB13

A—Upper Hose B—Clamp

TB90758,000023A -19-02APR13-2/3

CAUTION: Approximate weight of base cutter lift cylinder is 34 kg (75 lb.). T8130000622 —UN—13FEB13

11. Remove cap screw (B) and shim (C). 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.

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 B—Cap Screw (2 used) C—Shim

T8130000623 —UN—13FEB13

16. Repair or replace cylinder as necessary. (See Disassemble and Assemble Base Cutter Lift Cylinders (Track Harvester) in Section 70, Group 20.)

D—Washer E—Cap Screw and Lock Nut 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 6

1 7 8 9 10

11

T8130001053 —UN—27MAR13

12

13

1— Cylinder Rod 2— Lock Nut 3— Thrust Washer 4— O-Ring

5— Backup Ring 6— Piston 7— Piston Ring 8— O-Ring

9— Seal 10— Cylinder Head 11— Seals (2 used) 12— Cylinder Cap

CAUTION: Before removing cylinder for repair, block up machine and relieve all system pressure. 1. Remove cylinder from machine. (See Remove and Install Base Cutter Lift Cylinders (Track Harvester) in Section 70, Group 20.)

13— Cylinder Barrel

CAUTION: Do not use a flammable solvent to clean cylinder parts. An explosion may occur inside the cylinder, at the moment of pressurization. IMPORTANT: Do not reuse seals.

2. Drain oil from cylinder. Plug and cap fittings and hoses. 3. Clean exterior with solvent and dry to prevent dirt and debris from entering cylinder barrel. IMPORTANT: Clamping cylinder in a vise at middle or end of barrel may damage barrel. Clamp only at cylinder base end.

8. Clean inside of barrel using solvent and blow dry using compressed air. 9. Remove old seals and O-rings using soft metal tools to avoid damaging sealing surfaces of cylinder cap and piston. 10. Clean cylinder parts thoroughly with solvent. 11. Clean rod assembly.

4. Place cylinder in vise and extend rod fully. 5. Using appropriate spanner wrench rotate cylinder cap (12) counterclockwise and remove.

12. Light scratches, burrs, or dents may be repaired using emery cloth. Repair or replace as necessary.

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

TM100419 (02APR13)

70-20-28

TB90758,0000297 -19-28MAR13-1/3

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=340

Hydraulic Cylinders Assemble A

1. Ensure parts are thoroughly clean before assembly.

C

B

T8130001058 —UN—26MAR13

2. Check all seal widths, lengths, and diameters are same as old ones. 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. Piston

IMPORTANT: Curved side of backup ring must be installed toward O-ring. D

A—Seal (2used) B—O-Ring C—Wear Ring D—O-Ring

E

F

G

T8130001059 —UN—26MAR13

6. Install O-ring (D), backup ring (E), seal (F), and wiper seal (G) on cylinder head. E—Backup Ring F— Seal G—Wiper Seal H—Wiper Seal

H

T8130001060 —UN—26MAR13

Cylinder Head

Cylinder Cap Continued on next page

TM100419 (02APR13)

70-20-29

TB90758,0000297 -19-28MAR13-2/3

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).

10. Tighten lock nut to specification. 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.

T8130001319 —UN—28MAR13

9. Slide thrust washer (E) and lock nut (F) onto cylinder rod (D).

12. Apply anti-seize compound to cylinder barrel external threads. 13. Tighten cylinder cap to specification.

A—Cap B—Cylinder Head C—Piston

T8130001320 —UN—28MAR13

Specification Cylinder Cap—Torque....................................................... 711—779 N·m (525—575 lb.-ft.) D—Cylinder Rod E—Thrust Washer 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. X9811 —UN—23AUG88

2. Position topper cylinder (B) safety stop (A) in the upward position. 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. B—Topper Cylinder

T8130000705 —UN—13FEB13

A—Safety Stop

Continued on next page

TM100419 (02APR13)

70-20-31

TB90758,0000243 -19-28MAR13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=343

Hydraulic Cylinders

T8130000703 —UN—13FEB13

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.

T8130000704 —UN—13FEB13

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. 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 Divider Tilt Cylinder (Optional) in Section 70, Group 20.) 10. Install in reverse order of removal using the following special instructions:

• Grease cylinder pins.

A—Hoses (2 used) B—Cap Screws (2 used)

C—Lock Nuts (2 used) D—Cylinder Pins (2 used)

• Check hydraulic reservoir oil level and fill as

necessary. (See Hydraulic Oil in Section 10, Group 15.) 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)

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. 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.

T8130000624 —UN—13FEB13

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.

X9811 —UN—23AUG88

1. Park machine on level surface.

4. Clean crop divider tilt cylinder (A) and surrounding area. 5. Disconnect hose (B). Cap and plug all openings. B—Hose (2 used) T8130000625 —UN—13FEB13

A—Crop Divider Tilt Cylinder

Continued on next page

TM100419 (02APR13)

70-20-33

TB90758,0000244 -19-28MAR13-1/2

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.

8. Remove bracket (D). 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:

T8130000701 —UN—13FEB13

7. Remove cap screw (C).

• Grease cylinder pins. • Check hydraulic reservoir oil level and fill as

necessary. (See Hydraulic Oil in Section 10, Group 15.) C—Cap Screw D—Bracket

T8130000702 —UN—13FEB13

A—Lock Nut B—Cap Screw

TB90758,0000244 -19-28MAR13-2/2

TM100419 (02APR13)

70-20-34

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=346

Hydraulic Cylinders

CM073510072 —UN—26MAR08

Disassemble and Assemble Knockdown Tilt and Crop Divider Tilt Cylinder (Optional)

1— Tube 2— Hydraulic Cylinder Rod 3— Cylinder Head 4— Piston 5— Nut 6— Washer

7— Spherical Roller Bearing 8— Lubrication Fitting 9— Bushing 10— Ring 11— Seal

12— Seal 13— O-Ring 14— Backup Ring 15— O-Ring 16— Wear Ring 17— Backup Ring Continued on next page

TM100419 (02APR13)

70-20-35

18— O-Ring 19— Backup Ring 20— O-Ring 21— Wear Ring

TB90758,0000245 -19-02APR13-1/9

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=347

Hydraulic Cylinders 1. Remove cylinder from machine and clean thoroughly. (See Remove and Install Knockdown Tilt Cylinder (Optional) or Remove and Install Crop Divider Tilt Cylinders (Optional) in Section 70, Group 20.)

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.

IMPORTANT: Clamping cylinder in a vise at the middle or rod end of barrel may damage barrel. Clamp only at cylinder base end.

2. Place cylinder in vise with fitting ports facing down 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 B—Rod

T8130000763 —UN—26FEB13

A—Cylinder Barrel

TB90758,0000245 -19-02APR13-3/9

6. Using a spanner wrench, turn cylinder head (B) counterclockwise until threads on head separates from internal threads in cylinder barrel (A).

B

7. Remove complete rod assembly (C) from barrel.

T8130000764 —UN—26FEB13

A—Cylinder Barrel B—Cylinder Head

C

A

C—Rod Assembly

TB90758,0000245 -19-02APR13-4/9

8. Remove locknut (A), washer (B, piston (C) and cylinder head (D) from rod (E).

E

9. Remove all seals and O-rings from piston and rod head. C

10. Clean cylinder components thoroughly and inspect piston, cylinder head, and barrel for damage. Repair or replace as necessary. A—Lock Nut B—Washer C—Piston

B A

D—Cylinder Head E—Rod

Continued on next page

TM100419 (02APR13)

70-20-36

T8130000765 —UN—26FEB13

D

TB90758,0000245 -19-02APR13-5/9

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 with clean filtered oil. Oil on seals eases assembly and prevents seal damage.

A

B

T8130001061 —UN—26MAR13

C

12. Install wear ring (E), O-rings (F and H), wiper seal (I), rod seal (J), and backup ring (G) to cylinder head. D

13. Lightly coat new seals and rings with clean filtered oil. Oil on seals eases assembly and prevents seal damage. F— O-Ring G—Backup Ring H—O-Ring I— Wiper Seal J— Rod Seal

Piston

F

G

H

I E J

T8130001062 —UN—26MAR13

A—Wear Ring B—Seal C—O-Ring D—O-Ring Loader E—Wear Ring

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 to damage interior seals. B—Rod

T8130000766 —UN—26FEB13

A—Cylinder Head

B A

Continued on next page

TM100419 (02APR13)

70-20-37

TB90758,0000245 -19-02APR13-7/9

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 internal threads of lock nut (A) and install on rod. Tighten nut to specification.

C A

17. Lubricate exterior seals on cylinder head (D), piston, and barrel chamfer area with clean oil. A—Lock Nut B—Washer C—Piston

T8130000922 —UN—21MAR13

Specification Lock Nut—Torque.............................................................. 393—420 N·m (290—310 lb.-ft.)

E

D

B

D—Cylinder Head E—Rod

TB90758,0000245 -19-02APR13-8/9

18. Insert complete rod assembly (A) into cylinder barrel (B), ensuring not to damage seals. Light taps on rod end may be necessary.

A

T8130000767 —UN—26FEB13

19. Using spanner wrench tighten cylinder head into barrel 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.)

21. Test repaired cylinder for leaks and install on machine.

A—Rod Assembly

B—Cylinder Barrel 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. X9811 —UN—23AUG88

3. Clean elevator lift 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.

T8130000442 —UN—05FEB13

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. 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 section of elevator from lifting points (B) outward.

A—Left-Hand Lift Cylinder B—Lifting Points (2 used)

C—Hoses (2 used) D—Right-Hand Lift Cylinder

5. Tag and disconnect hoses (C). 6. Cap and plug hoses and fittings. Continued on next page

TM100419 (02APR13)

70-20-39

TB90758,000022D -19-28MAR13-1/2

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).

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

T8130000443 —UN—05FEB13

9. Remove spring pin (D), pin (C), and remove cylinder.

necessary. (See Hydraulic Oil in Section 10, Group 15 for recommended oil.) C—Pin D—Spring Pin

T8130000444 —UN—05FEB13

A—Cap Screw and Washer B—Pin

TB90758,000022D -19-28MAR13-2/2

TM100419 (02APR13)

70-20-40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=352

Hydraulic Cylinders

CM11472724A4 —UN—14FEB07

Disassemble and Assemble Elevator Lift Cylinders

1— Cylinder Tube 2— Lock Nut 3— Nylon Wear Ring 4— Seal

5— Expander Ring 6— Piston 7— O-Ring 8— Set Screw 9— O-Ring

10— Buffer Seal 11— Head 12— U-Cup Seal 13— Wiper Seal Continued on next page

TM100419 (02APR13)

70-20-41

14— Locking Collar 15— Cylinder Rod

TB90758,0000226 -19-28MAR13-1/8

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 Install Elevator Lift Cylinders in Section 70, Group 20.)

B

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.

IMPORTANT: Avoid cylinder damage. Set screw must me removed before rod assembly can be removed from barrel (C).

T8130000576 —UN—06FEB13

4. Place cylinder in vise and tighten securely. C

5. Remove set screw (A). 6. Remove locking collar (B). 7. Remove caps or plugs on cylinder barrel ports. A—Set Screw B—Locking Collar

C—Barrel

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 gentle blows from a dead- blow hammer. 11. Remove old seals. Use soft metal tools to avoid damaging sealing surfaces of cylinder head or piston.

C

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 B—Piston

Continued on next page

TM100419 (02APR13)

T8130000577 —UN—06FEB13

B

70-20-42

C—Cylinder Head D—Rod TB90758,0000226 -19-28MAR13-3/8

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 bronze filled TEFLON piston ring (C) with O-ring (D).

A T8130000578 —UN—06FEB13

1. Install O-ring into center groove. 2. Install piston ring onto first groove of piston. 3. Install nylon wear rings. A—Piston B—Nylon Wear Ring

C—Piston Ring D—O-Ring

D C

B

B

TB90758,0000226 -19-28MAR13-4/8

Assemble

A

1. Place rod eye into vise and support rod horizontally. 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 it onto rod with a dead blow hammer.

B

T8130000579 —UN—06FEB13

C 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 (250—275 lb.-ft.)

A—Piston B—Rod

C—Cylinder Head D—Locking Collar

D

B A

A—Nylon Wear Ring

C

E

A

B—Seal C—Expander Ring

D—Seal E—Expander Ring

4. Place clean cylinder barrel into vise. Generously apply system oil to barrel inner diameter, especially lead chamfer. Apply oil to piston outer diameter, nylon wear

ring (A), seal (B), expander ring (C), seal (D), buffer seal (E), and outer diameter of cylinder head.

Continued on next page

TM100419 (02APR13)

T8130000580 —UN—06FEB13

TB90758,0000226 -19-28MAR13-5/8

70-20-43

TB90758,0000226 -19-28MAR13-6/8

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=355

Hydraulic Cylinders

A

T8130000916 —UN—28FEB13

B

C

A—Barrel

B—Rod

C—Rod Eye

5. Clamp barrel (A) vertically or horizontally in vise. Align rod center line with barrel center line and carefully

strike end of rod eye (C) to drive rod (B) into barrel, at least 305 mm (12 in.).

Continued on next page

TM100419 (02APR13)

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TB90758,0000226 -19-28MAR13-7/8

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=356

Hydraulic Cylinders

B A

T8130000921 —UN—28FEB13

C

D

A—Barrel B—Set Screw

C—Locking Collar

D—Cylinder Head

6. Tap cylinder head into place, taking care not to cut O-ring or backup ring. 7. Brush anti-seize onto barrel threads . Turn locking collar (C) onto barrel threads, until snug. Use spanner wrench to tighten locking collar against cylinder head (D).

9. Apply Thread Lock and Sealer (Medium Strength) to set screw (B) and tighten to specification. Specification Set Screw—Torque............................................................... 20—33 N·m (15—25 lb.-ft.)

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. X9811 —UN—23AUG88

2. Shut off engine and remove key. 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.

T8120002358 —UN—03JAN13

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. 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 Cylinder in Section 70, Group 20.)

A—Upper Pin B—Hose C—Hose

D—Lower Pin E—Discharge Flap Cylinder

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 8 9 10

11 12

13

T8130000585 —UN—08FEB13

1

2 3 4 5

1— Cylinder Barrel 2— Nut 3— Piston Ring 4— O-Ring

5— Piston 6— O-Ring 7— Lock Ring 8— Backup Ring

9— Wiper Seal 10— Rod Guide 11— Wiper Seal Continued on next page

TM100419 (02APR13)

70-20-47

12— O-Ring 13— Cylinder Rod

TB90758,000023B -19-01APR13-1/9

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.

NOTE: Spray penetrating oil in access slot to 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

T8130001361 —UN—01APR13

3. Extend rod fully.

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). B—Cylinder Barrel

T8130001362 —UN—01APR13

A—Rod

Continued on next page

TM100419 (02APR13)

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TB90758,000023B -19-01APR13-3/9

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).

T8130001363 —UN—01APR13

IMPORTANT: When removing seals from piston and rod guide, do not damage, mark, or score any surfaces that contact seals. 8. Remove all seals and O-rings from piston and rod guide. A—Nut B—Piston

C—Rod 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.

HCD1084 —UN—19NOV01

10. Clean inside of barrel using solvent and blow dry using compressed air.

Continued on next page

TM100419 (02APR13)

70-20-49

TB90758,000023B -19-01APR13-5/9

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=361

Hydraulic Cylinders Assemble

A

T8130001063 —UN—26MAR13

IMPORTANT: All parts must be thoroughly cleaned and dried prior to reuse. Any contamination can lead to leakage problems and part damage. 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. Piston

A—Seal B—O-Ring C—Backup Ring

B

D—O-Ring E—Wiper Seal F— Rod Seal

C

D

E F

T8130001064 —UN—26MAR13

3. Apply light film of clean oil on all seals and rings.

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. 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 B—Piston

T8130001364 —UN—01APR13

NUT TORQUE SPECIFICATIONS Thread Size

C—Rod Guide D—Rod

Continued on next page

TM100419 (02APR13)

70-20-50

TB90758,000023B -19-01APR13-7/9

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). C—Rod Guide

T8130001365 —UN—01APR13

A—Cylinder Barrel B—Chamfer

TB90758,000023B -19-01APR13-8/9

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. C—Lock Ring D—Rod Guide

T8130001367 —UN—01APR13

A—Access Slot B—Lock Ring Hole

T8130001366 —UN—01APR13

8. Rotate rod guide (D) until lock ring hole (B) can be seen in access slot (A)

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.) 271 (LOCTITE®)

Thread Lock and Sealer (High Strength)

Used to seal and lock threads.

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.) TY9484 (Canadian) 515 (LOCTITE®)

Flexible Form-In-Place Gasket

Used to seal parts from fluid leakage.

PM37477 (U.S.) TY9473 (Canadian) 242 (LOCTITE®)

Thread Lock and Sealer (Medium Strength)

Used to lock and seal threads.

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 O-Ring-to-Valve Housing

Torque

6 N·m (53 lb.-in.)

Chopper Motor Drive Gear Cap Screw

Torque

275 N·m (200 lb.-ft.)

Chopper Motor Flange Cap Screws

Torque

271 N·m (200 lb.-ft.)

Topper Severing Disk (Whole Topper) and Secondary Extractor Fan Motor End Cover Cap Screws

Torque

272 N·m (200 lb.-ft.)

Secondary Extractor Rotate Motor End Cover Cap Screws

Torque

32 N·m (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

NOTE: Procedure for right-hand and left-hand gathering disk motors are the same. 1. Park machine on level surface. 2. Lower crop divider. 3. Lower topper completely. 4. Shut off engine and remove key.

T8120001594 —UN—25SEP12

Remove and Install Topper Gathering Disk Motor (Whole Topper)

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.

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.) 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.

T8120002628 —UN—17JAN13

10. Remove cap screws (F), nuts, and gathering disk motor.

Specification Gathering Disk-to-Motor Nut—Torque................................................................................373 N·m (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 B—Gathering Disk C—Nut D—Cotter Pin

E—Hose F— Cap Screw (4 used) G—Hose

T8120001593 —UN—17JAN13

• Tighten gathering disk-to-motor nut to specification.

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. N87636 —UN—05FEB10

3. Place motor in a vise with protective jaws, clamping 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

A

Continued on next page

TM100419 (02APR13)

70-25-3

PW66162,0000922 -19-26FEB13-2/12

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=367

Hydraulic Motors

NOTE: Springs and pins (B) retained by valve housing can move when valve housing is removed. Be prepared to catch components.

A

6. Lift valve housing (A) straight up. A—Valve Housing

B—Pin (2 used)

N87638 —UN—05FEB10

B

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

C—O-Ring D—Case Drain Plug

C D

Continued on next page

TM100419 (02APR13)

70-25-4

N87639 —UN—05FEB10

A—Valve Housing B—Seal

PW66162,0000922 -19-26FEB13-4/12

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=368

Hydraulic Motors

9. Remove pins (C) and springs (D).

B

10. Remove balance ring assembly (E).

D

C

A

11. Remove valve (A). 12. Remove inner and outer face seals (B) from balance ring.

D N87640 —UN—05FEB10

C 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). G—Valve Drive H—Valve Plate I— Seal J— Main Drive K—Geroler

F

G

H

J

K

Continued on next page

TM100419 (02APR13)

70-25-5

N88230 —UN—24MAR10

I

N87641 —UN—05FEB10

A—Valve B—Inner and Outer Face Seals C—Pins (2 used) D—Springs (2 used) E—Balance Ring F— Seal

PW66162,0000922 -19-26FEB13-5/12

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

Shaft and bearing assembly cannot be repaired. A worn or damaged shaft and bearing assembly must be replaced as a unit.

C

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.

N87643 —UN—08FEB10

A

19. Remove seal (B) from bearing housing (A). 20. Remove shaft and bearing assembly (E) from bearing housing.

A

IMPORTANT: Do not dry parts using paper towels or cloth as lint can damage hydraulic system.

N87644 —UN—08FEB10

21. Using an appropriate seal remover, remove exclusion seal (F), backup ring (G), and shaft pressure seal (H) from bearing housing. 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 compressed air.

A

23. Inspect all mating surfaces and parts for wear or damage, replace as necessary. H

E—Shaft and Bearing Assembly F— Exclusion Seal G—Backup Ring H—Shaft Pressure Seal

G

Continued on next page

TM100419 (02APR13)

70-25-6

N87645 —UN—08FEB10

F A—Bearing Housing B—Seal C—Shaft Face Seal D—Wear Plate

PW66162,0000922 -19-26FEB13-6/12

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.

29. Place motor in a vise with protective jaws clamping on mounting flange and output shaft facing downward.

N87646 —UN—08FEB10

C

28. Install shaft and bearing assembly using a press. Inspect shaft pressure seal for damage and replace as necessary.

D

30. Install seal (C). 31. Install seal (A) in wear plate (B) as shown. 32. Install wear plate. A—Seal B—Wear Plate C—Seal

D—Shaft and Bearing Assembly 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

B—Main Drive

N87896 —UN—10FEB10

A—Seal

Continued on next page

TM100419 (02APR13)

70-25-7

PW66162,0000922 -19-26FEB13-8/12

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. B

35. Install seal in valve plate (D).

C

37. Install valve drive (C) in geroler.

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 pocket in geroler and install valve, rotating clockwise to engage spline teeth. Do not rotate more than 1/2 spline tooth.

F

A—Main Drive B—Geroler C—Valve Drive

N87647 —UN—08FEB10

36. Install geroler on main drive (A).

D—Valve Plate E—Valve 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—Springs (2 used) D—Valve Housing

C B

C B

Continued on next page

TM100419 (02APR13)

70-25-8

N87648 —UN—08FEB10

A—Seal B—Pins (2 used)

PW66162,0000922 -19-26FEB13-10/12

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=372

Hydraulic Motors

NOTE: Do not bend or force inner and outer face seals. Failure to install inner face seal and outer face seal as shown can cause the motor to operate improperly.

A

C

B

D

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. D—Balance Ring E—Valve Housing F— Geroler

E D

F

Continued on next page

TM100419 (02APR13)

70-25-9

N87649 —UN—08FEB10

A—Outer Face Seal B—Inner Face Seal C—Pin Notch

PW66162,0000922 -19-26FEB13-11/12

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=373

Hydraulic Motors

Specification Valve Housing Cap Screw—Torque..............................................................................50 N·m (37 lb.-ft.)

47. Install case drain plug (C) with O-ring (B). Tighten to specification.

A B

Specification Case Drain Plug with O-Ring-to-Valve Housing—Torque.............................................................................6 N·m (53 lb.-in.)

C

A—Cap Screw (4 used) B—O-Ring

48. Remove tape from output shaft splines.

N87651 —UN—05FEB10

46. Install four caps screws (A) and tighten to specification in an alternating pattern.

C—Case Drain Plug

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

•

T8130000589 —UN—06FEB13

•

Used to dispense Araldite. 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. T8130000590 —UN—06FEB13

2. Clean chopper motor and surrounding area. 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.).

T8130000593 —UN—06FEB13

NOTE: Motor shown supported in removed position. 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 B—Cap Screw C—Cap Screw D—Drain Plug E—Hose Continued on next page

TM100419 (02APR13)

70-25-11

F— Hoses (2 used) G—Flange Cap Screw (5 used) H—Chopper Motor I— Lifting Device

PW66162,00009DE -19-02APR13-1/4

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=375

Hydraulic Motors

12. If necessary remove cap screw (A) and motor drive 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

T8130000592 —UN—06FEB13

NOTE: Apply heat to motor drive gear cap screw to aid in removal. Heat softens 0841306708 Araldite1 used to retain cap screw.

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. Continued on next page

TM100419 (02APR13)

70-25-12

PW66162,00009DE -19-02APR13-2/4

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. T8130000592 —UN—06FEB13

Apply 0841306708 Araldite1 to motor drive gear 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.

T8130000591 —UN—06FEB13

3. Install appropriate sized threaded rods (C) into opposite holes as shown to aid in assembly. 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 B—Drive Gear

6. Remove threaded rods and install remaining flange cap screws. Tighten flange cap screws to specification. Specification Chopper Motor Flange Cap Screws—Torque..................................................................271 N·m (200 lb.-ft.)

C—Threaded Rods (2 used)

7. Remove caps and plugs. Install hydraulic hoses.

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. Continued on next page

TM100419 (02APR13)

70-25-13

PW66162,00009DE -19-02APR13-3/4

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=377

Hydraulic Motors

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.) 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 B—Cap Screw

C—Cap Screw D—Drain Plug

T8130000589 —UN—06FEB13

NOTE: Be sure that drain plug (D) is installed.

PW66162,00009DE -19-02APR13-4/4

TM100419 (02APR13)

70-25-14

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=378

Hydraulic Motors

CM073510410 —UN—17SEP07

Disassemble and Assemble Chopper Motor

Continued on next page

TM100419 (02APR13)

70-25-15

PW66162,000094B -19-26FEB13-1/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=379

Hydraulic Motors 1— Steel Ring 2— Ring 3— O-ring 4— Seal 5— Cover 6— O-ring 7— Cylinder (5 used) 8— Piston 9— Housing 10— Plastic Slipper Seal

11— O-ring 12— Shaft Seal 13— Shaft 14— Retaining Clip 15— Bearing 16— Locating Pin 17— Drive Pin 18— Cap Screw (5 used)

19— Cap Screw 20— O-ring 21— O-ring 22— O-ring 23— Seal 24— Dowel Pin 25— Disk 26— Bushing 27— Distributor Cover

28— Ring 29— Seal 30— O-ring 31— Rotary Valve Sleeve 32— Shaft Key

PW66162,000094B -19-26FEB13-2/31

CM073510411 —UN—17SEP07

Disassemble and Assemble Tools

1— Jacking Plate

2— Extractor Jacks

3— Lever A—Bolt Circle

Disassemble NOTE: During assembly at the factory, one of the distributor cap screws is lead sealed. The number on the seal is a factory reference number and must not be removed. Warranty, where applicable, on motors returned for repairs is only valid if this seal is intact.

with fault diagnosis, mark the position of motor cover with respect to the motor body. Observe position of each of the cylinders with respect to motor housing. 1. Drain casing oil.

To aid in assembly, mark alignment of distributor ports with respect to the drain line holes the distributor. To aid Continued on next page

TM100419 (02APR13)

70-25-16

PW66162,000094B -19-26FEB13-3/31

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).

CM073510412 —UN—19MAR08

31— Rotary Valve Sleeve

CM073510413 —UN—19MAR08

18— Cap Screw (5 used) 27— Distributor Cover

PW66162,000094B -19-26FEB13-4/31

3. Remove drive pin (17) and centering bushing (26). 26— Centering Bushing

CM073510415 —UN—19MAR08

CM073510414 —UN—19MAR08

17— Drive Pin

Continued on next page

TM100419 (02APR13)

70-25-17

PW66162,000094B -19-26FEB13-5/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=381

Hydraulic Motors

4. Remove cap screws (19).

5. Attach an appropriate puller using distributor cap screw holes as shown. 6. Remove cover (5), O-rings (20), and locating pins (16). 19— Cap Screw 20— O-Ring

CM073510417 —UN—19MAR08

5— Cover 16— Locating Pin

CM073510416 —UN—19MAR08

NOTE: Threaded rod of puller is inserted through drive pin hole as shown.

PW66162,000094B -19-26FEB13-6/31

7. Using appropriate snap ring pliers, remove retaining clip (14).

CM073510418 —UN—19MAR08

14— Retaining Clip

Continued on next page

TM100419 (02APR13)

70-25-18

PW66162,000094B -19-26FEB13-7/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=382

Hydraulic Motors

NOTE: If necessary, tap cylinder trunnion with a rubber-headed hammer to loosen piston from shaft. 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 2— Ring 3— O-Ring 4— Seal

CM073510419 —UN—19MAR08

8. Rotate shaft so that piston (8) of the cylinder (7) to be removed is fully extended.

7— Cylinder (5 used) 8— Piston 10— Plastic Slipper Seal 11— O-Ring PW66162,000094B -19-26FEB13-8/31

12. Using a rubber-headed hammer, tap and remove shaft (13).

CM073510420 —UN—19MAR08

NOTE: Only remove shaft bearings if replacement is required. 13. Remove and discard shaft seal.

CM073510421 —UN—19MAR08

13— Shaft

Continued on next page

TM100419 (02APR13)

70-25-19

PW66162,000094B -19-26FEB13-9/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=383

Hydraulic Motors

CM073510422 —UN—19MAR08

14. If necessary, use an appropriate puller and remove shaft bearings (15).

PW66162,000094B -19-26FEB13-10/31

Assemble

1. Wrap spline area on motor shaft with transparent tape.

CM073510423 —UN—19MAR08

NOTE: Transparent tape applied to shaft splines prevents damage to lip of seal during installation.

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.

CM073510424 —UN—19MAR08

•

Outer bearing race must be installed into motor housing or cover and the inner race 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 cover or housing.

5. Smooth edges that may have been damaged during bearing removal. 6. If removed, install bearings.

Continued on next page

TM100419 (02APR13)

70-25-20

PW66162,000094B -19-26FEB13-12/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=384

Hydraulic Motors

CM073510425 —UN—19MAR08

7. Replace the shaft retaining ring, spring, and C clip to the rear side of the piston support ring.

PW66162,000094B -19-26FEB13-13/31

CM073510426 —UN—19MAR08

8. Dislodge C-clip from front side of the piston support ring.

Continued on next page

TM100419 (02APR13)

70-25-21

PW66162,000094B -19-26FEB13-14/31

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.

CM073510428 —UN—19MAR08

CM073510427 —UN—19MAR08

9. Install shaft (13) into bearing in motor cover (5).

PW66162,000094B -19-26FEB13-15/31

CM073510419 —UN—19MAR08

CM073510429 —UN—19MAR08

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.

Continued on next page

TM100419 (02APR13)

70-25-22

PW66162,000094B -19-26FEB13-16/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=386

Hydraulic Motors

CM073510430 —UN—19MAR08

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. 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.

CM073510431 —UN—19MAR08

15. Tap lightly with a rubber-headed hammer on cylinder trunnions and shaft end to ensure that the shafts are properly seated.

CM073510432 —UN—19MAR08

PW66162,000094B -19-26FEB13-18/31

5— Cover 6— O-Ring

9— Housing 16— Locating Pin

16. If removed, install locating pins (16).

20— O-Ring

17. Lubricate and install new O-rings (20 and 6). Continued on next page

TM100419 (02APR13)

70-25-23

PW66162,000094B -19-26FEB13-19/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=387

Hydraulic Motors

NOTE: Use care not to damage shaft seal.

CM073510433 —UN—19MAR08

18. Position housing (9) by aligning the trunnion seats with cylinder trunnions and gently lower housing into place.

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 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.

CM073510434 —UN—19MAR08

20. Install and tighten cap screws (19).

CM073510435 —UN—19MAR08

PW66162,000094B -19-26FEB13-20/31

Continued on next page

TM100419 (02APR13)

70-25-24

PW66162,000094B -19-26FEB13-21/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=388

CM073510437 —UN—17SEP07

Hydraulic Motors

21. Install O-ring in rotary valve.

22. Install plastic slipper with concave side against O-ring. PW66162,000094B -19-26FEB13-22/31

CM073510438 —UN—19MAR08

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.

PW66162,000094B -19-26FEB13-23/31

NOTE: Ensure that no objects fall into cover. Motor disassembly is necessary to remove object.

CM073510441 —UN—19MAR08

24. Install distributor drive pin into the shaft through hole in cover.

Continued on next page

TM100419 (02APR13)

70-25-25

PW66162,000094B -19-26FEB13-24/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=389

Hydraulic Motors

CM073510442 —UN—19MAR08

25. Insert locating pins into their holes in cover.

PW66162,000094B -19-26FEB13-25/31

NOTE: Motors without the disk do not have the locating pins. Disk must sit flush with cover.

CM073510443 —UN—19MAR08

Disk does not have to be pressed on. Five oil feed holes must line up with holes in cover. 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

CM073510444 —UN—19MAR08

27. Install centering bushing into disk.

Continued on next page

TM100419 (02APR13)

70-25-26

PW66162,000094B -19-26FEB13-27/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=390

Hydraulic Motors

CM073510445 —UN—19MAR08

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.

PW66162,000094B -19-26FEB13-28/31

CM073510439 —UN—19MAR08

29. Lubricate and install distributor cover O-ring into groove as shown.

CM073510440 —UN—19MAR08

PW66162,000094B -19-26FEB13-29/31

30. For distributors with bronze disk, install O-ring and plastic slipper with chamfer against O-ring. Continued on next page

TM100419 (02APR13)

70-25-27

PW66162,000094B -19-26FEB13-30/31

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=391

Hydraulic Motors

CM073510436 —UN—19MAR08

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 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.

CM073510447 —UN—19MAR08

Incorrect

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

3

9 11

6

10

7

8 2 7

4

6

5 5 3

11

4

10

2 1

19

16

17 16 18

15 14 13 17

12

22 13

21 17

14 11 12

9

14

15

17 11 13

14

Continued on next page

TM100419 (02APR13)

70-25-29

20

T8120001841 —UN—15OCT12

13

PW66162,00009A5 -19-26FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=393

Hydraulic Motors 1— Snap Ring 2— Shaft 3— Bearing 4— Spacer 5— Retaining Ring 6— Seal Retainer 7— Seal 8— Shaft Housing

9— Plug 10— Check Valve Assemblies (2 used) 11— Bushings (4 used) 12— Backup Seals (2 used) 13— Side Seals (4 used)

14— End Seal (4 used) 15— Thrust Plates (2 used) 16— Square Seals (2 used) 17— Dowel Pins (4 used) 18— Gear Set

19— Gear Housing 20— End Cover 21— Washer (4 used) 22— Cap Screw (4 used)

PW66162,00009A5 -19-26FEB13-2/2

Disassemble and Assemble Topper Severing Disk (Whole Topper) and Secondary Extractor Fan Motors T8120001732 —UN—03OCT12

Disassemble 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) B—End Cover

2. Place motor in a vise with drive shaft pointing downward. Mark lines (C) across all three motor sections as shown.

C—Lines (2 used) D—Motor

3. Remove cap screws (A), washers, and end cover (B). Continued on next page

TM100419 (02APR13)

70-25-30

PW66162,0000849 -19-17JAN13-1/20

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=394

Hydraulic Motors

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.

T8120001733 —UN—05OCT12

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.

6. Carefully remove gears (C). 7. Remove and discard square seal (D). C—Gears (2 used) D—Square Seal

T8120001734 —UN—03OCT12

A—Gear Housing B—Thrust Plate

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).

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 B—Thrust Plate

C—Square Seal D—Gear Housing Continued on next page

TM100419 (02APR13)

70-25-31

T8120001735 —UN—04OCT12

9. Remove and discard square seal (C).

PW66162,0000849 -19-17JAN13-3/20

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. T8120001736 —UN—03OCT12

C—End Cover

T8120001737 —UN—03OCT12

A—Shaft Housing B—Bushings (4 used)

PW66162,0000849 -19-17JAN13-4/20

13. Place shaft housing (C) in a vise with mounting face upward. 14. Remove the snap ring (A).

A—Snap Ring B—Shaft Assembly

T8120001738 —UN—03OCT12

15. Using an appropriate puller, remove shaft assembly (B). C—Shaft Housing

Continued on next page

TM100419 (02APR13)

70-25-32

PW66162,0000849 -19-17JAN13-5/20

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. C—Seal

T8120001740 —UN—04OCT12

T8120001739 —UN—04OCT12

A—Seal Retainer B—Shaft Housing

PW66162,0000849 -19-17JAN13-6/20

17. If necessary, remove check valves (B) from shaft housing (A). B—Check Valves (2 used) T8120001835 —UN—04OCT12

A—Shaft Housing

Continued on next page

TM100419 (02APR13)

70-25-33

PW66162,0000849 -19-17JAN13-7/20

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). C—Spacer D—Retaining Ring

T8120001878 —UN—15OCT12

A—Shaft B—Bearing

PW66162,0000849 -19-17JAN13-8/20

Clean and Inspect

NOTE: Hydraulic oil pressure pushes gears against 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.

T8120001831 —UN—04OCT12

1. Clean and inspect all parts for wear or damage. Replace as necessary.

3. Check gears (D) for nicks, scoring, or grooves on gear hub and gear teeth surfaces. Replace as necessary. 4. Check all housing dowel pins and replace as necessary. A—Straight Edge B—Bore

C—Feeler Gauge D—Gears (2 used)

Continued on next page

TM100419 (02APR13)

70-25-34

T8120001832 —UN—04OCT12

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.).

PW66162,0000849 -19-17JAN13-9/20

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=398

Hydraulic Motors

T8120001834 —UN—04OCT12

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. 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.

T8120001833 —UN—04OCT12

A—Shaft

Continued on next page

TM100419 (02APR13)

70-25-35

PW66162,0000849 -19-17JAN13-11/20

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=399

Hydraulic Motors

1. Using medium grit emery cloth, clean housing machined surfaces. Clean all motor parts and housings with solvent and blow dry with compressed 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). C—End Cover

T8120001737 —UN—03OCT12

A—Shaft Housing B—Bushings (4 used)

T8120001736 —UN—03OCT12

Assemble

PW66162,0000849 -19-17JAN13-12/20

3. If removed, install check valves (B) into shaft housing (A). 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

TM100419 (02APR13)

70-25-36

T8120001835 —UN—04OCT12

NOTE: Check valves are “peened” in place to prevent valves from loosening.

PW66162,0000849 -19-17JAN13-13/20

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=400

Hydraulic Motors

5. Place shaft housing (B) in a vice with flange side upward.

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. C—Seal Retainer

T8120001837 —UN—04OCT12

A—Seal B—Shaft Housing

T8120001836 —UN—04OCT12

6. Apply Flexible Form-In-Place Gasket to the outer edge of new seal (A) and seal bore.

PW66162,0000849 -19-17JAN13-14/20

10. Install bearing (B), spacer (C), and retaining ring (D) onto shaft (A). C—Spacer D—Retaining Ring

T8120001878 —UN—15OCT12

A—Shaft B—Bearing

Continued on next page

TM100419 (02APR13)

70-25-37

PW66162,0000849 -19-17JAN13-15/20

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)

A—Snap Ring B—Shaft Assembly

T8120001738 —UN—03OCT12

12. Install snap ring (A). C—Shaft Housing

PW66162,0000849 -19-17JAN13-16/20

13. Remove shaft housing from vice and position shaft housing in vice with flange side downward.

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)

T8120001838 —UN—04OCT12

NOTE: Position housings using lines marked at disassembly.

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. D—End Seal (4 used) E—Gear Housing

T8120001839 —UN—05OCT12

A—Thrust Plate (2 used) B—Side Seal (4 used) C—Backup Seal (2 used)

Continued on next page

TM100419 (02APR13)

70-25-38

PW66162,0000849 -19-17JAN13-18/20

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.

T8120001840 —UN—05OCT12

C—Square Seal D—Thrust Plate

T8120001880 —UN—18OCT12

A—Gear Housing B—Gears (2 used)

Continued on next page

TM100419 (02APR13)

70-25-39

PW66162,0000849 -19-17JAN13-19/20

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.

T8120001732 —UN—03OCT12

20. Position marked lines on end cover (B) and gear housing and install end cover. Tap end cover lightly 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 (200 lb.-ft.)

22. Remove motor (D) from vice and rotate shaft with a wrench to make certain there is no binding. Start-up procedure 1. Before connecting any hoses, fill all motor ports with clean hydraulic oil to provide initial lubrication.

A—Cap Screw (4 used) B—End Cover

C—Lines (2 used) D—Motor

2. After motor installation, operate motor at least 2 minutes at no load and at low rpm (400 rpm minimum). During this break-in period, motor must run free and not develop an excessive amount of heat. PW66162,0000849 -19-17JAN13-20/20

TM100419 (02APR13)

70-25-40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=404

Hydraulic Motors

CM073510233 —UN—05SEP07

Repair Base Cutter and Primary Extractor Motors

Continued on next page

TM100419 (02APR13)

70-25-41

PW66162,0000859 -19-27FEB13-1/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=405

Hydraulic Motors 1— Drive Shaft Assembly 2— End Cover 3— Valve 4— Housing 5— Cap Screw (2 used) 6— Cap Screw (6 used) 7— Cap Screws (4 used)

8— Seal Ring 9— O-Ring 10— Back-Up Ring 11— Fitting 12— Bearing Cup 13— Gasket 14— Pins (2 used) 15— Port Plate 16— Rear Bearing Shim (as required)

17— Rear Bearing Cone 18— Rear Bearing Cup 19— Rotary Group 20— Cap Screw 21— Shaft Seal 22— Spacer 23— Retaining Ring 24— Plug

25— Sealing Flat Washer 26— Relief Valve (2 used) 27— Relief Valve Seal Set (2 used)

PW66162,0000859 -19-27FEB13-2/44

CM073510234 —UN—05SEP07

Disassemble

CM073510235 —UN—05SEP07

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

3. Install a 3 inch sheet metal screw with the point blunted into punched hole far enough to remove shaft seal.

CM073510236 —UN—05SEP07

CM073510237 —UN—05SEP07

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

TM100419 (02APR13)

70-25-42

PW66162,0000859 -19-27FEB13-4/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=406

Hydraulic Motors

NOTE: Some motor configurations do not use valve block assembly.

CM073510239 —UN—19MAR08

6. Position motor on mounting flange as shown. 7. Loosen, but do not remove, relief valves (26) and plugs (24) from valve block (3). 8. Remove cap screws (7) and valve block. 24— Plugs (2 used) 26— Relief Valves (2 used)

CM073510240 —UN—19MAR08

3— Valve Block 7— Cap Screws (4 used)

PW66162,0000859 -19-27FEB13-5/44

9. Remove O-rings (9) and back-up rings (10) from the mounting face of valve block (3). 10— Back-Up Rings (2 used) CM073510241 —UN—19MAR08

3— Valve Block 9— O-Rings (2 used)

Continued on next page

TM100419 (02APR13)

70-25-43

PW66162,0000859 -19-27FEB13-6/44

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. CM073510242 —UN—19MAR08

10. Remove relief valves (26) from valve block (3). 11. Remove plugs (24) from valve block. 26— Relief Valves (2 used)

CM073510243 —UN—19MAR08

3— Valve Block 24— Plug (2 used)

PW66162,0000859 -19-27FEB13-7/44

CM073510244 —UN—19MAR08

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. 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. 13— Gasket 14— Pins (2 used)

CM073510245 —UN—19MAR08

2— End Cover 5— Cap Screw (2 used) 6— Cap Screw (6 used)

Continued on next page

TM100419 (02APR13)

70-25-44

PW66162,0000859 -19-27FEB13-8/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=408

Hydraulic Motors

NOTE: Rear bearing cup is “slip fit” into end cover.

CM073510246 —UN—19MAR08

Retained shims are used to adjust shaft bearing end play. 15. Remove rear bearing cup (18) from end cover (2). 16. Remove and retain rear bearing shims (16) from end cover. 18— Rear Bearing Cup

CM073510247 —UN—19MAR08

2— End Cover 16— Rear Bearing Shims

PW66162,0000859 -19-27FEB13-9/44

If using a small screw driver to pry bearing plate 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 B—Bearing Plate

C—Housing

Continued on next page

TM100419 (02APR13)

70-25-45

CM073510248 —UN—19MAR08

IMPORTANT: Handle bearing plate and valve plates with extreme care. They are machined to close tolerances for flatness.

PW66162,0000859 -19-27FEB13-10/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=409

Hydraulic Motors

CM073510249 —UN—19MAR08

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 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

CM073510250 —UN—19MAR08

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).

PW66162,0000859 -19-27FEB13-12/44

CM073510251 —UN—19MAR08

20. Remove and discard sealing washer (25) from cap screws (20). Replace with new sealing washers.

Continued on next page

TM100419 (02APR13)

70-25-46

PW66162,0000859 -19-27FEB13-13/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=410

Hydraulic Motors

CM073510252 —UN—19MAR08

21. Push inward on shaft assembly (1) to dislodge the swashplate (D) from its pocket in housing (4).

PW66162,0000859 -19-27FEB13-14/44

CM073510253 —UN—05SEP07

22. Carefully remove the output shaft/cylinder barrel assembly from housing.

PW66162,0000859 -19-27FEB13-15/44

CM073510254 —UN—05SEP07

23. Position the shaft/cylinder barrel subassembly with the shaft facing up. Carefully lift out the output drive shaft subassembly.

Continued on next page

TM100419 (02APR13)

70-25-47

PW66162,0000859 -19-27FEB13-16/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=411

Hydraulic Motors

CM073510255 —UN—05SEP07

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. 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

CM073510256 —UN—19MAR08

26. If the bearing cup (12) needs replacing, carefully remove the cup using a hammer and drift punch (E).

PW66162,0000859 -19-27FEB13-18/44

CM073510257 —UN—19MAR08

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 make it easier to remove cylinder barrel (C) from the swashplate (D).

Continued on next page

TM100419 (02APR13)

70-25-48

PW66162,0000859 -19-27FEB13-19/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=412

Hydraulic Motors

CM073510258 —UN—19MAR08

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). 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

1. Lubricate and install shoe retainer plate (H) and piston shoes (I) in cylinder barrel (C) assembly. After installation, freely lubricate brass shoe faces with clean hydraulic fluid.

CM073510259 —UN—19MAR08

IMPORTANT: Before reassembly, clean all parts and assemblies in clean solvent and blow them dry with compressed air. Inspect and replace 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. height of retaining strap spacer with a micrometer or vernier caliper. There are two fixed spacer heights – one for the 33, 39, 46 units and one for the 54, 64 units. Spacers are critical to the unit design and may not be interchanged.

2. Before assembling the motor any further, you must check the fixed clearance of motor. Measure the

PW66162,0000859 -19-27FEB13-21/44

CM073510260 —UN—19MAR08

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. 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 retainer plate).

1— Spacer 2— Retaining Strap 3— Cap Screw 4— Piston Continued on next page

TM100419 (02APR13)

70-25-49

5— Shoe Retainer Plate 6— Piston Shoes 7— Thrust Plate 8— Swashplate PW66162,0000859 -19-27FEB13-22/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=413

Hydraulic Motors

CM073510261 —UN—19MAR08

5. Apply one or two drops of Loctite 271 in the first or second thread, in each of the four holes in the swashplate.

PW66162,0000859 -19-27FEB13-23/44

CM073510262 —UN—19MAR08

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.

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 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

TM100419 (02APR13)

70-25-50

CM073510263 —UN—19MAR08

PW66162,0000859 -19-27FEB13-24/44

PW66162,0000859 -19-27FEB13-25/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=414

Hydraulic Motors

CM073510264 —UN—05SEP07

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.).

PW66162,0000859 -19-27FEB13-26/44

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.

CM073510265 —UN—05SEP07

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.

Continued on next page

TM100419 (02APR13)

70-25-51

CM073510266 —UN—05SEP07

PW66162,0000859 -19-27FEB13-27/44

PW66162,0000859 -19-27FEB13-28/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=415

Hydraulic Motors

CM073510267 —UN—05SEP07

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.

PW66162,0000859 -19-27FEB13-29/44

CM073510268 —UN—05SEP07

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.).

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 the shoulder of the output shaft.

Continued on next page

TM100419 (02APR13)

70-25-52

CM073510269 —UN—19MAR08

PW66162,0000859 -19-27FEB13-30/44

PW66162,0000859 -19-27FEB13-31/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=416

Hydraulic Motors

CM073510270 —UN—19MAR08

14. Install two dowel pins (14) and gasket (13) on end cover (2).

PW66162,0000859 -19-27FEB13-32/44

CM073510271 —UN—19MAR08

15. Lubricate and install bearing shims (16) and bearing cup (18) into end cover (2).

PW66162,0000859 -19-27FEB13-33/44

17. Install cap screws into the end cover (2), slowly and 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

TM100419 (02APR13)

70-25-53

CM073510272 —UN—05SEP07

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.

PW66162,0000859 -19-27FEB13-34/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=417

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 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).

CM073510273 —UN—05SEP07

Hydraulic Motors

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. 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.

CM073510274 —UN—05SEP07

PW66162,0000859 -19-27FEB13-35/44

PW66162,0000859 -19-27FEB13-36/44

CM073510275 —UN—19MAR08

20. Lubricate the O-ring seal of the stationary seal subassembly, and then install the seal.

Continued on next page

TM100419 (02APR13)

70-25-54

PW66162,0000859 -19-27FEB13-37/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=418

Hydraulic Motors

CM073510276 —UN—19MAR08

21. Install spacer (22) into housing (4), then using snap ring pliers, install retainer ring (23).

PW66162,0000859 -19-27FEB13-38/44

CM073510277 —UN—19MAR08

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 (18), aligning it with the dowel pins.

PW66162,0000859 -19-27FEB13-39/44

24. Install the cap screws (5) and (6) into end cover (2). Tighten them slowly and evenly. Torque the cap screws 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

TM100419 (02APR13)

70-25-55

CM073510278 —UN—19MAR08

23. Holding the valve plate (15) firmly in position, install the end cover (2) on housing (4).

PW66162,0000859 -19-27FEB13-40/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=419

Hydraulic Motors

CM073510279 —UN—19MAR08

25. Install O-rings and back-up rings on valve block (3).

PW66162,0000859 -19-27FEB13-41/44

26. The high-pressure ports require an O-ring (A) and 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.

CM073510280 —UN—19MAR08

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.

PW66162,0000859 -19-27FEB13-42/44

CM073510281 —UN—19MAR08

27. Position the valve block (3) on end cover (2). Install four hex bolts (7). Torque bolts to 38 N·m (28 lb.-ft.).

Continued on next page

TM100419 (02APR13)

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PW66162,0000859 -19-27FEB13-43/44

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=420

Hydraulic Motors

CM073510282 —UN—19MAR08

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.).

PW66162,0000859 -19-27FEB13-44/44

TM100419 (02APR13)

70-25-57

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=421

Hydraulic Motors

CM073510333 —UN—11SEP07

Cooling Package Motor

Continued on next page

TM100419 (02APR13)

70-25-58

PW66162,000085A -19-26FEB13-1/16

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=422

Hydraulic Motors 1— Front Cover 2— End Cover 3— Housing 4— Gear Assembly 5— Cap Screw (4 used)

6— Key 7— Pin (2 used) 8— Thrust Plate (2 used 9— Snap Ring 10— Seal (2 used)

11— Seal (4 used) 12— Seal (4 used) 13— Seal 14— Seal (2 used) 15— Spacer 16— Spacer

17— Check Valve (2 used) 18— Washer (4 used) 19— Washer 20— Nut

PW66162,000085A -19-26FEB13-2/16

Disassemble 1. Place the motor in a vise with drive shaft pointing downward. CM073510334 —UN—11SEP07

NOTE: Marked lines aid in assembly. 2. Mark a line across all motor sections. 3. Remove cap screws (5) and washers (18) from end cover (2). 18— Washers (4 used)

CM073510335 —UN—19MAR08

2— End Cover 5— Cap Screws (4 used)

PW66162,000085A -19-26FEB13-3/16

CM073510336 —UN—19MAR08

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. 4. Remove end cover (2). 2— Cover 3— Housing

7— Pins (2 used)

Continued on next page

TM100419 (02APR13)

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PW66162,000085A -19-26FEB13-4/16

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). 4— Gear Assembly 8— Trust Plate (2 used)

CM073510337 —UN—19MAR08

1— Front Cover 3— Housing

PW66162,000085A -19-26FEB13-5/16

6. Place front cover (1) in a vise with mounting flange upward.

1— Front Cover

CM073510338 —UN—19MAR08

7. Remove snap ring (9) using a pair of snap ring pliers. 9— Snap Ring

Continued on next page

TM100419 (02APR13)

70-25-60

PW66162,000085A -19-26FEB13-6/16

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).

CM073510339 —UN—19MAR08

9. Clean and inspect all parts for wear or damage, replace if necessary. 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 13— Seal

15— Spacer 16— Spacer PW66162,000085A -19-26FEB13-7/16

Assemble

NOTE: Replacement is necessary only if parts 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

CM073510340 —UN—19MAR08

1. Place front cover (1) in a vise with mounting flange upward.

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. CM073510341 —UN—19MAR08

Install seal with metal side upward. 3. Using an appropriate driver, install seal (13) into front cover (1). 4. Wipe off excess sealant. 1— Front Cover

13— Seal

Continued on next page

TM100419 (02APR13)

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PW66162,000085A -19-26FEB13-9/16

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). 15— Spacer 16— Spacer

CM073510342 —UN—19MAR08

1— Front Cover 9— Snap Ring

CM073510343 —UN—19MAR08

PW66162,000085A -19-26FEB13-10/16

7. Lubricate and install new seals (14) into grooves in each side of housing (3).

8. Place housing onto front cover (1) and tap with a 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). 11— Seal (4 used) 12— Seal (4 used)

CM073510344 —UN—19MAR08

8— Trust Plate (2 used) 10— Seal (2 used)

Continued on next page

TM100419 (02APR13)

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PW66162,000085A -19-26FEB13-12/16

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=426

Hydraulic Motors

NOTE: Housing shown removed from front cover for clarity.

1— Front Cover 3— Housing

CM073510345 —UN—19MAR08

10. Carefully install one thrust plate (8) through housing (3) and into place onto front cover (1). 8— Trust Plate

PW66162,000085A -19-26FEB13-13/16

11. Lightly lubricate drive shaft from gear assembly (4). NOTE: Avoid damaging seal (13). CM073510347 —UN—19MAR08

12. Install drive shaft through front cover (1) Rotate and 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 3— Housing

4— Gear Assembly 8— Thrust Plate Assembly

PW66162,000085A -19-26FEB13-14/16

NOTE: Ensure that housing seals remain in position.

CM073510348 —UN—19MAR08

15. Install end cover (2). Align pins with the holes in housing (3). 16. Tap end cover lightly in the center to engage pins. 2— End Cover

3— Housing

Continued on next page

TM100419 (02APR13)

70-25-63

PW66162,000085A -19-26FEB13-15/16

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=427

Hydraulic Motors

17. Install new washers (18) and cap screws (5). Torque to specification. 5— Cap Screw (4 used) 18— Washer (4 used)

CM073510349 —UN—19MAR08

1— Front Cover 2— End Cover 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

CM073510283 —UN—12SEP07

Disassemble and Assemble Secondary Extractor Rotate Motor

1— Cap Screw 2— Cover 3— Seal 4— Seal Ring 5— Commutator Ring

6— Commutator Plate 7— Manifold 8— Rotor 9— Plate 10— Link

11— Key 12— Shaft 13— Bearing 14— Thrust Washer 15— Bearing Continued on next page

TM100419 (02APR13)

70-25-65

16— Seal 17— Washer 18— Housing 19— Bearing 20— Seal PW66162,000085F -19-26FEB13-1/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=429

Hydraulic Motors

• Torque Wrench — lb.-ft. (N·m) • Sockets: 1/2 or 9/16 in. thin wall • Allen Sockets: 3/16 and 3/8 in. • Adjustable Crescent Wrench • SAE 10W40 SE or SF oil • Special Bearing Mandrel • Feeler Gauge 0.005 in. (.13 mm) • Blind Hole Bearing Puller • Corrosion Resistant Grease

Suggested Tools

• Clean, petroleum-based solvent • Emery paper • Vise with soft jaw • Air pressure source • Arbor Press • Screw Driver • Masking Tape • Breaker Bar

PW66162,000085F -19-26FEB13-2/42

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

Disassemble

PW66162,000085F -19-26FEB13-3/42

CM073510285 —UN—26MAR08

2. Remove cap screws (1).

Continued on next page

TM100419 (02APR13)

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PW66162,000085F -19-26FEB13-4/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=430

Hydraulic Motors

CM073510286 —UN—26MAR08

3. Inspect cap screws for damaged threads, or sealing rings under cap screw head. Replace damaged cap screws.

PW66162,000085F -19-26FEB13-5/42

CM073510287 —UN—12SEP07

4. Remove end cover (2) and O-ring seal (4). Discard O-ring.

PW66162,000085F -19-26FEB13-6/42

CM073510288 —UN—26MAR08

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.

Continued on next page

TM100419 (02APR13)

70-25-67

PW66162,000085F -19-26FEB13-7/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=431

Hydraulic Motors

CM073510289 —UN—26MAR08

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. 6. Remove commutator plate (6). Inspect the plate for cracks or burrs.

CM073510291 —UN—26MAR08

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, burrs, wear, or scoring. If any of these conditions exist, replace the commutator plate (6) and commutator ring (5) as a matched set.

CM073510290 —UN—26MAR08

PW66162,000085F -19-26FEB13-8/42

Continued on next page

TM100419 (02APR13)

70-25-68

PW66162,000085F -19-26FEB13-9/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=432

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 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.

CM073510292 —UN—26MAR08

Hydraulic Motors

PW66162,000085F -19-26FEB13-10/42

CM073510293 —UN—26MAR08

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.

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. 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

TM100419 (02APR13)

70-25-69

CM073510294 —UN—26MAR08

PW66162,000085F -19-26FEB13-11/42

PW66162,000085F -19-26FEB13-12/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=433

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 centerline. If there is more than 0.005 inches (0.13 mm) of clearance, replace the rotor set.

CM073510295 —UN—26MAR08

Hydraulic Motors

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.

CM073510296 —UN—26MAR08

13. Inspect the drive link for cracks, worn or damaged splines. No end play should be observed between 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. CM073510297 —UN—26MAR08

16. Remove key (11).

Continued on next page

TM100419 (02APR13)

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PW66162,000085F -19-26FEB13-15/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=434

Hydraulic Motors

NOTE: A slight “polish” is permissible in the shaft 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.

CM073510298 —UN—26MAR08

NOTE: Minor shaft wear in the seal area is permissible. If wear exceeds 0.020 inches (0.51 mm) diametrically, replace coupling shaft.

18. Inspect for damaged or worn internal and external splines or keyway. Replace the coupling shaft if necessary.

CM073510299 —UN—26MAR08

19. Remove and discard seal (4) from housing (18).

PW66162,000085F -19-26FEB13-16/42

20. Remove thrust bearing (15) and thrust washer (14).

CM073510300 —UN—26MAR08

21. Inspect for wear and corrosion. Be sure that all rollers are in place in the thrust bearing.

Continued on next page

TM100419 (02APR13)

70-25-71

PW66162,000085F -19-26FEB13-17/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=435

Hydraulic Motors

CM073510301 —UN—26MAR08

22. Remove and discard seal (16) and back up washer (17) from housing (18).

PW66162,000085F -19-26FEB13-18/42

CM073510302 —UN—26MAR08

23. Remove housing (18) from the vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is required.

PW66162,000085F -19-26FEB13-19/42

CM073510303 —UN—26MAR08

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 areas, discard the housing assembly.

Continued on next page

TM100419 (02APR13)

70-25-72

PW66162,000085F -19-26FEB13-20/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=436

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 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.

CM073510304 —UN—26MAR08

Hydraulic Motors

PW66162,000085F -19-26FEB13-21/42

CM073510307 —UN—26MAR08

CM073510306 —UN—26MAR08

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 previously retained in the housing by bearing (13).

Continued on next page

TM100419 (02APR13)

70-25-73

PW66162,000085F -19-26FEB13-22/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=437

Hydraulic Motors Assemble

CM073510308 —UN—26MAR08

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. 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.

CM073510309 —UN—26MAR08

If the bearing mandrel specified is not available and alternate methods are used to press in bearing/bushing (13) and (19), the bearing/bushing 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 bearing/bushing into counter bore at mounting flange end of the housing. Install bearing/bushing to a depth

0.151—0.161 inches (3.84—4.09 mm) from the end of bearing counter bore. PW66162,000085F -19-26FEB13-23/42

CM073510310 —UN—26MAR08

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 bearing/bushing (19).

Continued on next page

TM100419 (02APR13)

70-25-74

PW66162,000085F -19-26FEB13-24/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=438

Hydraulic Motors

CM073510312 —UN—26MAR08

CM073510311 —UN—26MAR08

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.

PW66162,000085F -19-26FEB13-25/42

CM073510313 —UN—26MAR08

4. Clamp housing mounting flange into a soft-jawed vise with coupling shaft bore downward.

Continued on next page

TM100419 (02APR13)

70-25-75

PW66162,000085F -19-26FEB13-26/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=439

Hydraulic Motors

CM073510315 —UN—11SEP07

CM073510314 —UN—26MAR08

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).

Continued on next page

TM100419 (02APR13)

70-25-76

PW66162,000085F -19-26FEB13-27/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=440

Hydraulic Motors

CM073510317 —UN—11SEP07

CM073510316 —UN—26MAR08

6. Assemble thrust washer (14) then thrust bearing (15).

PW66162,000085F -19-26FEB13-28/42

CM073510318 —UN—26MAR08

7. Apply masking tape around the splines or keyway shaft (12) to prevent damage to the seal.

Continued on next page

TM100419 (02APR13)

70-25-77

PW66162,000085F -19-26FEB13-29/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=441

Hydraulic Motors

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.

CM073510319 —UN—26MAR08

IMPORTANT: Outer bearing (19) is NOT lubricated by hydraulic system oil. Be sure that bearing is thoroughly lubricated with recommended grease.

PW66162,000085F -19-26FEB13-30/42

9. Apply a small amount of grease to a new seal ring (4) and insert it into the housing (18) seal ring groove.

CM073510320 —UN—26MAR08

NOTE: Two alignment studs installed finger tight into housing (18) cap screw holes, approximately 180 degrees apart, aids in assembly and alignment of components.

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. CM073510321 —UN—26MAR08

10. Install drive link (10) with the long splined end downward into coupling shaft (12). Engage drive link splines with coupling shaft splines.

Continued on next page

TM100419 (02APR13)

70-25-78

PW66162,000085F -19-26FEB13-32/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=442

Hydraulic Motors

CM073510322 —UN—26MAR08

11. Assemble wear plate (9) over the drive link (10) and alignment stubs onto the housing (18).

PW66162,000085F -19-26FEB13-33/42

CM073510323 —UN—26MAR08

12. Lubricate and install a new seal ring (4) into groove on wear plate side of rotor set.

PW66162,000085F -19-26FEB13-34/42

NOTE: Rotor set counter bore side must be down against 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).

CM073510324 —UN—26MAR08

NOTE: If necessary, remove one alignment stud out of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over drive link.

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

TM100419 (02APR13)

70-25-79

PW66162,000085F -19-26FEB13-35/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=443

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 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).

CM073510325 —UN—26MAR08

Hydraulic Motors

PW66162,000085F -19-26FEB13-36/42

NOTE: Be sure that the correct manifold surface is against the rotor set.

CM073510326 —UN—26MAR08

15. Install manifold (7) over alignment studs, drive link (10), and onto rotor set.

PW66162,000085F -19-26FEB13-37/42

CM073510327 —UN—26MAR08

16. Lubricate and install a new seal ring (4) into groove exposed on manifold.

Continued on next page

TM100419 (02APR13)

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PW66162,000085F -19-26FEB13-38/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=444

Hydraulic Motors

CM073510328 —UN—26MAR08

17. Install commutator plate (6) over alignment studs onto the manifold.

PW66162,000085F -19-26FEB13-39/42

18. with flat side upward, lubricate and install a new seal ring (3) into commutator ring (5).

CM073510329 —UN—26MAR08

CQ280284 —UN—19MAR08

19. Install commutator ring over the end of drive link (10) and onto manifold (7) with seal ring side upward.

Continued on next page

TM100419 (02APR13)

70-25-81

PW66162,000085F -19-26FEB13-40/42

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).

CM073510330 —UN—26MAR08

CQ280283 —UN—19MAR08

21. Install end cover over alignment studs and onto the commutator set.

Continued on next page

TM100419 (02APR13)

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PW66162,000085F -19-26FEB13-41/42

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=446

Hydraulic Motors

22. Install cap screws (1) into open holes in end cover.

24. Using an alternating pattern, tighten end cover cap screws to specification.

CM073510332 —UN—26MAR08

CQ280282 —UN—19MAR08

CM073510331 —UN—26MAR08

Specification Secondary Extractor Rotate Motor End Cover Cap Screws—Torque....................................................................32 N·m (24 lb.-ft.)

CQ280285 —UN—20MAR08

23. Remove alignment studs and install remaining end cover cap screws.

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.

CM053510252 —UN—24MAR08

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. 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.

CM053510253 —UN—24MAR08

5. If the shaft is deeply grooved, insert a shim behind the seal to reposition the seal on the shaft. 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 B—Shim Continued on next page

TM100419 (02APR13)

70-25-84

C—Grooves

PW66162,0000860 -19-28FEB13-1/2

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. CM053510254 —UN—16AUG05

11. Inspect the O-ring groove and the valve plate. Lightly grease a new O-ring and install into valve plate groove. 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 bolts and torque to 86 N·m (63.4 lb.-ft.). Disassemble 1. Tape the splines on shaft and mark position of the cover plate assembly. 2. Remove bolts from the cover plate. Remove cover plate and control plate. 3. Carefully remove the cylinder. Do not damage it in any way. 4. Remove the circlip and front cover. 5. Remove the shims. 6. Using a puller, remove the rotary group as a complete unit. 7. Remove rotary group retaining plate. The bolts are held by Loctite. Clean and Inspect

5. If pistons are changed, they should only be replaced as a complete set. When changing other components, recalibration is required. 6. The cylinder block and control plate must be replaced as a set. Assemble 1. Insert the center pin with retaining ring. Correctly fit the retaining plate. 2. Apply Thread Lock and Sealer (Medium Strength) sparingly to bolt only. 3. Heavily grease and install the spring pad and Belleville washers as shown. Make sure that all parts are installed in their correct position. 4. Install the pistons in their bores. 5. Press the pistons firmly into the cups while holding the cylinder block in a central position. Swivel the cylinder block to maximize the angle.

1. Inspect the drive shaft for corrosion or erosion. Check for damage to the splines and traces of wear scratches. Make sure that bearing cups are free from

6. Make sure that a new shaft seal has been installed.

2. Inspect the piston, center pin, and retaining plate for scratches, wear and pitting.

8. Turn the motor over and install the shims.

3. Inspect the cylinder bores for scratches and wear. Check the cylinder block and control plate for cracks, scratches, and unevenness. It should have a minimum hardness of 700 HV10. 4. Check for damage or wear where the bearings fit into the housing.

7. Heat the housing to 80 °C (176 °F) and install it over the rotating group, until the housing stops.

9. If the shaft is deeply grooved, insert a shim behind the seal. 10. Install a new O-ring, ensure that it is a snug fit. Grease the O-ring and lips of the shaft seal and install the cover. 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

CM002500259 —UN—12JUL00

Variable Displacement Ground Drive Motor Exploded View (Optional)

Continued on next page

TM100419 (02APR13)

70-25-86

PW66162,000098D -19-27FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=450

Hydraulic Motors 1— Ring-Distance 2— Ring Kit-Piston 3— Shaft Assembly 4— O-ring 5— O-ring 6— Housing-Bearing 7— Ring-Retaining 8— O-ring 9— Seal-Lip 10— Carrier-Seal 11— Bolt 12— O-ring 13— Housing-Motor 14— Shaft-Synch 15— Roller 16— Pin-Support 17— Block-Cylinder

18— Bearing 19— Pin 20— Plate-Bearing 21— Valve-Segment 22— Gasket-End Cap 23— Pin 24— Housing 25— Ring-Seal 26— Lever-Feedback 27— Bolt 28— Bolt 29— Piston-Servo 30— Nut-Seal Lock 31— Bolt 32— O-ring 33— Bolt 34— Nut 35— O-ring 36— O-ring 37— Bolt

38— Bolt 39— Plug 40— O-ring 41— Bolt 42— O-ring 43— Cover-Piston 44— Bolt 45— Plug 46— O-ring 47— O-ring 48— Plug 49— O-ring 50— Spring 51— Guide-Spring 52— Piston 53— Guide-Spring 54— Spring 55— Seat-Spring 56— Spring 57— Seat-Spring 58— Bushing Assy

59— O-ring 60— Ring 61— Plug 62— Bolt 63— Filter-Screen 64— O-ring 65— Orifice 66— Nut-Seal 67— Cap 68— Plug 69— O-ring 70— Bolt 71— Plug 72— Orifice 73— Spool 74— Plug 75— Relief-Charge 76— Spring 77— Poppet

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)

6— Bearing Housing

7— Retaining Ring

CM073510352 —UN—19MAR08

CM073510351 —UN—19MAR08

CM002500263 —UN—12JUL00

CM073510350 —UN—19MAR08

Replace Shaft Seal

8— O-Ring 10— Seal Carrier

IMPORTANT: Absolute cleanliness is essential when working with hydraulic components. Contamination can result in serious damage or inadequate operation. Clean all parts with solvent and blow dry with compressed air. Avoid damage to machined surfaces when clamping parts in a vise. Replace all seals, O-rings, and gaskets whenever motor is repaired. Cap and plug all open hoses and fittings. NOTE: Lip seals can be replaced without major disassembly of motor. However, replacement

of shaft seal requires removal of the motor from final drive. 1. Remove and discard outer O-ring (12) from bearing housing (6). 2. Remove retaining ring (7) from bearing housing. NOTE: Do not damage bearing housing bore or shaft during seal carrier removal. 3. Carefully remove seal carrier (10) from bearing housing. 4. Remove O-ring (8) from bearing housing. Continued on next page

TM100419 (02APR13)

70-25-88

PW66162,0000862 -19-26FEB13-1/23

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.

10— Seal Carrier

CM073510354 —UN—12SEP07

9— Seal

CM073510353 —UN—19MAR08

7. Inspect seal contact area on shaft for rust, wear, or contamination.

Continued on next page

TM100419 (02APR13)

70-25-89

PW66162,0000862 -19-26FEB13-2/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=453

Hydraulic Motors

NOTE: Apply a sealant to outside surface of the seal prior to installation into seal carrier. This prevents 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.

CM073510355 —UN—19MAR08

8. Lubricate and install new O-ring (8) into the groove of bearing housing (6).

11. Install carrier assembly onto shaft and into bore of bearing housing.

9— Seal 10— Seal Carrier 12— Outer O-Ring

CM073510357 —UN—19MAR08

3— Shaft 6— Bearing Housing 7— Retaining Ring 8— O-Ring

CM073510356 —UN—19MAR08

12. Install retainer ring (7) and outer O-ring (12).

Continued on next page

TM100419 (02APR13)

70-25-90

PW66162,0000862 -19-26FEB13-3/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=454

Hydraulic Motors

CM073510358 —UN—12SEP07

Disassemble Cartridge

1— Distance Spacer Ring 3— Shaft Assembly

4— O-ring 5— O-ring 6— Bearing Housing

7— Retaining Ring 11— Cap Screw 13— Motor Housing Continued on next page

TM100419 (02APR13)

70-25-91

PW66162,0000862 -19-26FEB13-4/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=455

Hydraulic Motors

1. Remove and discard O-ring (12).

3. Remove seal carrier (10), seal (9), and O-ring (8) from shaft assembly (3). 3— Shaft Assembly 6— Bearing Housing 7— Retaining Ring 8— O-Ring

9— Seal 10— Seal Carrier 12— O-Ring

CM073510359 —UN—19MAR08

2. Remove retaining ring (7)..

PW66162,0000862 -19-26FEB13-5/23

4. Remove cap screws (11). 5. Separate bearing housing (6) from motor housing (13). CM073510360 —UN—19MAR08

13— Motor Housing

CM073510361 —UN—19MAR08

6— Bearing Housing 11— Cap Screw

Continued on next page

TM100419 (02APR13)

70-25-92

PW66162,0000862 -19-26FEB13-6/23

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). CM073510362 —UN—19MAR08

5— O-Ring 6— Bearing Housing

CM073510363 —UN—19MAR08

1— Spacer Ring 4— O-Ring

PW66162,0000862 -19-26FEB13-7/23

CM073510364 —UN—19MAR08

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).

Continued on next page

TM100419 (02APR13)

70-25-93

PW66162,0000862 -19-26FEB13-8/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=457

Hydraulic Motors

CM073510365 —UN—19MAR08

9. Remove inner ring (7) from bearing housing (6).

PW66162,0000862 -19-26FEB13-9/23

CM073510366 —UN—19MAR08

Disassemble and Assemble Housing Assembly

24— End Cover Housing 25— Seal Ring

26— Feed Back Lever 27— Pointed Set Screw

28— Lock Screw 29— Servo Piston Continued on next page

TM100419 (02APR13)

70-25-94

61— Plug PW66162,0000862 -19-26FEB13-10/23

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).

28— Lock Screw 61— Plug

CM073510369 —UN—19MAR08

CM073510368 —UN—19MAR08

24— End cap 26— Feedback Lever 27— Pointed Set Screw

CM073510367 —UN—19MAR08

3. Remove feedback lever (26) through the port in end cap.

Continued on next page

TM100419 (02APR13)

70-25-95

PW66162,0000862 -19-26FEB13-11/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=459

CM073510370 —UN—19MAR08

Hydraulic Motors

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

TM100419 (02APR13)

70-25-96

PW66162,0000862 -19-26FEB13-12/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=460

Hydraulic Motors

1. Lubricate and install seal (25) onto servo piston (29).

CM073510371 —UN—19MAR08

NOTE: End of servo piston with seal is located opposite the multifunction block/control mounting surface of the end cap. 2. Lubricate and install servo piston into end cap (24). 29— Servo Piston

CM073510372 —UN—19MAR08

24— End cap 25— Seal

Continued on next page

TM100419 (02APR13)

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PW66162,0000862 -19-26FEB13-13/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=461

CM073510374 —UN—19MAR08

Hydraulic Motors

NOTE: Off set of feedback lever must be located away from the multifunction block control of end cap.

CM073510373 —UN—19MAR08

3. Install feedback lever (26) into the servo piston (29) through the port in end cap housing (24). 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 24— End Cap 26— Feedback Lever

29— Servo Piston 27— Pointed Set Screw

Continued on next page

TM100419 (02APR13)

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PW66162,0000862 -19-26FEB13-14/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=462

CM073510375 —UN—19MAR08

Hydraulic Motors

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 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.)

CM073510367 —UN—19MAR08

5. Install plug (61) into end cap.

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

TM100419 (02APR13)

70-25-99

PW66162,0000862 -19-26FEB13-15/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=463

Hydraulic Motors

CM053510150 —UN—21JUL05

Reconditioning and Replacement of Shaft Assembly

A—Speed Sensor Ring B—Piston Assemblies

E—Bearing F— Bearing Retaining Nut G—Seal Area

C—Synchronizing Shaft Insert D—Bearing

There is an optional magnetic speed sensor ring (A) that is pressed into a machined surface of the output shaft flange. NOTE: Do not damage the magnetic speed sensor ring. Check the seal area of the shaft (G) and the output splines for damage or wear. Inspect the synchronizing shaft insert (C) and the spring seat (H) for wear. The internal spring must not be damaged. These parts are retained by three hardened steel pins pressed into blind holes in the synchronizing shaft insert (C), and are not individually serviceable. Inspect shaft bearings (D and E) for wear and roughness. Check that the bearing retaining nut (F) is firmly staked to the output shaft, and that no noticeable looseness is present in the bearings (D and E).

NOTE: If the bearing adjustments for used bearings are incorrect or if used bearings must be replaced, a complete shaft assembly including pistons and new bearings must be installed. Check the piston assemblies (B) for damage and wear. It is normal for the piston balls to be tight in their sockets. The piston sockets are retained in the output shaft by an interference press fit. NOTE: If a piston(s) must be replaced, this entire assembly, including pistons and new bearings, must be installed. The replacement output shaft assembly includes pistons and bearings.

Continued on next page

TM100419 (02APR13)

H—Spring Seat

70-25-100

PW66162,0000862 -19-26FEB13-16/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=464

Hydraulic Motors

CM073510376 —UN—12SEP07

Reconditioning and Replacement of Bearing Plate, Valve Segment, and Cylinder Block

17— Cylinder Block

20— Bearing Plate

21— Valve Segment PW66162,0000862 -19-26FEB13-17/23

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.

CM073510377 —UN—12SEP07

Continued on next page

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=465

Hydraulic Motors

CM073510378 —UN—12SEP07

2. Inspect the valve segment (21) for damage or wear on the sealing surfaces. Inspect the spindle (B) for wear.

PW66162,0000862 -19-26FEB13-19/23

CM073510379 —UN—12SEP07

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.

PW66162,0000862 -19-26FEB13-20/23

CM073510380 —UN—12SEP07

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 cylinder block (17) requires replacement, remove the bearing using a suitable puller.

Continued on next page

TM100419 (02APR13)

70-25-102

PW66162,0000862 -19-26FEB13-21/23

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=466

Hydraulic Motors

CM073510381 —UN—12SEP07

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” (11.75 + 0.25 mm).

PW66162,0000862 -19-26FEB13-22/23

CM053510151 —UN—21JUL05

Piston Ring Reconditioning and Replacement

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 removal of the piston rings from the pistons. Install new piston rings onto the pistons. NOTE: When installing new spherical piston rings, make sure that the spherical surface conforms to the shape of the piston.

A radial identification mark provided on the outer side of the piston rings must NOT overlap each other. IMPORTANT: Fill motor with clean hydraulic oil before start up.

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

TS281 —UN—23AUG88

Used to service nitrogen accumulators. 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.

T8130000586 —UN—05FEB13

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. 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.

T8130000588 —UN—05FEB13

NOTE: Right-hand base cutter accumulator shown. Procedure for left-hand base cutter and crop 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. A—Cap

CAUTION: Pressure MUST be relieved in floating crop divider valve before servicing crop divider accumulator. (See Remove and Install Floating Crop Divider Valves in Section 70, Group 15 for pressure release procedure.) 5. For floating crop divider valve accumulators, relieve pressure. 6. Remove cap (A). CAUTION: Internal hex plug is under high pressure. Fully loosening or removal of internal

hex plug can allow pressurized nitrogen to escape and eject internal hex plug from accumulator causing serious injury to you or others. IMPORTANT: Before connecting JDG11007 Nitrogen Accumulator Service Kit to accumulator, slightly loosen accumulator internal hex plug to avoid damage to service kit. 7. Loosen accumulator internal hex plug. Continued on next page

TM100419 (02APR13)

B—Internal Hex Plug

70-30-2

PW66162,0000845 -19-28FEB13-1/2

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.

T8130000587 —UN—05FEB13

8. For checking accumulator (D), install JDG11007 Nitrogen Accumulator Service Kit1 to accumulator. 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). A—Ratchet B—Gas Cocks (2 used) C—Pressure Gauge

D—Accumulator E—Accumulator Valve F— Knurled Screw

NOTE: 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. Close gas cocks and accumulator valve.

11. Adjust accumulator charge pressure to specification.

13. Remove service kit and tighten accumulator hex plug to specification.

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)

Specification Accumulator Internal Hex Plug—Torque.................................................................................20 N·m (15 lb.-ft.)

14. Install cap.

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

TS281 —UN—23AUG88

•

Used to connect dry nitrogen bottle to JDG10976 Nitrogen Accumulator Service Kit. Tool Number—JT05711 Nitrogen Accumulator Service Kit Used to service nitrogen accumulators. Tool Number—JDG10976

T8130000598 —UN—11FEB13

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 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) B—Cap

Use only dry nitrogen to charge accumulator. Never fill accumulator with oxygen. An explosion could result, if oil and oxygen mix under pressure. Never charge accumulator over recommended pressure.

C—Accumulator D—Hose

6. Remove nuts, cap screws (A), and accumulator. 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

TM100419 (02APR13)

70-30-4

PW66162,0000949 -19-15FEB13-1/2

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.

T8130000685 —UN—15FEB13

NOTE: If the accumulator is not connected to an external nitrogen source under pressure, pressure is reduced by opening gas cock valve. 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 B—Valve C—Regulator

Specification Topper Accumulator Charge—Pressure.................................................................... 6 550 kPa (65.5 bar) (950 psi) Elevator Accumulator Charge—Pressure.................................................................... 8 274 kPa (82.7 bar) (1 200 psi)

13. If pressure is not to specification, close regulator output valve.

D—Dry Nitrogen Tank E—Accumulator F— Gas Cock Valve

17. Charge accumulator until output gauge reads specification with dry nitrogen tank valve closed. 18. Close valve on dry nitrogen tank and regulator output valve. 19. Turn gas cock valve attached to accumulator counterclockwise. 20. Remove all adapters from accumulator.

14. Open valve (B) on dry nitrogen tank. 15. Adjust JT05711 Regulator until gauge reads correct pressure specification. 16. Open regulator output valve.

21. Remove service kit and install cap. 22. Install accumulator to harvester in reverse order of removal.

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

Contents

Section 80 Miscellaneous

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).

6. Install in reverse order of removal. E—Cap Screw (2 used) F— Engine Compartment Door G—Ladder

T8130000680 —UN—12FEB13

T8130000600 —UN—12FEB13

A—Cap Screw (2 used) B—U-Bolts (2 used) C—Cap Screw (5 used) D—Ladder Platform

T8130000599 —UN—12FEB13

5. Remove cap screws (E) and ladder (G).

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

Contents

Section 90 Operator's Station

Page Page

Group 05—Air Conditioning System Other Material................................................ 90-05-1 Special Tools ................................................. 90-05-1 Specifications ................................................ 90-05-2 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

Cab Door Latch Striker ................................ 90-20-13 Cab Tilt Procedure....................................... 90-20-14 Remove and Install Cab .............................. 90-20-15

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 System Flush

Used to flush air conditioning system.

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 Compressor

Torque

32—40 N·m (24—29 lb.-ft.)

Suction Line-to-Air Conditioning Compressor

Torque

34—42 N·m (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 Manifold Attaching Cap Screws

Torque

26 N·m (19 lb.-ft.) PW66162,00008E2 -19-09JAN13-1/1

Service Parts Kits The following kits are available through your parts catalog:

• Compressor Clutch Hub And Pulley Kit • 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 too diluted and shortening compressor life. Always use a recommended final flushing solvent after using a parts cleaning solvent for the primary flush.

FLUSHING: Flushing the system or a component is a cleaning process using a liquid solvent to remove oil and debris.

Failure to purge the system properly dilutes flushing solvent.

When to flush the air conditioning system:

• The compressor has an internal failure. • No oil remains in used compressor. • Oil drained from compressor appears or smells

Use 0.47 L (1 pt.) of clean solvent for flushing a serviceable compressor that will be reinstalled on a machine.

overheated.

• System was contaminated with a mixture of refrigerant oils.

PURGING:

for dirt, moisture, or debris to enter the tubing or components. System has an internal blockage.

Purging the system or a component is a cleaning process using a gas to force liquid from the system. Purging alone cannot completely remove refrigerant oil from the system.

• System was left open to the atmosphere long enough •

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 refrigerants.

IMPORTANT: Use only fresh solvent for the primary flush.

• System was left open to atmosphere and flushing could not be performed.

Automotive parts cleaning solvent used according to applicable guidelines can be utilized for a system primary flush. IMPORTANT: Do Not Use diesel fuel, gasoline, fuel oil, water, alcohol or any cleaning fluids formulated for dissolving oil, grease and antifreeze.

• Installation of new lines, condenser, or evaporator was required.

EVACUATING: Evacuating the system is a process to remove air and moisture from the system, by creating a vacuum. SOLVENTS

FINAL FLUSH:

• Use 1.9 L (1/2 gal.) ACC-U-FLUSH II® Air Conditioning System Flush.

• Review applicable MSDS data for hazard identification rating.

• Separate the air conditioning system into two circuits and follow the flushing procedure listed in this group.

• Recover all used solvents with appropriate flushing equipment.

• Purge the air conditioning system with compressed air for the recommended amount of time specified in the flushing procedure.

ACC-U-FLUSH II® Air Conditioning System Flush is the solvent is recommended for flushing air conditioning systems. NOTE: New solvent used from a parts cleaning tank can be used, providing a final flush with ACC-U-FLUSH II® Air Conditioning System Flush is performed. Parts tank solvents do not evaporate at temperatures below 60 °C (140 °F). ACC-U-FLUSH II® Air Conditioning System Flush is necessary for the final flush because it evaporates quickly and is easily removed. PW66162,00008E4 -19-09JAN13-1/1

Hose and Tubing O-Ring Connection Torques Metal Tube Outside Diameter

Torque

Thread and Fitting Size 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 discharge of any refrigerant into the atmosphere and requires that refrigerant be recovered using the approved recovery equipment. IMPORTANT: Use correct refrigerant recovery, recycling, and charging stations. DO NOT mix refrigerant, hoses, fittings, components, or refrigerant oils.

Systems containing R-12 refrigerant use different oil than systems using R-134a. Certain seals are not compatible with refrigerant. The difference in the refrigerant oils is that R-12 systems use a MINERAL BASED OIL. R-134a systems use a SYNTHETIC OIL called PAG (polyakyleneglycol). These two oils are NOT COMPATIBLE and MUST NOT be 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 contact eyes or skin. Liquid refrigerant can freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment. DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element, and lighted smoking materials.

DO NOT heat refrigerant over 52 °C (125 °F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with your bare hands. Skin can freeze to container. Wear gloves. If skin freezes to container, pour COOL water over container to free skin. Go to a physician or hospital immediately for treatment. PW66162,00008E7 -19-09JAN13-1/1

TM100419 (02APR13)

90-05-4

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=484

Air Conditioning System JT02178-5 R-134a Dye Injector.1 Install low-side hose to outlet of JT02178-5 R-134a Dye Injector.

Leak Test With Dye SPECIAL TOOLS NEEDED:

4. Purge air from low-side hose and dye injector to remove air and impurities.

• Enhancer Glasses • • •

Used to enhance testing dye. Tool Number—JT02178-4 Ultra Violet Lamp Used to detect testing dye. Tool Number—JT02178-1 Recovery, Recycling, and Recharging Unit Used to service air conditioning system. Tool Number—JDG10555 R-134a Dye Injector Used to inject testing dye. Tool Number—JT02178-5

5. Close both valves on JT02178-5 R-134a Dye Injector and carefully remove cap. Add R-134a Refrigerant/PAG Oil Dye into injector and close cap tightly. 6. Open dye injector outlet side valve first and then open inlet valve. Recharging air conditioning system carries dye into system. 7. Run harvester with air conditioning on for 15 minutes to circulate refrigerant and dye.

CAUTION: Always wear safety glasses when working with refrigerants. Contact with refrigerant can cause serious injury. IMPORTANT: Use only approved dye in John Deere systems, other dyes may not have compatible oil for R-134a systems. DO NOT allow dye to come into contact with vehicle painted surfaces. Wipe off IMMEDIATELY in case of spillage.

Check For Leaks in System 1. Perform an operational check to be sure that air conditioning system is functioning properly to circulate dye. CAUTION: Light is made for intermittent use ONLY. DO NOT hold light switch on for more than 5 minutes at one time. DO NOT touch lens end of light when hot. NEVER look directly into light or expose skin. DO NOT operate light with cracked lens or broken housing. Always wear JT02178-4 Enhancer Glasses when using light.

Check for presence of dye in system: If dye has been installed in the system, the receiver dryer should be tagged with a decal.

Turn off sugar cane harvester before testing components.

If necessary, add dye to system. 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 Dye Injector when injecting dye.

2. Shut off engine and remove key.

If system is at full charge or unknown, recover a minimum of 0.23 kg (0.5 lb.) of refrigerant before attempting to inject dye. 1. Perform an operational check on system before trying to inject dye. 2. Recover refrigerant as necessary. (See Discharge and Recover Air Conditioning System in Section 90, Group 05.)

3. Put on JT02178-4 Enhancer Glasses1 before using light. 4. Shine JT02178-1 Ultra Violet Lamp1 on components to test for leaks. Leaks are indicated by a yellow tint on components where dye has left system. 5. Clean area of leak using Fluorescent Dye Cleaner and recheck to confirm leak is still present. 6. Repair air conditioning system as necessary. 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.

•

g. Repeat previous two steps at least three times.

• • • • • • •

Air Conditioning Flusher Used to flush air conditioning system. Tool Number—JT02075 Fitting Used to connect caps. Tool Number—JT02099 Fitting Used to connect caps. Tool Number—JT02100 Cap Used to cap opening. Tool Number—JT03194 Adapter Used to connect flusher. Tool Number—JT02102 Adapter Used to connect flusher. Tool Number—JT03197 Adapter Used to connect flusher. Tool Number—JT02101 Adapter Used to connect flusher. Tool Number—JT03188

4. Remove and discard receiver dryer. 5. Flushing can be performed on harvester. Divide system into two circuits:

• Condenser, including inlet and outlet hoses. (Steps 6 through 13)

• Evaporator, including inlet and outlet hoses. (Steps 14 through 30)

Flush/Purge Condenser: IMPORTANT: DO NOT attempt to flush through compressor or receiver dryer. Flushing through expansion valve or orifice tube is acceptable if refrigerant oil has a normal odor and appearance. 6. Connect flusher outlet hose to inlet connection of compressor discharge line using JT02102 Adapter1 to flush condenser. 7. Attach a return hose and aerator nozzle to receiver dryer inlet line using JT03197 Adapter1. Put nozzle in container to collect flushing solvent.

1. Discharge system. (See Discharge and Recover Air Conditioning System in Section 90, Group 05.) NOTE: Add flushing solvent to system with JT02075 Air Conditioning Flusher1. If compressor is being replaced, go to step 4. 2. Remove compressor and measure oil drained from both manifold ports.

8. Fill flusher tank with 4 L (1 gal.) of solvent and fasten all connections.

3. Clean compressor as follows: IMPORTANT: Keep fluid loss at a minimum. ACC-U-FLUSH II® Air Conditioning System Flush evaporates at 85 °F. Keep container lids on at all times when not in use. a. Pour 240 mL (8 fl oz.) of ACC-U-FLUSH II® Air Conditioning System Flush into suction port and 120 mL (4 fl oz.) into discharge port. Plug both ports in compressor manifold, using JT020991 and JT021001 with JT031941 Caps. b. Turn compressor end for end and roll compressor side to side. c. Remove both plugs from manifold ports and drain solvent from compressor. d. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders. e. Invert compressor, roll to all sides, and drain thoroughly.

NOTE: New solvent used from a parts cleaning tank can be used, providing a final flush with ACC-U-FLUSH II® Air Conditioning System Flush is performed. Parts tank solvents do not evaporate at temperatures below 60 °C (140 °F). ACC-U-FLUSH II® Air Conditioning System Flush is necessary for the final flush because it evaporates quickly and is easily removed.

NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging. 9. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve. 10. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles. 11. Continue forcing air through system to purge out solvent. Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent. 12. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry. 13. Solvent from condenser that is not contaminated with burnt oil or metal particles can be used to flush evaporator. Used solvent can be placed into a shop parts cleaner. Continued on next page

TM100419 (02APR13)

90-05-6

PW66162,00008E9 -19-09JAN13-1/2

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 with shop air through the flushing equipment.

14. Flush evaporator through expansion valve if oil appears normal.

e. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard and continue purging until cardboard is dry.

15. Connect flusher outlet hose to compressor suction line using JT02101 Adapter1. 16. Attach a hose and aerator nozzle to receiver dryer outlet line using JT03188 Adapter1. Put nozzle in container to collect flushing solvent.

f. After flushing both circuits, put used ACC-U-FLUSH II® Air Conditioning System Flush in a separate, clean container and cap immediately.

17. Repeat Steps 8, 9, and 10 to flush evaporator. 18. Purging the evaporator circuit takes 12—15 minutes to thoroughly remove solvent. 19. If system is contaminated with burned refrigerant oil or debris, remove expansion valve to flush evaporator. 20. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry.

NOTE: Identify the container as ACC-U-FLUSH II® Air Conditioning System Flush). This solvent can be used to flush additional machines. Dispose of solvent that has an excessive amount of dilution from parts solvent used for primary flush. Dispose of solvent in compliance with local and state regulations. g. Cap system hoses or lines immediately after removal of test equipment to prevent moisture from entering the system.

21. Reinstall expansion valve. Final Flush 22. Final flush uses the same procedure as primary flush for condenser and evaporator, except for solvent used. a. Add 1.9 L (0.5 gal.) of ACC-U-FLUSH II® Air Conditioning System Flush to the flusher tank. b. Connect a supply line of moisture-free air or dry nitrogen to the flusher valve. NOTE: Air pressure must be at least 490 kPa (4.9 bar) (70 psi) but not more than 620 kPa (6.2 bar) (90 psi) maximum for final flushing and purging. c. Open the air valve to force flushing solvent into the condenser or evaporator circuit. Flusher is empty when hose pulsing stops. Reuse the same solvent to do both circuits.

23. Fasten connections and mounting brackets. 24. Install a new receiver dryer compatible with R-134a refrigerant. (See Replace Receiver Dryer in Section 90, Group 10.) 25. Add required oil. (See Determine Correct Oil Charge in Section 90, Group 05.) 26. Install compressor and connect refrigerant lines to manifold. 27. Connect clutch coil wire and install drive belt. 28. Purge system. (See Purge Air Conditioning System in Section 90, Group 05.)

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 compressor suction port and open valves.

SPECIAL TOOL NEEDED:

• Manifold with Gauges

Used to service air conditioning system. Tool Number—JT02051

IMPORTANT: Air compressors used for purging systems require a water separator. Purging without a separator adds moisture, creating hydrofluoric acid when combined with refrigerant oil. Acid is corrosive to metal tubing. 1. Connect dry nitrogen hose to JT02051 Manifold with Gauges1 center hose.

3. Connect Manifold with Gauges discharge hose to compressor discharge port and open valve. Disconnect discharge hose from Manifold with Gauges to allow purging nitrogen to atmosphere. 4. Open nitrogen tank valve and adjust regulator to 275 kPa (2.75 bar) (40 psi). Purge system for 2 minutes. Disconnect nitrogen supply. 5. Evacuate system. (See Evacuate Air Conditioning System in Section 90, Group 05.)

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. T8120002619 —UN—09JAN13

2. Open engine compartment door and remove protective 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 hydrocarbons. Mixing substitutes with approved John Deere products can cause contamination to air conditioning service equipment, components, and refrigerant supplies. 3. Connect JDG10555 Refrigerant, Recovery, and Recycling Unit1 to machine using the following instructions:

• •

Connect low-side hose (blue) (A) from charging unit to low pressure (suction) test port. Connect high-side hose (red) (B) to high pressure (discharge) test port.

IMPORTANT: DO NOT run compressor while evacuating the system. 4. Follow Recovery, Recycling, and Recharging Unit manufacturer's instructions for discharging system.

A—Low-Side Hose (blue)

B—High-Side Hose (red)

If 98 kPa (980 mbar) (29 in. Hg.) vacuum cannot be obtained in 15 minutes, test system for leaks. (See Leak Test With Dye in Section 90, Group 05.) Repair leaks as necessary. 7. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low-side and high-side valves. 8. Turn vacuum pump off. 9. If vacuum decreases more than 3.4 kPa (34 mbar) (1 in. Hg) in 5 minutes, there is a leak in the system. Repair as necessary. 10. Start the evacuating process.

• 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 conditions. Subtract 3.4 kPa (34 mbar) (29 in. Hg.) for each 300 m (1000 ft.) elevation above sea level. 6. Evacuate system until low-side gauge registers 98 kPa (980 mbar) (29 in. Hg.) vacuum.

• Close low and high-side valves. • Stop evacuation.

11. Charge system. (See Charge Air Conditioning System in Section 90, Group 05.)

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.

T8120002619 —UN—09JAN13

2. Open engine compartment door and remove protective caps to access air conditioning fittings. 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 John Deere products can cause contamination to air conditioning service equipment, components, and refrigerant supplies.

A—Low-Side Hose (blue)

B—High-Side Hose (red)

5. Evacuate system. (See Evacuate Air Conditioning System in Section 90, Group 05.)

3. Connect JDG10555 Recovery, Recycling, and Recharging Unit1. Connect low-side hose (blue) (A) from charging unit to low pressure (suction) test port. Connect high-side hose (red) (B) to high pressure (discharge) test port.

6. Charge air conditioning system. Add R-134a refrigerant until system is charged to specification. Specification Refrigerant—Charge.................................................................... 2.27 kg (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 Remove compressor if a refrigerant leak was detected and repaired. (See Remove and Install Compressor in Section 90, Group 05.) NOTE: Refrigerant oil drained from a new compressor can be reused.

3. Flush complete system with ACC-U-FLUSH II® Air Conditioning System Flush. 4. Perform a volumetric efficiency test on compressor to determine serviceable condition. (See Test Volumetric Efficiency in Section 90, Group 05.) If compressor is 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 oil is less than 6 mL (0.2 fl oz.), perform the following:

6. Install 260 mL (8.8 fl oz.) of PAG Refrigeration Oil in compressor.

1. Remove and discard receiver dryer.

7. Connect all components, evacuate, and charge system. (See Evacuate Air Conditioning System and Charge Air Conditioning System in Section 90, Group 05.)

2. Remove, clean, and bench test expansion valve, but do not disassemble valve.

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

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. New service part compressors contain 230 mL (7.7 fl. oz.) of oil. The amount of oil that cannot be drained is 81 mL (2.7 fl. oz.). Approximately 60 mL (2.0 fl. oz.) will have seeped into the cylinders during shipping and storage. Typically 21 mL (0.7 fl. oz.) of oil covers internal surfaces of the compressor exposed to refrigerant gas and cannot be drained.

TS266 —UN—23AUG88

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, and PAG Refrigeration Oil.

Specification Compressor—Oil Charge.......................................................................................... 230 mL (7.7 fl. oz.)

The normal operating oil level of a compressor removed from operation is 30—45 mL (1.0 to 1.5 fl. oz.). Specification Compressor—Oil Level...........................................................30—45 mL (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

TS266 —UN—23AUG88

Used to inject oil into air conditioning system. Tool Number—JT02129 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 to early compressor failure.

Condenser .................................................... 40 mL (1.4 fl. oz.)

DO NOT leave air conditioning system or refrigerant oil containers open. Oil easily absorbs moisture.

............................................ 10 mL (0.35 fl. oz.) Compressor .................................................. 50 mL (1.7 fl. oz.) Hoses ......................................................... 20 mL (0.7 fl. oz.)

DO NOT spill refrigerant oil on acrylic or ABS plastic. Oil deteriorates these materials rapidly.

Compressor:

Evaporator .................................................... 40 mL (1.4 fl. oz.) Receiver Dryer

Identify refrigerant oil containers and measures to eliminate accidental mixing of different oils. System: NOTE: If the complete system was purged with all components in place, the amount of refrigerant oil lost is negligible. If the entire system is disassembled and all lines and components have been discharged and cleaned, add 160 mL (5.4 fl. oz.) PAG Refrigeration Oil to the system after assembly. During start-up, add 60 mL (2 fl. oz.) of refrigerant oil to the low-pressure line to lubricate compressor and bring total system to full capacity of 220 mL (7.4 fl. oz.). Add refrigerant oil charge using JT02129 Air Conditioning Oil Injector1.

NOTE: Determine amount of system refrigerant oil charge prior to installation of compressor. Remove compressor to determine correct refrigerant oil charge if any of the following components listed have been removed, drained, and flushed. If a new compressor is installed, fill with 50 mL (1.7 fl. oz.) PAG Refrigeration Oil. Hoses: NOTE: Equation for figuring amount of oil needed for hose length is 3 mL of oil per 30 cm of hose (0.1 fl. oz. of oil per 1 ft. of hose). If any section of hose is removed and flushed, or is replaced with a new hose, measure hose length and use the formula to determine the correct amount of oil to add to the system.

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

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 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.

TS266 —UN—23AUG88

Replace Compressor Relief Valve

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.)

Specification Relief Valve—Opening Pressure........................................................................ 3450—4140 kPa (34.5—41.4 bar) (500—600 psi) A—Relief Valve

T8120002620 —UN—09JAN13

5. Charge system. (See Charge Air Conditioning System in Section 90, Group 05.)

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). T8120002621 —UN—09JAN13

6. Disconnect suction hose (B) and discharge hose (A). 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 B—Suction Hose C—Connector

11. Determine correct oil charge of compressor. (See Determine Correct Oil Charge in Section 90, Group 05.) 12. Install compressor in reverse order of removal using the following special instructions:

• Evacuate and charge system.

(See Evacuate Air Conditioning System and Charge Air Conditioning System in Section 90, Group 05.)

• Tighten discharge and suction hoses to specification. Specification Discharge Line-to-Air Conditioning Compressor—Torque............................................................ 32—40 N·m (24—29 lb.-ft.) Suction Line-to-Air Conditioning Compressor—Torque............................................................ 34—42 N·m (25—31 lb.-ft.)

D—Cap Screws (3 used) E—Belt

IMPORTANT: If a new clutch was installed on compressor, cycle compressor on and off with engine running. Cycle in 1 second intervals for 5 seconds. Burnish clutch and hub surfaces by cycling clutch five times in 5 seconds.

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

• Lip Seal Protector

SPECIAL TOOLS NEEDED:

Used to protect lip seal during installation. Tool Number—JDG746

• Compressor Holding Fixture

H63259 —UN—07APR00

Used to hold compressor.

A—Rear Pins B—Rear Housing C—Rear Gasket D—Rear Discharge Reed Valve E—Rear Valve Plate F— Rear Suction Reed Valve

G—Rear O-Ring H—Front O-Ring I— Front Suction Reed Valve J— Front Valve Plate K—Front Discharge Reed Valve

1.

L— Front Gasket M—Snap Ring N—Lip Seal O—Washer (4 used) P—Through Bolt (4 used) Q—Felt Seal

R—Felt S—Front Housing T— Front Pins (2 used)

4. Inspect valves for an even wear pattern and cylinders for scoring or excessive wear. Replace compressor if necessary.

Clean compressor using solvent PRIOR to 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, Group 05.)

5. Remove snap ring (M).

IMPORTANT: Be careful NOT to damage sealing surfaces when removing front and rear housings. 3. Disassemble compressor. Discard O-rings, gaskets, lip seal, snap ring, and through bolts. Replace with parts from service kits.

6. Turn housing over and remove felt seal (Q) and felt (R) from front housing (S). 7. Remove lip seal (N) from housing using a 5/8 in. OD driver. 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

TM100419 (02APR13)

90-05-15

PW66162,00008F2 -19-11FEB13-1/5

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=495

RW21162 —UN—24JUN92

N42194KP —UN—08FEB99

Air Conditioning System

A—Bushing

IMPORTANT: Only use PAG Refrigeration Oil for R-134a to lubricate O-rings, gaskets, and lip seals. Other oils could damage the compressor. 9. Apply PAG Refrigeration Oil to bore of front housing. 10. Install a new lip seal in front housing until it bottoms in bore.

11. Install a new snap ring, flat side down. IMPORTANT: Bushing must be in position before assembling compressor. 12. Insert bushing (A) into position as shown. PW66162,00008F2 -19-11FEB13-2/5

13. Install pins (A) and O-ring (B) in rear housing (C). C—Rear Housing

N42194FR —UN—26JAN99

A—Pins B—O-ring

Continued on next page

TM100419 (02APR13)

90-05-16

PW66162,00008F2 -19-11FEB13-3/5

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. C—Front Discharge Reed Valve

N42194GP —UN—26JAN99

A—Front Suction Reed Valve B—Front Valve Plate

Continued on next page

TM100419 (02APR13)

90-05-17

PW66162,00008F2 -19-11FEB13-4/5

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=497

H63259 —UN—07APR00

Air Conditioning System

A—Rear Pins B—Rear Housing C—Rear Gasket D—Rear Discharge Reed Valve E—Rear Valve Plate F— Rear Suction Reed Valve

G—Rear O-Ring H—Front O-Ring I— Front Suction Reed Valve J— Front Valve Plate K—Front Discharge Reed Valve

15. Install a new rear gasket (C), flat side down, and housing (B) on rear cylinder. 16. Install front cylinder pins (T) and a new front O-ring (H) in front cylinder.

L— Front Gasket M—Snap Ring N—Lip Seal O—Washer (4 used) P—Through Bolt (4 used) Q—Felt Seal

R—Felt S—Front Housing T— Front Cylinder Pins (2 used)

21. Remove lip seal protector. 22. Install bolts (P) and new washers (O). Uniformly tighten bolts, then final tighten to specification. Specification Front Housing Bolt—Torque..................................................................................26 N·m (19 lb.-ft.)

NOTE: Front valve plate (J) is marked with an "F" and installed with face upward. 17. Install parts (I—K) over front cylinder pins. 18. Install a new front gasket (L) with flat side downward. 19. Place JDG746 Lip Seal Protector1 on shaft and lubricate with PAG Refrigeration Oil.

23. Install felt (R) and felt seal (Q) using clutch hub. 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

• • • •

RW21157 —UN—24JUN92

•

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 Jaws Used with Puller D05277ST Tool Number—JDG748 Hub Protector Used to protect hub during removal. Tool Number—JDG771 Clutch Hub

1. Mount compressor on DFRW20 Compressor Holding 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 H65447 —UN—04JAN01

3. Hold clutch hub using JDG747 Clutch Spanner Wrench1 (A). H

4. Remove clutch shaft cap screw (B). G

5. Remove clutch hub (C). E

B

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 Jaws1, and JDG771 Hub Protector1.

A—JDG747 Compressor Clutch Spanner B—Clutch Shaft Cap Screw C—Clutch Hub D—Pulley Snap Ring

9. Disconnect clutch coil lead wire.

E—Pulley F— Clutch Coil Snap Ring G—Clutch Coil H—Shim

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. 12. Check pulley bearing operation. Replace pulley as required.

Specification Clutch Shaft Cap Screw—Torque..............................................................................14 N·m (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—Clearance..................................................................................0.35—0.65 mm (0.014—0.026 in.)

Specification Clutch Shaft Cap Screw—Torque..............................................................................14 N·m (120 lb.-in.)

RW21159 —UN—24JUN92

3. Tighten clutch shaft cap screw to specification after correct clearance is obtained.

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.) C—Manifold Gasket RW21160 —UN—24JUN92

A—Hex Head Cap Screw (4 used) 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.) RW41334A —UN—19DEC97

IMPORTANT: Do not lose inner clutch hub shims. 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:

• Shaft seal • Manifold seal • Housing seals at front, rear, and midsection of •

compressor body Relief valve

• Suction coupler Schrader valve If a leak is detected, repair compressor as necessary and repeat test. 7. Assemble compressor and add required oil. (See Determine Correct Oil Charge in Section 90, Group 05.)

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. RW40028A —UN—20AUG98

5. Secure compressor in a vise with ports upward. 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 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). 10. Stop rotating shaft and check “leak down” time. Compressor should hold peak vacuum for a minimum of 3 seconds. If compressor does not hold for 3

A—Suction Test Port

seconds, inspect compressor valve plates and cylinder walls for damage. 11. Open suction port of compressor to atmosphere.

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. Continued on next page

TM100419 (02APR13)

90-05-22

PW66162,00008F7 -19-09JAN13-1/2

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.

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. 17. Leak test the compressor. (See Test Shaft Seal Leakage in Section 90, Group 05.) A—Discharge Port

RW40029A —UN—20AUG98

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.

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: Used to service air conditioning system using R-134a refrigerant. Tool Number—JDG10555 CAUTION: To prevent the risk of injury, always wear protective goggles and gloves when working on the air conditioning system.

TS266 —UN—23AUG88

• Recovery, Recycling, and Recharging Unit

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.

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:

T8120002620 —UN—09JAN13

2. Set temperature control for maximum cooling.

• 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.

8. Cap fittings when finished to prevent contamination from entering system. A—Relief Valve B—Low-Side Hose (blue)

C—High-Side Hose (red)

T8120002622 —UN—09JAN13

7. Follow manufacturer's instructions when using the Recovery, Recycling, and Recharging Unit.

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 Switch

Torque

32 N·m (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. T8130000681 —UN—12FEB13

3. Tag and disconnect refrigerant hoses (A and B). Cap and plug hoses and fittings. 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 B—Refrigerant Hose

5. Check and add compressor oil as necessary. (See Compressor Oil Information in Section 90, Group 05.) 6. Install new receiver dryer.

C—Receiver Dryer D—Cap Screws (2 used)

9. Charge air conditioning. (See Charge Air Conditioning System in Section 90, Group 05.)

7. Connect refrigerant hoses. 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 Fuel cooler is integrated into the air conditioning system condenser. (See Remove and Install Air Conditioning

Condenser-Fuel Cooler in Section 20, Group 20 for removal and installation of air conditioning condenser-fuel cooler.) PW66162,0000935 -19-22JAN13-1/1

Repair Condenser CAUTION: Avoid personal injury. Fins on condenser are sharp. Use protective clothing. 1. If contamination appears in the condenser, flush entire system. 2. Inspect condenser. Fins must be straight and clean. 3. Cap outlet and install a Schrader-type service valve in inlet.

4. Place refrigerant container in a pail of water heated to a maximum of 125 °F (51.5 °C), which gives a pressure of 1200 kPa (12 bar) (170 psi.). 5. Connect refrigerant supply to the Schrader-type valve. 6. Open refrigerant container valve and test condenser for leaks with a leak detector. Replace condenser if a leak is observed. it. 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). T8130000682 —UN—12FEB13

3. Remove high pressure switch (A). 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 Conditioning System in Section 90, Group 05.)

A—High Pressure Switch

B—Electrical Connector

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

2. Disconnect batteries. (See Battery Disconnect Switch in Section 40, Group 05.) 3. Pull upward and remove storage bin (A). 4. Pull upward on knob (B) and remove seat back (C). A—Storage Bin B—Knob

C—Seat Back

N56385 —UN—22MAR01

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

PW66162,000089E -19-09NOV12-1/3

NOTE: It is not necessary to remove screws (B) around load center.

A—Screws (8 used) B—Screws (4 used)

N56386 —UN—29MAR01

5. Remove screws (A) and pull instructional seat (C) forward slightly. C—Instructional Seat

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.

9. Install instructional seat in reverse order of removal. A—Nuts (4 used)

B—Load Center

N56383 —UN—29MAR01

8. Inspect instructional seat and replace as necessary.

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.

H83632 —UN—07JUN05

The original factory adhesive used to bond the windshield in place is a urethane type. When installing this glass, 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 the cure time. However, if it is necessary to operate the

harvester, for the first 48 hours use caution to avoid bumps 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). B—Sun Visor H63271 —UN—30MAR00

A—Cap Screw (3 used)

Continued on next page

TM100419 (02APR13)

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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.) B—Headliner H63270 —UN—30MAR00

A—Tab (5 used)

PW66162,0000895 -19-09NOV12-3/12

4. Remove nuts (A and B) and wiper arm (C). C—Wiper Arm

H83549 —UN—23MAY05

A—Nut B—Nut

PW66162,0000895 -19-09NOV12-4/12

5.

Remove cap screws (A) and grab handle (B). B—Grab Handle

H83552 —UN—23MAY05

A—Cap Screw (3 used)

Continued on next page

TM100419 (02APR13)

90-20-2

PW66162,0000895 -19-09NOV12-5/12

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=510

Cab

6.

Remove boot (A), nut (B) and plate (C). C—Plate

H83553 —UN—23MAY05

A—Boot B—Nut

PW66162,0000895 -19-09NOV12-6/12

7.

Disconnect connector (B).

8. Push wiper motor assembly (A) towards roof and remove wiper motor assembly. B—Connector H83554 —UN—23MAY05

A—Wiper Motor Assembly

PW66162,0000895 -19-09NOV12-7/12

9. Remove cap screws (A) and lower cab panel.

H76826 —UN—08MAY03

A—Cap Screw (3 used)

Continued on next page

TM100419 (02APR13)

90-20-3

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=511

Cab

10. Remove front and rear inner roof mounts (A and B). B—Rear Inner Roof Mount (2 used)

H83557 —UN—23MAY05

A—Front Inner Roof Mount (2 used)

H83558 —UN—23MAY05

Front Cab Mount

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). B—Blocks H83561 —UN—23MAY05

A—Inner Cab Roof

Continued on next page

TM100419 (02APR13)

90-20-4

PW66162,0000895 -19-09NOV12-10/12

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.

H40068 —UN—10OCT88

13. Apply a thin coat of adhesive to area (A) on both clamps (B) provided. 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 B—Clamp

C—Clamp Placement 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 by pushing it up until the two new brackets (A) contact the head panel (B).

B

17. Tighten two clamps attached to cab floor (C).

E

A

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. D—Shims E—Clamp Leg

D

C

H67759 —UN—29MAY01

A—Bracket B—Head Panel C—Clamp Screw

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.

H83614 —UN—26MAY05

NOTE: Cap screw (C) is longer than cap screw (B). Note locations to aid in installation. 2. Remove cap screws (B and C). 3. Remove communications/CB antenna (D). A—Screw (12 used) B—Cap Screw

C—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. H83571 —UN—23MAY05

IMPORTANT: Inspect seal along cab outer roof for 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.)

A—Nut B—Nut

H83549 —UN—23MAY05

3. Remove nuts (A and B) and wiper arm (C). C—Wiper Arm

Continued on next page

TM100419 (02APR13)

90-20-6

PW66162,0000897 -19-09NOV12-1/8

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=514

Cab

4.

Remove cap screws (A) and grab handle (B). B—Grab Handle

H83552 —UN—23MAY05

A—Cap Screw (3 used)

PW66162,0000897 -19-09NOV12-2/8

5.

Remove boot (A), nut (B) and plate (C). C—Plate

H83553 —UN—23MAY05

A—Boot B—Nut

PW66162,0000897 -19-09NOV12-3/8

6.

Disconnect connector (B).

7. Push wiper motor assembly (A) towards roof and remove wiper motor assembly. B—Connector H83554 —UN—23MAY05

A—Wiper Motor Assembly

Continued on next page

TM100419 (02APR13)

90-20-7

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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. B—Access Hole

H83581 —UN—24MAY05

H83580 —UN—24MAY05

A—Cover (2 used)

PW66162,0000897 -19-09NOV12-5/8

10. Remove clips (A) from cab roof.

H83582 —UN—24MAY05

A—Clip (3 used)

Continued on next page

TM100419 (02APR13)

90-20-8

PW66162,0000897 -19-09NOV12-6/8

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=516

Cab

H83585 —UN—24MAY05

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. 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.

H83586 —UN—24MAY05

16. Route main harness on top of cab through access hole (C) and into cab. 17. Remove screw (E) and communications/CB radio antenna cable. A—Connector B—Light Grommet (4 used) C—Access Hole D—Connector (2 used)

E—Screw F— Antenna Wire G—Cap Screw

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.

H83557 —UN—23MAY05

CAUTION: Approximate weight of inner cab roof is 31 kg (69 lb). 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:

• •

(See procedure in Section 40, Group 30.) Remove cab lights. (See procedure in Section 40, Group 25.) Remove ballast. (See procedure in Section 40, Group 25.)

23. Install in reverse order of removal. A—Front Cab Mount (2 used) B—Rear Cab Mount (2 used)

C—Washer Hose

H83596 —UN—26MAY05

• Remove speakers.

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).

H83575 —UN—01JUN05

2. Push up and pull back on forward edge of front headliner (E) to release from clips. Remove front 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 to remove headliner.

A—Overhead Control Panel B—Sound Resonator Cover (2 used) C—Screw D—Dome Light

6. Lower overhead control panel (A) and dome light (D).

E—Front Headliner F— Location G—Clip (4 used)

7. Remove sound resonator covers (B). 8. Using a putty knife, move headliner away from cab frame to release headliner from clips (G) at locations (F) and lower headliner.

10. Install in reverse order of removal.

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

1.

Remove snap rings (A) and hinge pins (B).

2.

Remove cab door.

3. Repair or replace cab door as necessary. 4. Install cab door using hinge pins (B) and snap rings (A). B—Hinge Pin

H73475 —UN—01OCT02

A—Snap Ring

H73474 —UN—01OCT02

CAUTION: Support cab door prior to removing hinge pins. Door may shatter if dropped.

PW66162,000089A -19-09NOV12-1/1

TM100419 (02APR13)

90-20-10

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=518

Cab

TM100419 (02APR13)

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Cab

Disassemble and Assemble Cab Door 2 5

6

1 7

2

4 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

25 26

Continued on next page

TM100419 (02APR13)

90-20-12

H73479 —UN—02OCT02

28

PW66162,000089B -19-09NOV12-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=520

Cab 1— Strap Nut 2— Spring Washer (2 used) 3— Striker 4— Socket Head Screw (2 used) 5— Screw 6— Cover 7— Latch 8— Bearing 9— Tube 10— Nut (2 used)

11— Washer (2 used) 12— Screw (2 used) 13— Bracket 14— Spacer 15— Door 16— Bushing 17— Gasket 18— Handle 19— Gasket 20— Bushing 21— Washer

22— Cap 23— Screw 24— Pin (2 used) 25— Hinge (2 used) 26— Snap Ring (2 used) 27— Bushing 28— Washer (8 used) 29— Lock Washer (4 used) 30— Screw (4 used)

31— Lock Nut (2 used) 32— Washer (2 used) 33— Washer 34— Screw 35— Isolator 36— Washer 37— Lock Nut

Disassemble and assemble door as required to make repairs. PW66162,000089B -19-09NOV12-2/2

Cab Door Latch Striker B

C D

A

H73480 —UN—02OCT02

C

A—Socket Head Screw (2 used)

B—Striker Plate C—Spring Washer (2 used)

D—Strap Nut

NOTE: Make sure washers (C) are not lost when removing striker plate (B).

5. Check proper operation of door latch from inside and outside cab. Make further adjustments as required.

1. Remove socket head screws (A), striker plate (B), spring washers (C), and strap nut (D).

6. Tighten socket head screws (A) to specification.

2. Inspect parts for wear. Replace parts as required. 3. Install striker plate (B) and washers (C), with cup side toward cab frame, using socket head screws (A). Do not tighten at this time.

Specification Striker Plate Socket Head Screws—Torque............................................................................72 N·m (53 lb.-ft.)

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

NW271870 —UN—19MAY06

NW271890 —UN—22MAY06

Cab Tilt Procedure

Raise Cab 1. Park machine on level surface. T8130000684 —UN—14FEB13

2. Engage topper and base cutter safety stops. 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.

T8130000683 —UN—14FEB13

9. Open left-hand engine compartment door and locate pump handle inside of door. Insert pump handle into pump (B). 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 B—Pump C—Control Lever D—Up Position

Lower Cab CAUTION: Ensure that area beneath cab is clear of personnel and equipment.

E—Down Position F— Cord G—Upper Hole H—Pin

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). 2. Remove pin (H) from upper hole (G) and insert into lower hole.

4. Return pump handle to storage in door. 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. T8130000406 —UN—29JAN13

NOTE: If base cutter must be in raised position, safety stops MUST be engaged. 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, Group 05.)

A—Hose and Connector Shield

B—Cap Screw (4 used)

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).

11. Disconnect windshield washer hose (D). 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.) D—Windshield Washer Hose E—Clamp F— Harness Connector (6 used)

T8130000408 —UN—29JAN13

A—Air Conditioning Hose B—Air Conditioning Hose C—Clamp

T8130000407 —UN—29JAN13

10. Loosen clamps (C and E). Tag and disconnect heater hoses.

Continued on next page

TM100419 (02APR13)

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Cab

15. Disconnect harness connectors (A and C).

A—Harness Connector B—Harness Bundle

T8130000409 —UN—29JAN13

16. Cut all necessary tie bands. Pull harness bundle (B) and hose bundle (D) through lower cab frame and set aside. C—Harness Connector D—Hose Bundle

DM84283,0000217 -19-28FEB13-3/8

17. Disconnect evaporator drain hose (A) and set aside.

T8130000410 —UN—29JAN13

A—Evaporator Drain Hose

DM84283,0000217 -19-28FEB13-4/8

18. Remove cap screws (A) and washers. 19. Cut all necessary tie bands and set steering valve aside. T8130000411 —UN—29JAN13

A—Cap Screw (4 used)

Continued on next page

TM100419 (02APR13)

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=524

Cab

20. Attach proper lifting strap (A) to three location shown cab.

T8130000414 —UN—15FEB13

A—Lifting Strap

DM84283,0000217 -19-28FEB13-6/8

21. Disconnect ground cable (G). 22. Remove cap screw (B), lock nut (A), washers, and safety cable (C). T8130000413 —UN—29JAN13

23. Remove safety stop release rope (D). 24. Set lift cylinder (E) and safety stop (F) aside. 25. Lower cab to its upright position. A—Lock Nut B—Cap Screw C—Safety Cable D—Safety Stop Release Rope

E—Lift Cylinder F— Safety Stop G—Ground Cable

DM84283,0000217 -19-28FEB13-7/8

NOTE: Left-hand side shown. Right-hand side same.

T8130000412 —UN—29JAN13

26. Remove cap screw (A), lock nut (B), and washers (C) from each side. 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. Fill cooling system with correct coolant. b. Charge air conditioning system. (See Charge Air Conditioning System in section 90, Group 05.) c. Ensure hydraulic reservoir is full. (See Hydraulic Oil in Section 10, Group 15.) for recommended oil.

A—Cap Screw B—Lock Nut

C—Washer (2 used)

d. Start engine. Operate machine for 5 minutes and operate all hydraulic systems and functions for 1 minute. 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)

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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.

A—Cap Screws (2 used per blade) B—Blade (8 used)

T8120002186 —UN—13NOV12

2. Install new blades with serrated side (C) facing upwards. C—Serrated Side

PW66162,0000921 -19-18JAN13-1/1

Topper Assembly Removal

3. Remove the splined hub from topper motor shaft.

CAUTION: To prevent possible injury, remove topper blades from disk before disassembling or remove the complete topper assembly from harvester. 1. Remove topper segment blades.

4. Label and disconnect hydraulic hoses. Cap and plug hoses and fittings. NOTE: If necessary, apply heat to remove nut. Araldite or Loctite was used during assembly. 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 on the right side and the LH is on the left. Torque mounting bolts and nuts to 108 N·m (80 lb.-ft.). 2. Apply Araldite to motor studs. Install nuts, washers, and topper motor. Torque nuts to 108 N·m (80 lb.-ft.).

7. Install the collector drum on the motor. 8. Apply Araldite to the motor shaft and tighten the nut to 33 N·m (25 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 install twelve bolts and washers to mount with topper disk and torque to 47 N·m (35 lb.-ft.).

11. Connect all hoses and fittings. 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

CM053510267 —UN—16AUG05

Shredder Topper Exploded View

Continued on next page

TM100419 (02APR13)

100-05-2

PW66162,000092B -19-21JAN13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=530

Topper 1— Shredder Frame Assembly 2— Shredder Drum Cover 3— Lock Nut 4— Cotter Pin 5— Shredder Topper Cover 6— Expansion Plug 7— Bolt 8— Lock Washer 9— Washer 10— HB Bolt 11— Bolt 12— HD Washer 13— Shredder Topper Shield 14— Bolt 15— Lock Nut 16— Snap Ring

17— Support Washer 18— Bearing Hub 19— Bearing 20— Extractor Fan Adapter 21— Topper Drum Assembly 22— Bolt 23— Segment Blade 24— Nut 25— Bolt 26— Lock Washer 27— Topper Baseplate Assembly 28— Shear Bar Plate 29— Shear Bar Plate 30— Bolt 31— Throat Plate LH Sheet

32— Throat Palte RH Sheet 33— N/A 34— Bolt 35— Motor Mount Assembly 36— N/A 37— N/A 38— Lock Washer 39— Gathering Disc Plate 40— Gathering Hub Plate 41— Drum Stop (Shipping Only) 42— N/A 43— N/A 44— RMT-Elab Seal Frame (Position at final assembly with drum in place.)

45— Topper Blade Shim 46— Shredder Topper Cover 47— Rubber Grommet 48— Grommet 49— RMT-Guard 50— Shredder Topper Belt 51— Shredder Topper Belt Mount 52— Bolt 53— Lock Nut

PW66162,000092B -19-21JAN13-2/2

Topper Assembly Removal 1. Remove bolts (22), nuts (24), and segment blades (23). 2. Remove drum cover (2), baseplate assembly (27), and throat sheets (31 & 32). 3. Remove six bolts (25) and washers (26). Remove drum assembly (21). 4. Remove covers (5 & 46) to gain access to motor (33) and hydraulic hoses and fittings.

6. Remove the two bolts and washers that secure the motor to the frame (1) and hub assembly (18). It may be necessary to apply heat to remove bolts, because Araldite and Loctite was used during assembly. 7. Remove six bolts (34) and washers (26) holding bearing hub assembly (18). 8. Remove snap-ring (16) and washer (17) to separate hub (18) and adapter (20). Remove bearings (19) from hub assembly (18).

5. Label and cap all hydraulic hoses and fittings. PW66162,000092C -19-21JAN13-1/1

Drum and Topper Assembly 1. Install bearings (19) in hub assembly (18) with bearing seals towards inside of housing (seals down). Pack bearings with grease.

9. Install fixed blades (23) with bolts (22), shims (45) and nuts (24). Torque to 35 nm (26 lb-ft). 10. Install motor mount assemblies using bolts and nuts.

2. Place bearing hub assembly (18) onto extractor adapter (20). Spin hub assembly (18) to check freedom of movement.

11. Install collector drum motors ensuring that the LH is on the left side and the RH is on the right side. Torque bolts and nuts to 108 Nm (80 lb-ft).

3. Install bearing hub assembly (18) into frame assembly (1). Install six bolts (34) and washers (26) with Loctite 242 (0841304201) and torque to 108 Nm (80 lb-ft).

12. Remove pins (4) and nut located on the collector motor.

4. Install the topper motor (33) into the frame (1). Install two bolts (42) and washers (26) with Loctite 242 (0841304201) and torque to 108 Nm (80 Lb-Ft). 5. Install all hoses and fittings. 6. Place drum assembly (21) onto adapter (20). Install six bolts (25) and washers (26) with loctite 242 (0841304201) and torque bolts to 108 Nm (80 lb-ft). Turn drum to check clearance and freedom of movement. 7. Install drum cover (2) with six bolts (7), lock washers (8) and flat washers (9). 8. Bolt baseplate assembly (27) to fixed legs on frame (1) using bolts (14) and nuts (15). Do Not Tighten Bolts At This Time.

13. Heat the collector drums (39 & 40) to 149°C (300°F) to clean off old araldite. 14. Install the collector drums (39 & 40) on the motors. 15. Apply araldite to the motor shafts and tighten the nut to 33 Nm (25 lb-ft). 16. Install pin (4) and bend the pin tabs to lock. 17. Install throat plates (31 & 32) and shear bar plates (28 & 29) using bolts (14 & 11) and nuts (3 & 15). Do Not Tighten Bolts At This Time. 18. Install side shields (13) with bolts (14) and nuts (15). 19. Tighten all bolts and nuts on lower drum assembly. 20. Install segment blades (23) on topper drum assembly (21). Turn drum to check for clearance and freedom of movement. 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

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110-1

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Contents

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Group 05

Crop Divider

CM053510274 —UN—17AUG05

Crop Divider Linkage Exploded View

1— Upper Linkage Top Plate 2— Upper Linkage Bottom Plate

3— Bushings (4 used) 4— Grease Fittings (2 used)

5— Flat Washers (4 used) 6— Lock Washers (4 used)

7— Cap Screws (4 used)

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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 removed from the harvester chassis.

NOTE: See Parts Manual for complete crop 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 1. Label, disconnect, and cap all necessary hoses and fittings. 2. Disconnect floating shoe assembly from the main frame at the chain adjustment end and remove fasteners from the pivot point.

6. Splined hub adapter is Araldited to the motor shaft and retained by single bolt. To remove, loosen the center bolt and apply a puller to the drive spline. 7. Assemble in reverse order using the following special instructions:

• Replace damaged or worn parts as necessary. • Check the condition of mating splines and shafts.

3. Remove retaining fasteners from pivot pins and remove the pins. This frees the crop divider assembly from the harvester for disassembly.

Repair or replace as necessary.

• Check motor seal for leakage and replace as necessary.

• The scroll adjustment is 3 mm (1/8 inch) up and

4. Label, disconnect, and cap all hoses and fittings 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 with the motor splined adapter hub.

must be used to affix splines.

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 cultivation, crop divider shoe assemblies are used to direct cane into the base cutters. Shoe assemblies are secured to the crop divider with a cap screw and supported by an adjustment chain at the rear.

2. Disconnect support chain and remove cap screw. 3. Raise crop divider until the main frame clears the crop divider shoe assembly and remove. PW66162,000079C -19-27FEB13-1/1

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Crop Divider

Gauge Wheel Exploded View (If Equipped) IMPORTANT: Install nut (N) and tighten until heavy drag is felt on hub as it is rotated. Then back nut off one rotation. Install cotter pin and bend one leg of pin over spindle.

CQ282584 —UN—11FEB09

Apply John Deere SD POLYUREA Grease or an equivalent SAE multipurpose-type grease to fittings (J).

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=537

Crop Divider 1— Nut 2— Washer 3— Stand 4— Bolt 5— Seal Kit 6— Bolt 7— Hub 8— Nut 9— Bearing

10— Roller Race 11— Bearing 12— Roller Race 13— Washer 14— Fitting 15— Cap Screw

16— Lock Washer 17— Nut 18— Dust Cap 19— Slotted Nut 20— Cotter Pin 21— Cap Screw

22— Bushing 23— Lock Nut 24— Axle 25— Tire and Wheel

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Contents

Section 120 Knockdown Roller

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

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Group 05

Knockdown Roller Specifications Item

Measurement

Specification

Spline Hub Cap Screws

Torque

75 N·m (55 lb.-ft.)

Hydraulic Motor-to-Motor Mount cap Screws

Torque

110 N·m (81 lb.-ft.)

Hub Spline Adapter-to Knockdown Roller Cap Screws

Torque

34 N·m (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

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=541

Knockdown Roller

CM053510275 —UN—17AUG05

Knockdown Roller Exploded View

Flush with edge (A). Bolt Placement Detail (B).

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Knockdown Roller 1— Knockdown Roller 2— Lock Washer 3— Lock Washer 4— Hub Spline Adapter

5— Hex Bolt 6— Cap Screws 7— Spline Hub 8— Spacer 9— Motor Mount 10— Guard Assembly

11— Hex Bolt 12— Lock Nut 13— Hex Nut 14— Paddle Plate 15— Cap Screw

16— Lock Washer 17— Lock Nut 18— Expansion Plug

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Remove and Install Knockdown Roller 1. Park machine on level surface, shut off engine, and remove key,

NOTE: Hydraulic motors and motor mounts are removed as an assembly.

2. Clean knock down roller and surrounding area.

6. Remove nuts (13) and lock washers (3) that secure motor mount assembly (9).

3. Label and disconnect hoses connected to the two knockdown motors. Cap and plug hoses and fittings.

7. Remove both motor mount assemblies and knockdown roller.

4. Remove cap screws (11) and nuts (12) that secure the roller guards. Remove roller guards.

8. Install in reverse order of removal.

5. Using an appropriate lifting device, support knockdown roller. PW66162,0000963 -19-13FEB13-1/1

Disassemble and Assemble Knockdown Roller

4. Assemble in reverse order using the following special 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. • Tighten hydraulic motors to motor mounts to

NOTE: Heat fasteners to soften Araldite and aid in disassembly.

specification.

• Tighten hub spline adapter cap screws to specification.

2. Remove cap screws (6), lock washers (3), and spline hubs (7) from each side of knockdown roller.

• Tighten motor mount-to frame cap screws to

3. Remove cap screws (15), lock nuts (17), and paddle plates (14).

• Tighten guard assembly cap screws to specification.

4. Remove hydraulic motor from motor mount (9). 5. Remove cap screws (5), lock washers (2) and hub spline adapters (4) from each hydraulic motor. Assemble IMPORTANT: Be sure to inspect splines of hub adapter and spline hub. Replace hub adapter and spline hub as a set. Do not mix old parts with new. 1. Clean all parts and inspect for wear or damage. Repair or replace as necessary. 2. Inspect hydraulic motor for leakage. 3. Clean remaining Araldite from all internal and external threads and splines. Inspect, repair, or replace as necessary.

specification.

Specification Spline Hub Cap Screws—Torque............................................................................75 N·m (55 lb.-ft.) Hydraulic Motor-toMotor Mount cap Screws—Torque.......................................................................... 110 N·m (81 lb.-ft.) Hub Spline Adapter-to Knockdown Roller Cap Screws—Torque............................................................................34 N·m (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.) PW66162,0000964 -19-22FEB13-1/1

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Knockdown Roller

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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

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Group 05

Base Cutter Gear Case Other Material Number

Name

Use

PM38652 (U.S.) 620 (LOCTITE®)

Bearing Mount (High Temperature)

Used to mount and retain bearing assemblies.

PM37553 (U.S.)

Loctite® Hi-Tack Gasket Sealant

To hold gaskets in place during installation.

PM37477 (U.S.) TY9473 (Canadian) 242 (LOCTITE®)

Thread Lock and Sealer (Medium Strength)

Used to lock and seal threads.

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

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Base Cutter Gear Case

CM073510663 —UN—15OCT07

Base Cutter Gear Case—3520

Continued on next page

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Base Cutter Gear Case 1— Shaft Assembly (2) 2— Seal Carrier (2) 3— Single Lip (Top) Seal (2 used) 4— Seal (Bottom) (2) 5— Gear Case 6— Bolt (4) 7— Bearing Cone (4 used) 8— Flat Washer (4 used) 9— Bearing Cup (4 used)

10— Leg Gear (2 used) 11— Leg Washer (2) 12— Shaft Nut (2 used) 13— Bolt (2 used) 14— Lock Nut (2 used) 15— Bearing (4) 16— Pinion Gear 17— Idler Gear 18— Pin (3 used) 19— Cover Gasket

20— Cover 21— Bolt (30) 22— Hub Cap Gasket (3) 23— Cap (3) 24— Bolt (18) 25— Fitting 26— Kickers (8) 27— Lock Nuts (16) 28— Bolt (16) 29— Flat Washer (16) 30— Lock Washer (30) 31— Snap-Ring (2)

32— O-ring 33— Shield Mount (2 used) 34— Magnetic Plug (3) 35— Sight Gauge 36— V-Ring Seal (2) 37— Grease Fitting (2 used) 38— Check Valve (5 pound) (2 used)

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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 9 7 36 4 2

CQ282569 —UN—11DEC08

1

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Base Cutter Gear Case 1— Base Cutter Shaft Assembly (2) 2— Base Cutter Seal Adapter (2) 3— Single Lip (Top) Seal (2) 4— Seal (Bottom) (2) 5— Base Cutter Gear Case Assembly 6— Bolt (4) 7— Cone Bearing (4) 8— Flat Washer (4) 9— Bearing Cup (4)

10— Base Cutter Leg Gear (2) 11— Base Cutter Leg Washer (2) 12— Slotted Fine Thread Nut (2) 13— Bolt (2) 14— Lock Nut (2) 15— Bearing (4) 16— Base Cutter Pinion Gear 17— Base Cutter Idler Gear 18— Dowel Pin (3)

19— Base Cutter Cover Gasket 20— Base Cutter Cover 21— Bolt (30) 22— Hub Cap Gasket (3) 23— Cap (3) 24— Bolt (18) 25— Fitting 26— Kickers (8) 27— Lock Nuts (16) 28— Bolt (16) 29— Flat Washer (16) 30— Lock Washer (30)

31— Snap-Ring (2) 32— O-ring 33— Shield Mount (2) 34— Magnetic Plug (3) 35— Sight Gauge 36— V-Ring Seal (2) 37— Zerk (2) 38— Check Valve (5 pound) (2)

PW66162,000097E -19-12FEB13-2/2

Base Cutter Gear Case Assembly SPECIAL TOOLS NEEDED:

• Base Cutter Gear Case Support

•

CQ280263 —UN—27FEB08

•

Used to support base cutter gear case for repairs. Tool Number—CB11444166 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

CM073510664 —UN—03MAR08

1. Check base cutter shaft (1) where seal carrier (2) fits for smooth clean surface.

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Base Cutter Gear Case

NOTE: Clean gear case with air pressure all during assembly.

CM073510665 —UN—03MAR08

2. Install base cutter gear case into CB11444166 Base Cutter Gear Case Support1. 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).

CM073510666 —UN—03MAR08

5. Apply Teflon Thread Paste to sight glass (35) and install into gear case.

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Base Cutter Gear Case

6. Apply Teflon Tape to plugs (34). Install one plug into top port of each gear case leg.

CM073510695 —UN—03MAR08

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CM073510694 —UN—03MAR08

34— Plug (2 used)

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Base Cutter Gear Case

7. Apply liquid Teflon to grease fittings (37) and install in each bottom port on gear case leg.

CQ280270 —UN—27FEB08

CM073510696 —UN—03MAR08

37— Grease Fittings (2 used)

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CM073510667 —UN—03MAR08

8. Place shaft bearing cups (9) in freezer for at least 30 minutes.

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Base Cutter Gear Case

9. Install seal carrier (2) onto shaft (1) with Bearing Mount (High Temperature) or blue silicone. 2— Seal Carrier (2 used)

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CM073510668 —UN—03MAR08

1— Shaft (2 used)

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Base Cutter Gear Case

CM073510669 —UN—03MAR08

10. Install pinion bearings (15) and idler bearings (15) in gear case (5) with Bearing Mount (High Temperature).

3520

CQ282574 —UN—20JAN09

15

CM073510670 —UN—03MAR08

3522

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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.

36— V-Ring Seal

CM073510671 —UN—03MAR08

1— Shafts (2 used) 2— Seal Carriers (2 used)

CQ280264 —UN—27FEB08

11. Install V-ring seal (36) on top of seal carriers (2). Insure the thick lip of V-ring seal is against the seal carrier.

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CM073510672 —UN—03MAR08

12. Heat bearing cones (7) in oven for 15 minutes.

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Base Cutter Gear Case

IMPORTANT: Make sure bearing cone (7) is fully seated on shaft.

CM073510673 —UN—03MAR08

NOTE: Wear welding gloves when handling heated bearings. 13. Install bearing cones (7) onto each shaft (1).

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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.

5— Gear Case

CM073510676 —UN—03MAR08

CM073510675 —UN—03MAR08

CM073510674 —UN—03MAR08

3— Single Lip Seals (2 used)

CQ280265 —UN—27FEB08

14. Install top single lip seals (3) into gear case (5).

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3520 and 3522 Sugar Cane Harvester Repair 040213 PN=559

Base Cutter Gear Case

15. Remove bearing cup (9) from freezer.

CM073510678 —UN—03MAR08

CQ280266 —UN—27FEB08

CM073510677 —UN—03MAR08

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.

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CM073510679 —UN—03MAR08

17. Position gear case (5) with legs of gear case facing upward.

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Base Cutter Gear Case

CM073510680 —UN—03MAR08

18. Apply Bearing Mount (High Temperature) and install cold shaft bearing cups (9) into gear case (5). Insure that bearing cup is fully seated.

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19. Install bottom seal (4) into gear case (5).

CM073510682 —UN—03MAR08

CM073510681 —UN—03MAR08

20. Insure the bottom seal is fully seated.

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Base Cutter Gear Case

21. Position gear case (5) with gear case legs facing downward.

CM073510684 —UN—03MAR08

CM073510683 —UN—15OCT07

22. Install shaft assembly (1) into gear case.

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Base Cutter Gear Case

NOTE: Clean shaft area before installing bearing.

CM073510686 —UN—03MAR08

CM073510685 —UN—03MAR08

23. Install top (hot) bearing cone (7). Tap bearing cone on inner race lightly to seat in cup (9).

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Base Cutter Gear Case

CM073510688 —UN—03MAR08

CQ280267 —UN—27FEB08

CM073510687 —UN—03MAR08

24. Install gear (10), washer (11), and nut (12) onto shaft (1).

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Base Cutter Gear Case

26. Tighten base cutter shaft nut to specification. 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.

CM073510689 —UN—03MAR08

25. Using CB11422828 Base Cutter Holding Tool1, secure shaft (1) to CB11444166 Base Cutter Gear Case Support.

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).

CM073510690 —UN—03MAR08

CQ280268 —UN—27FEB08

29. Install bolt (13) and lock nut (14).

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. PW66162,000097F -19-27FEB13-20/29

CM073510691 —UN—03MAR08

30. Repeat necessary steps and install second base cutter shaft.

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Base Cutter Gear Case

31. Install bearings (15) and idler gear (17) into gear case (5).

CM073510692 —UN—03MAR08

32. Attach 1190290188 Base Cutter Timing Tool to base cutter legs. 33. With base cutter legs in the “timed” position, install pinion gear (16).

3520

15

17 CQ282576 —UN—21JAN09

16

CM073510693 —UN—03MAR08

3522

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NOTE: Use SAE multi-purpose extreme pressure performance grease containing 3 to 5% molybdenum disulfide to fill grease cavities. CM073510697 —UN—03MAR08

Grease emitted from check valve indicates 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

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Base Cutter Gear Case

CM073510698 —UN—03MAR08

37. Using Hi-Tack Gasket Sealant, attach gasket (19) to base cutter cover.

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CM073510699 —UN—03MAR08

38. Install cover (20) to gear case (5) and install pins (18).

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Apply Thread Lock and Sealer (Medium Strength) on all gear case bolts. 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 21— Cap Screws

30— Lock washers 33— Shield Mounts (2 used) Continued on next page

TM100419 (02APR13)

CM073510700 —UN—03MAR08

NOTE: Start from the middle of the cover and work your way outward.

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Base Cutter Gear Case

CM073510701 —UN—03MAR08

40. Install snap rings (31), one for pinion gear and one for idler gear.

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41. Install gaskets (22), hub cap (23) and cap screws. Tighten shaft cover cap screws to specification.

CQ280271 —UN—27FEB08

Specification Hub Cap Cap Screws—Torque..........................................................................13.5N·m (119 lb.-in.)

CM073510702 —UN—03MAR08

NOTE: Apply Thread Lock and Sealer (Medium Strength) to hub cap cap screws.

Continued on next page

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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.

43. Fill gear case with 85W140 gear oil and check for leaks.

CM073510703 —UN—16OCT07

Specification Base Cutter Motor Cap Screws—Torque....................................................................... 119.3 N·m (88 lb.-ft.)

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Base Cutter Gear Case

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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)

CM053510276 —UN—22AUG05

Butt-Lifter Roller (B1)

Continued on next page

TM100419 (02APR13)

140-05-1

PW66162,0000973 -19-22FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=573

Buttlifter Roller (B1) 1— External Bearing Cradle 2— Lock Washer 3— Nut 4— Splined Hub Adapter 5— Lock Washer 6— Cap Screw 7— Bolt 8— Splined Hub 9— Hex Bolt 10— Hex Bolt

11— Cart Sphere Bearing 12— Zerk 13— Wave Bar Plate 14— Hex Nut 15— Roller Pin 16— External Bearing Cradle 17— Roller 18— Zerk 19— Zerk 20— Spacer Sheet

21— External Roller Shaft 22— Motor Mount 23— Feed Roller Bearing Mount 24— Cap Screw 25— Feed Roller Cast Stop 26— Stop Spacer 27— Lock Nut

28— Rubber Stop 29— Set Screw 30— Socket Bolt 31— Hex Nut 32— Lock Washer 33— Zerk 34— Expansion Plug 35— Zerk

PW66162,0000973 -19-22FEB13-2/2

Remove and Install Butt-Lifter Roller 1. Park machine on level surface. Shut off engine and remove key. 2. Clean butt-lifter roller and surrounding area. 3. Tag and disconnect motor hydraulic hoses on each side of harvester. Cap and plug hoses and fittings.

10. Remove nuts (3) and washers (2), and cap screws holding motor to motor mount. Remove motor. 11. Clean all parts and inspect for wear or damage and replace as necessary. 12. Install butt-lifter in reverse order using these special instructions:

• If splined hub or splined hub adapter need replaced,

4. Using an appropriate lifting device, support butt-lifter roller.

replace as a set.

• Clean remaining Araldite from all internal and external threads and splines.

NOTE: Heat may be necessary to loosen Araldite applied to mounting hardware.

• Apply Araldite to the internal splines of splined hub adapter.

• Apply Araldite and tighten motor-to-motor mount

5. Remove four nuts (3) and washers (2) attaching motor 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 housing in frame if necessary.

(24) to specification.

• Apply Araldite and tighten splined hub adapter cap screw (6) to specification.

6. Pull motor mounts outward until splined hub adapters (4) clear splined hubs (8) and roller rests on motor mounts. 7. Check that lifting device supporting butt-lifter is positioned correctly. 8. Remove motor mounts from each side. Lower butt-lifter roller to ground. NOTE: Heat may be necessary to loosen Araldite applied to splined hub adapter cap screw (6).

Specification Butt-Lifter Motor-to-Motor Mount Nuts—Torque...................................................................109 N·m (80 lb.-ft.) Butt-Lifter Splined Hub Cap Screws—Torque..................................................................109 N·m (80 lb.-ft.) Butt-Lifter Splined Hub Adapter Cap Screw—Torque..............................................................................32 N·m (24 lb.-ft.)

• The maximum out-of-alignment to the side wall is 5

9. Remove cap screw (6), washers (5), and splined hub 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 1. Clean all parts and inspect for wear or damage; 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.

3. Clean remaining Araldite (this should have crystallized after application from heat) from all internal and external threads and splines. Inspect, repair, or replace as necessary.

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 lb-ft).

1. Assembly is the reverse of disassembly. NOTE: Do not apply Araldite to the splines of the adapter. The Araldite will travel backward to the motor seal if is applied to the adapter. 2. Apply Araldite to the internal splines of hub (4) only.

4. Apply Araldite and torque bolt (6) to 32 N·m (24 lb-ft). 5. The maximum out-of-alignment to the side wall is 5 mm (0.197 inch). The end float of the rollers is between the two motors, is a maximum of 7 mm (0.275 inch). 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

CM053510277 —UN—22AUG05

Bottom Feed Roller (B2, B3, B4, B5)

Continued on next page

TM100419 (02APR13)

140-10-1

PW66162,000096B -19-12FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=577

Bottom Feed Roller 1— External Bearing Cradle 2— Lock Washer 3— Hex Nut 4— Splined Hub Adapter 5— Lock Washer 6— Hex Bolt 7— Bolt 8— Splined Hub 9— Hex Bolt 10— Hex Bolt

11— Cart Sphere Bearing 12— Zerk 13— Wave Bar Plate 14— Hex Nut 15— Roller Pin 16— External Bearing Cradle 17— Roller 18— Zerk 19— Zerk 20— Spacer Sheet

21— External Roller Shaft 22— Motor Mount 23— Feed Roller Bearing Mount 24— Hex Bolt 25— Feed Roller Cast Stop 26— Stop Spacer 27— Lock Nut 28— Rubber Stop

29— Set Screw 30— Socket Bolt 31— Hex Nut 32— Lock Washer 33— Zerk 34— Expansion Plug 35— Zerk

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 washers (2) from external shaft (21). Remove external shaft (21). Remove the motor housing (22) on the opposite end; this will leave the roller suspended on the supports. The roller can now be lowered to the ground.

1. Label, remove and cap hydraulic hoses and fittings. 2. Remove four nuts (3) and washers (2) holding motor mount assembly (22) to the frame.1 NOTE: Heat may need to be used. 3. Pull the housing outward until hub adapter (4) is clear of hub (8) and roller rests on mount (22). This can be done by using two 1/2 inch bolts NC to jack hub from the frame. 4. On the opposite side of the roller, remove four nuts (3) and washers (2) from bearing flange (23).

6. Remove fasteners (5 & 6) securing adapter (4) to the motor. 7. Using a hex head (Allen) wrench, loosen bolts holding the motor mount (22). There is a slot located in the housing for this purpose. 8. Remove the motor from the housing.

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 1. Clean all parts and inspect for wear or damage; 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.

3. Clean remaining Araldite (this should have crystallized after application of heat) from all internal and external threads and splines. Inspect, repair, or replace as necessary.

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 motors, is a maximum of 7 mm (0.275 inch).

3. Apply Araldite and torque nut (3) and bolt (9, 24) to 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

CM053510278 —UN—22AUG05

Top Floating Feed Roller (T1, T2, T3, T4, T5)

Continued on next page

TM100419 (02APR13)

140-15-1

PW66162,000096F -19-12FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=579

Top Feed Roller 1— External Bearing Cradle 2— Lock Washer 3— Hex Nut 4— Splined Hub Adapter 5— Lock Washer 6— Hex Bolt 7— Bolt 8— Splined Hub 9— Hex Bolt 10— Hex Bolt

11— Cart Sphere Bearing 12— Zerk 13— Wave Bar Plate 14— Hex Nut 15— Roller Pin 16— External Bearing Cradle 17— Roller 18— Zerk 19— Zerk 20— Spacer Sheet

21— External Roller Shaft 22— Motor Mount 23— Feed Roller Bearing Mount 24— Hex Bolt 25— Feed Roller Cast Stop 26— Stop Spacer 27— Lock Nut 28— Rubber Stop

29— Set Screw 30— Socket Bolt 31— Hex Nut 32— Lock Washer 33— Zerk 34— Expansion Plug 35— Zerk

PW66162,000096F -19-12FEB13-2/2

Top Floating Feed Roller Repair 1. If necessary, remove the bottom roller that will provide better access to the top. 2. Label, remove and cap hydraulic hoses and fittings. 3. Remove bolt (24) and washer (2) that are securing motor mount (22). Support the weight of the roller and remove the mount (22). This can be done using two 1/2 inch NC bolts to jack the mount from the frame.1 4. On the opposite side of the roller, remove four bolts (9) and washers (2) from bearing flange (23). Loosen 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

5. Remove three nuts (14), and washers (5) from each pivot pin (15). These are located on both ends of the roller. 6. With the weight of the roller still supported, remove both pivot pins (15). This will allow the roller to be lowered to the ground through space provided when the appropriate bottom roller was removed. 7. Remove fasteners (6 & 5) which are securing adapter (4) to the motor. 8. Remove the motor from the motor mount assembly.

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 1. Clean all parts and inspect for wear or damage; 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.

3. Inspect bearing (11) and flange (23) for wear or damage. 4. Clean the remaining Araldite (this should have crystallized after application of heat) from all internal and external threads and splines. Inspect, repair or replace as necessary. 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 motors, is a maximum of 7 mm (0.275 inch).

4. Apply Araldite and torque bolts (9, 10, 24) to 109 N·m (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 mount from hammering the side wall.

6. Apply Araldite and torque nuts (14) to 68 N·m (36 lb-ft).

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.) 271 (LOCTITE®)

Thread Lock and Sealer (High Strength)

Used to seal and lock threads.

PM37477 (U.S.) 242 (LOCTITE®)

Thread Lock and Sealer (Medium Strength)

To seal and retain threads.

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 Cap Screws

Torque

237.2 N·m (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 Cap Screws

Torque

427 N·m (315 lb.-ft.)

Chopper Adjustment Lever Cap Screws

Torque

427 N·m (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

CM053510283 —UN—23AUG05

Chopper Gear Case Exploded View

Continued on next page

TM100419 (02APR13)

150-05-3

PW66162,00007B2 -19-11FEB13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=585

Chopper 1— Gear Case 2— Cap Screw 3— Bearing Hub 4— Drum Adapter (2 used) 5— Expansion Plug 6— Hex Bolt 7— Seal Housing Bearing 8— Cap Screw 9— Dowel Pin 10— Spherical Roller Bearing 11— Bearing Keeper Ring 12— Cap Screw 13— Duocone Seal

14— Gear (2 used) 15— Washer 16— Cap Screw 17— Bearing Cup 18— Pinion Shaft 19— Bearing Cone 20— Bearing Retainer 21— Washer 22— Hex Bolt 23— Seal 24— Clutch 25— Flywheel 26— O-ring 27— Drain Magnetic Plug 28— Cover Gasket

29— Access Cover Gasket 30— Access Cover Gasket 31— Bearing Holder Gasket 32— O-ring 33— Fitting 34— O-ring 35— Cover 36— Breather 37— Access Cover 38— Access Cover 39— Cap Screw 40— Cap Screw 41— Gear 42— N/A 43— Washer 44— Cap Screw

45— Chopper Adjustment Lever 46— Pin Adjustment 47— Hex Bolt 48— Backing Plate (2 used) 49— Retainer Plate 50— Washer 51— Cap Screw 52— Sight Gauge 53— Duocone (2 used) 54— Hex Bolt 55— Hex Bolt 56— Washer

PW66162,00007B2 -19-11FEB13-2/2

TM100419 (02APR13)

150-05-4

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=586

Chopper

CM073510704 —UN—23OCT07

Chopper Drum Exploded View

A—Gear Box Side B—Bearing Side C—Cane Flow 1— Upper Chopper Drum 2— Lower Chopper Drum

3— Washer 4— Kicker Chopper Keeper 5— Rubber Chopper Kicker 6— Blade Clamping Bar (3 used)

7— Chopper Blade (3 used) 8— Cap Screw (7 used each blade) 9— Washer (7 used each blade)

10— Cap Screw 11— Lock Nut 12— Cap Screw 13— Cap Screw 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 remove key.

• Araldite Applicator •

2. Clean chopper gear case and surrounding area. 3. Remove chopper motor. (See Remove and Install Chopper Motor in Section 70, Group 25.) 4. Remove chopper blades and retainers. (See Remove and Install Chopper Blades and Kicker Plates in Section 150, Group 05.)

CM073510585 —UN—10OCT07

•

Used to dispense Araldite. Tool Number—0841306707 Araldite Applicator Nozzle Used to dispense Araldite. Tool Number—0841306709 Araldite Cartridge Used to retain and lock threads. Tool Number—0841306708

5. Remove flywheel hub cap, nut, washers, clutch pressure plate, metal locking disk, friction disk, flywheel, and splined hub. Continued on next page

TM100419 (02APR13)

150-05-6

PW66162,00009DF -19-02APR13-1/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=588

Chopper

CAUTION: Dowel pins hold cover to gear case. Be careful, cover is heavy.

35— Cover 40— Cap Screws

CM073510586 —UN—10OCT07

6. Remove cap screws (40 and 44) from cover (35). Using an appropriate pry bar, remove cover. 44— Cap Screws

PW66162,00009DF -19-02APR13-2/40

7. Remove cap screws (39) and access covers (37 and 38). 39— Cap Screws CM073510643 —UN—24MAR08

37— Access Cover 38— Access Cover

Continued on next page

TM100419 (02APR13)

150-05-7

PW66162,00009DF -19-02APR13-3/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=589

Chopper

8. Remove adjustment lever (45). 9. Remove timing gears (14). CM073510587 —UN—03MAR08

45— Adjustment Lever

CM073510588 —UN—03MAR08

14— Timing Gears (2 used)

PW66162,00009DF -19-02APR13-4/40

NOTE: Where Araldite has been used, the application of heat aids in disassembly.

CM073510589 —UN—10OCT07

10. Remove bearings on opposite side of chopper.

Continued on next page

TM100419 (02APR13)

150-05-8

PW66162,00009DF -19-02APR13-5/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=590

Chopper

CM073510590 —UN—03MAR08

11. Remove bearing shaft hubs.

PW66162,00009DF -19-02APR13-6/40

12. Install chopper shaft hanger tool into the bottom bearing adapter (A) and chopper shaft.

CM073510591 —UN—03MAR08

13. Unbolt bearing adapters.

PW66162,00009DF -19-02APR13-7/40

NOTE: Where Araldite has been used, the application of heat aids in disassembly

CM073510592 —UN—03MAR08

14. Remove shield ring halves from inside choppers.

Continued on next page

TM100419 (02APR13)

150-05-9

PW66162,00009DF -19-02APR13-8/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=591

Chopper

15. Remove drum adapter (4). 16. Remove lower chopper drum. CM073510593 —UN—03MAR08

17. Repeat necessary steps for upper drum removal.

PW66162,00009DF -19-02APR13-9/40

18. Remove bearing keeper rings (11). 19. Remove bearing (10) and bearing hub (3). CM073510594 —UN—24MAR08

11— Bearing Keeper Rings (2 used)

CM073510595 —UN—24MAR08

3— Bearing Hub (2 used) 10— Bearing (2 used)

Continued on next page

TM100419 (02APR13)

150-05-10

PW66162,00009DF -19-02APR13-10/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=592

Chopper

CAUTION: Some chopper components are sharp, heavy, and oily. CM073510596 —UN—24MAR08

20. Remove bearing retainer (20). 21. Remove pinion shaft assembly (18). 20— Bearing Holder

CM073510597 —UN—24MAR08

18— Pinion Shaft Assembly

PW66162,00009DF -19-02APR13-11/40

22. Remove bearing seal (13) and housing (7). 13— Bearing Seal CM073510598 —UN—24MAR08

7— Housing

Continued on next page

TM100419 (02APR13)

150-05-11

PW66162,00009DF -19-02APR13-12/40

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. 48— Backing Plates (2 used)

CM073510599 —UN—24MAR08

2— Cap Screws (4 used each plate)

PW66162,00009DF -19-02APR13-13/40

Install Install chopper gear case (1) onto frame as shown

NOTE: Apply 0841306708 Araldite1 to backing plate cap screws. 0841306707 Araldite Applicator1 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.

CM073510610 —UN—03MAR08

Specification Inner Gear Case Backing Plate Cap Screws—Torque.......................................................................237.2 N·m (175 lb.-ft.)

CM073510609 —UN—03MAR08

1.

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. Continued on next page

TM100419 (02APR13)

150-05-12

PW66162,00009DF -19-02APR13-14/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=594

Chopper

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 plate cap screws to specification. Specification Duocone Seal Plate Cap Screws—Torque....................................................................... 119.3 N·m (88 lb.-ft.)

CM073510611 —UN—03MAR08

NOTE: Always install upper chopper drum first.

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. PW66162,00009DF -19-02APR13-15/40

CM073510612 —UN—03MAR08

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.

Continued on next page

TM100419 (02APR13)

150-05-13

PW66162,00009DF -19-02APR13-16/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=595

Chopper

CM073510613 —UN—03MAR08

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). a. Place seal with installer onto bearing seal housing (7).

CM073510615 —UN—03MAR08

CM073510614 —UN—03MAR08

b. Tap installer lightly and install into bearing seal housing (7) to seat seal.

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). CM073510616 —UN—03MAR08

a. Place seal with installer onto Duocone seal plate (53) on chopper drum. b. Tap installer lightly onto Duocone seal plate (53) to seat seal.

Continued on next page

TM100419 (02APR13)

150-05-14

PW66162,00009DF -19-02APR13-18/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=596

Chopper

CM073510617 —UN—03MAR08

7. Lubricate and install O-ring (26) onto bearing hub (3).

PW66162,00009DF -19-02APR13-19/40

CM073510618 —UN—03MAR08

8. Lightly oil the seal retainer surfaces of both halves of seal.

PW66162,00009DF -19-02APR13-20/40

CM073510619 —UN—03MAR08

9. Install line up pins (three long bolts with heads removed) into Duocone seal plate (53) on drum.

Continued on next page

TM100419 (02APR13)

150-05-15

PW66162,00009DF -19-02APR13-21/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=597

Chopper

CM073510620 —UN—03MAR08

10. Install bearing adapter on chopper shaft hanger, then slide hanger into chopper drum from opposite side of seal.

PW66162,00009DF -19-02APR13-22/40

CM073510621 —UN—03MAR08

11. Install drum into frame with line up pins going through bearing hub (3).

PW66162,00009DF -19-02APR13-23/40

CM073510622 —UN—03MAR08

12. Install gear adapter (4) onto line up pins and bearing hub (3).

Continued on next page

TM100419 (02APR13)

150-05-16

PW66162,00009DF -19-02APR13-24/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=598

Chopper

13. Install cap screws (6) with flat washers (43) into the remaining nine holes of drum adapter (4). Tighten cap 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.)

CM073510623 —UN—03MAR08

NOTE: Apply Thread Lock and Sealer (High Strength) to drum adapter cap screws.

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. CM073510624 —UN—10OCT07

A—Frame Wall

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. PW66162,00009DF -19-02APR13-26/40

CM073510625 —UN—03MAR08

16. Drive expansion plugs (5) in bearing shaft hub (3) opposite bolt flange side.

Continued on next page

TM100419 (02APR13)

150-05-17

PW66162,00009DF -19-02APR13-27/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=599

Chopper

17. Install bearing shaft hub, cap screws (9), and washers (10) onto chopper drum. Tighten bearing shaft hub 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.

CM073510626 —UN—03MAR08

NOTE: Apply Thread Lock and Sealer (High Strength) to bearing shaft hub cap screws.

PW66162,00009DF -19-02APR13-28/40

Install bearing with grease fitting downward. 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.)

CM073510627 —UN—03MAR08

NOTE: Apply Thread Lock and Sealer (High Strength) to bearing cap screws and bearing locking collar set screws.

CM073510628 —UN—03MAR08

20. Install locking collar on bearing and tighten set screws.

Continued on next page

TM100419 (02APR13)

150-05-18

PW66162,00009DF -19-02APR13-29/40

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.) CM073510629 —UN—03MAR08

22. Repeat necessary steps and install lower chopper drum. 23. Clean inside of chopper gear case with solvent and blow dry with compressed air.

PW66162,00009DF -19-02APR13-30/40

24. Install bearing cones (19) onto pinion shaft (18). Place pinion shaft assembly and bearing cups (17) into freezer to cool. 1— Chopper Gear Case 17— Bearing Cup (2 used)

18— Pinion Shaft 19— Bearing Cone (2 used)

CM073510630 —UN—24MAR08

NOTE: Heat bearing cone in an oven to aid in assembly.

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. Specification Chopper Gear-to-Drum Adapter Cap Screws—Torque..........................................................................427 N·m (315 lb.-ft.)

CM073510631 —UN—03MAR08

PW66162,00009DF -19-02APR13-31/40

1

For further information, see SERVICEGARD online tool catalog or your John Deere dealer. Continued on next page

TM100419 (02APR13)

150-05-19

PW66162,00009DF -19-02APR13-32/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=601

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. Specification Chopper Gear-to-Drum Adapter Cap Screws—Torque..........................................................................427 N·m (315 lb.-ft.)

CM073510632 —UN—03MAR08

Chopper

PW66162,00009DF -19-02APR13-33/40

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 chopper adjustment lever cap screws to specification. Specification Chopper Adjustment Lever Cap Screws—Torque..........................................................................427 N·m (315 lb.-ft.) 4— Drum Adapter 14— Upper Gear 45— Adjustment Lever

46— Pin 47— Cap Screws (2 used)

CM073510633 —UN—03MAR08

27. Install pin (46) into upper gear (14).

PW66162,00009DF -19-02APR13-34/40

CM073510597 —UN—24MAR08

29. Remove pinion shaft assembly from freezer and install assembly in chopper gear case.

Continued on next page

TM100419 (02APR13)

150-05-20

PW66162,00009DF -19-02APR13-35/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=602

Chopper

30. Using gasket adhesive, attach gasket (28) to cover (35). 35— Cover CM073510640 —UN—24MAR08

28— Gasket

PW66162,00009DF -19-02APR13-36/40

32. Install cover (35) and cap screws to chopper gear case. Tighten gear case cover cap screws to specification. Specification Gear Case cover Cap Screws—Torque.......................................................................... 110 N·m (80 lb.-ft.) 44— Gear Case Cover Cap Screws

35— Cover

CM073510641 —UN—24MAR08

31. Apply Loctite Thread Lock and Sealer (Medium Strength) to chopper gear case cover cap screws (44).

PW66162,00009DF -19-02APR13-37/40

34. Apply Loctite Thread Lock and Sealer (Medium Strength) to access cover cap screws. 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 30— Gasket 35— Chopper Gear Case Cover

37— Access Cover 38— Access Cover 39— Cap Screws Continued on next page

TM100419 (02APR13)

CM073510634 —UN—24MAR08

33. Using gasket adhesive, attach gaskets (29 and 30) to covers (37 and 38).

150-05-21

PW66162,00009DF -19-02APR13-38/40

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=603

Chopper

36. Install seal (23) to bearing retainer (20).

38. Apply Loctite Thread Lock and Sealer (Medium 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.) 23— Seal 31— Gasket

CM073510636 —UN—24MAR08

20— Bearing Retainer 21— Washer 22— Cap Screw

CM073510635 —UN—24MAR08

37. Using gasket adhesive, attach gasket (31) to bearing retainer.

PW66162,00009DF -19-02APR13-39/40

41. Install chopper motor. (See Remove and Install Chopper Motor in Section 70, Group 25.) 42. Fill chopper gear case with oil. (See Pump Drive, Base Cutter, and Chopper Gear Case Oil in Section 10, Group 15.)

CM073510644 —UN—24MAR08

40. Install Teflon tape on magnetic drain plug (27) and install.

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

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.

CM073510602 —UN—03MAR08

CQ280273 —UN—27FEB08

Specification Bearing Seal Housing Cap Screws—Torque.................................................................48.8 N·m (36 lb.-ft.)

CQ280272 —UN—27FEB08

CM073510600 —UN—03MAR08

1. Clean chopper gear case. Wash with hot water pressure washer and rinse with Geoguard (SUP1405706). Blow dry with compressed air.

Continued on next page

TM100419 (02APR13)

150-05-23

PW66162,00007B4 -19-11FEB13-1/5

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=605

Chopper

NOTE: Install the oil filler groove to top of gear case.

CM073510603 —UN—03MAR08

3. Install expansion plug (5) into bearing hub (3).

PW66162,00007B4 -19-11FEB13-2/5

4. Press bearing (10) onto bearing hub (3). 10— Bearing CM073510604 —UN—03MAR08

3— Bearing Hub

PW66162,00007B4 -19-11FEB13-3/5

NOTE: Block and support gear case before applying press force to install bearing assembly.

CM073510605 —UN—03MAR08

5. Press bearing assembly into bearing seal housing (7).

Continued on next page

TM100419 (02APR13)

150-05-24

PW66162,00007B4 -19-11FEB13-4/5

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=606

Chopper

6. Install bearing keeper ring (11) and cap screws. Tighten bearing keeper ring cap screws to specification. Specification Bearing Keeper Ring Cap Screws—Torque.........................................................................48.8 N·m (36 lb.-ft.)

CM073510608 —UN—03MAR08

11— Bearing Keeper Ring

CM073510606 —UN—03MAR08

NOTE: Apply Thread Lock and Sealer (High Strength) to bearing keeper ring cap screws.

PW66162,00007B4 -19-11FEB13-5/5

Remove and Install Chopper Blades and Kicker Plates 1. Remove nuts (11), cap screws (10), and kickers plates (5). 5— Kicker Plate (3 used) 10— Cap Screw

11— Nut

Continued on next page

TM100419 (02APR13)

150-05-25

CM073510708 —UN—24MAR08

Remove

PW66162,00007BB -19-11FEB13-1/4

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=607

Chopper

2. Remove cap screws (8), washers (9), clamping bar (6), and blades (7). 8— Cap Screw (7 used each blade) 9— Washer (7 used each blade)

CM073510707 —UN—24MAR08

6— Clamping Bar (3 used) 7— Blade (3 used)

PW66162,00007BB -19-11FEB13-2/4

Install 1. Clean chopper drum and clamping bars. CM073510707 —UN—24MAR08

2. Apply Anti-Seize Lubricant to cap screws (8). 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 Screws—Torque.......................................................................298.2 N·m (220 lb.-ft.)

6— Clamping Bar (3 used) 7— Blade (3 used)

8— Cap Screw (7 used each blade) 9— Washer (7 used each blade) PW66162,00007BB -19-11FEB13-3/4

Specification Kicker Plate Cap Screws)—Torque......................................................................155.9 N·m (115 lb.-ft.) 5— Kicker Plate (3 used) 10— Cap Screw

11— Nut

CM073510708 —UN—24MAR08

5. Install cap screws (10), kicker plates (5), and nuts (11). Tighten kicker plate cap screws to specification.

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

•

NW271120 —UN—15MAY06

•

Used to dispense Araldite. 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 remove key.

Cane flow

2. Clean chopper drums, gear case, and surrounding area. CQ291723 —UN—16APR12

3. If necessary, install new blades and kicker plates. (See Remove and Install Chopper Blades and Kicker 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.

CM023500100 —UN—07FEB05

8. Repeat steps necessary to check blade contact. 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 adapter and adjustment lever cap screws to specification.

A—Flywheel Cover B—Access Cover C—Location

Specification Chopper Adjustment Lever Cap Screws—Torque..........................................................................427 N·m (315 lb.-ft.)

Chopper Gear-to-Drum Adapter Cap Screws—Torque..........................................................................427 N·m (315 lb.-ft.)

Continued on next page

TM100419 (02APR13)

D—Cap Screw E—Position

150-05-27

PW66162,00009E0 -19-02APR13-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=609

Chopper

NOTE: Apply Loctite Thread Lock and Sealer (Medium Strength) to access cover cap screws. 11. Install access cover and tighten cap screws to specification.

Specification Chopper Access Cover Cap Screws—Torque....................................................................27 N·m (20 lb.-ft.)

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. T8130000594 —UN—07FEB13

2. Remove cap screws (A) and cover (B). 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.

T8130000595 —UN—07FEB13

c. Compare the new position of flywheel mark to the housing mark. Check that flywheel clutch slippage (H) is to specification. 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) B—Cover C—Flywheel Shield D—Line

5. Determine adjustment needs:

• Flywheel rotation is within specification — no adjustments are necessary.

• Flywheel rotation is more than 1/4 turn — clutch set

E—Rotate Flywheel Clutch Nut Clockwise (less slippage) F— Flywheel Clutch Nut G—Rotate Flywheel Clutch Nut Counterclockwise (more slippage) H—Flywheel Clutch Slippage

too loose. Rotate nut clockwise (E).

• Flywheel rotation is less than 1/8 turn — clutch set too tight. Rotate nut counterclockwise (G).

6. If adjustments are made, repeat necessary steps and check slippage.

7. Install cover and cap screws. 8. Close flywheel shield. 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.) 271 (LOCTITE®)

Thread Lock and Sealer (High Strength)

Used to seal and lock threads.

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

T8120002636 —UN—07JAN13

CAUTION: Avoid serious injury or death, Shut OFF engine, remove ignition key, and wait for harvesting functions to completely stop 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 • Counterclockwise rotation — decrease chain tension

A—Jam Nut B—Adjustment Nut

C—Increase Tension Rotation 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 21— Tube 24— Hub 25— Fan Blade (4 used) 26— Doubler Plate 27— Backing Plate 29— Carriage Bolt (4 used) 32— Washer

CM073510645 —UN—15OCT07

7— Hub Cap Screw (16 used) 9— Cap Screw 10— Lock Nut 11— Washer 15— Washer 16— Nut 17— Cotter Pin 19— Lock Washer

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. CM073510646 —UN—15OCT07

3. Clean the shaft and apply one “dab” of grease to 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. 6. Install and torque motor shaft nut (16) to 542 N·m (400 lb-ft).

7. Do not back off nut (16) to install the cotter pin (17). Tighten if needed, then install cotter pin.

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.

CM073510648 —UN—15OCT07

1. Temporarily install, but do not tighten two hub cap screws (7) into hub (24). 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) 24— Hub 25— Fan Blade (4 used)

4. Repeat step 2 at 180° from the first blade.

26— Doubler Plate 27— Backing Plate

5. Remove the first two temporary hub cap screws from step 1. 6. Repeat step 2 for remaining fan blades. Continued on next page

TM100419 (02APR13)

160-05-3

PW66162,00007C1 -19-13FEB13-1/2

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.

CM073510649 —UN—15OCT07

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”). 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.) 15— Flat Washer 29— Carriage Bolt (4 used) CM073510650 —UN—15OCT07

5— Nut 7— Hub Cap Screw 11— Flat Washer

PW66162,00007C1 -19-13FEB13-2/2

Safety Start-Up

2. Follow proper Lock-Out Tag-Out procedure for starting up the machine

4. Slowly increase fan speed at a rate of 100 RPMs per 1/2 minute until full speed has been achieved. If any vibration was observed from the fan, STOP the machine immediately and follow proper Lock-Out Tag-Out procedures before investigating any possible problem.

3. Start fan at 100 to 200 RPMs to check for vibration. (Be sure no personnel are within 300 feet of the machine.)

5. If no vibration was observed, proceed with normal and safe machine operation.

1. Be sure all personnel and tools have evacuated the area.

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

CM053510309 —UN—21SEP05

Elevator Floor and Wearstrips Installation

1— Tail End Wearstrip 2— Lower Middle Wearstrip 3— Lower Bottom Wearstrip 4— Middle Top Wearstrip

5— Middle Middle Wearstrip 6— Middle Bottom Wearstrip 7— Rolled Wearstrip 8— Bottom Corner Floor Assembly

9— Middle Left Hand Floor Assembly 10— Middle Right Hand Floor Assembly 11— Bolt 12— Washer Continued on next page

TM100419 (02APR13)

170-05-1

13— Lock Nut 14— Floor Bottom Retainer

PW66162,00007C3 -19-23OCT12-1/2

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

CM053510310 —UN—21SEP05

Elevator Extension

Continued on next page

TM100419 (02APR13)

170-05-3

PW66162,00007C4 -19-23OCT12-1/2

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=623

Elevator Systems Installation 1— Elevator Frame — 12 in. Left Hand Top Extension 2— Elevator Frame — 12 in. Right Hand Top Extension 3— Elevator Frame — 12 in. Right Hand Bottom Extension 4— Elevator Frame — 12 in. Left Hand Bottom Extension 5— N/A

6— Floor Assembly — 12 in. Extension Right Hand 7— Floor Assembly — 12 in. Extension Left Hand 8— Sheet — Top Brace 12 in. Extension 9— Wearstrip — Top 12 in. Extension 10— Wearstrip — Middle 11— Wearstrip — Bottom

12— Hi Ridge Slat Assembly 13— Sheet — Wild Cart Guard 14— Sheet — Cart Guard Clip 15— Elevator Chain 16— Connecting Link 17— Inner Link 18— Bolt 19— Nut 20— Bolt 21— Bolt 22— Washer 23— Nut 24— Bolt 25— Washer

1. Install items 1 and 2.

26— Nut 27— Bolt 28— Hose Clamp 29— Bolt 30— Bolt 31— Elevator Cover Plate 32— Flex Trim 33— Bolt 34— Bolt 35— Direct Drive Mount Assembly 36— Direct Drive Mount Assembly 37— Washer

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 The elevator has a high clearance to minimize the damage caused by various cane collection containers that come into contact with the underside of the elevator. The elevator is adjustable in height; this is controlled from the cab by two hydraulic cylinders supporting the elevator. This allows the elevator to be lowered for traveling in areas of overhead obstructions, and to minimize the height of platforms required to work on the secondary extractor. The elevator swings through 180°.

links. The conveyor is driven by orbital motors, mounted on both sides, and it is fully reversible to clear blockages. To maintain correct chain tension, the drive shaft grease cylinders are mounted in order to allow chain adjustment. The chains are driven by two sprockets that are bolted to the motors. The idler shaft sprockets are held in place by a machined shaft, bearings, and retaining nuts. There are replaceable wearstrips bolted to the elevator chain runners. When these have excessive wear, they should be replaced along with all retaining bolts.

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 T8120002637 —UN—07JAN13

CAUTION: Be extremely careful when relieving 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 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.

A—Grease Fitting

B—Grease Relief Valve

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

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Elevator Systems Installation

T8130000349 —UN—24JAN13

Checking Elevator Chain Tension

CAUTION: Avoid serious injury. Shut OFF engine and remove ignition key before checking chain tension. T8130000350 —UN—24JAN13

1. Starting from the lower part of the elevator, measure 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 B—Lower Wear Strip C—Gap

NOTE: Verify wear strips are not excessively worn when checking chain tension. Replace wear strips if necessary (refer to Remove and Install Elevator Wear Strips in this section). 2. Under lower part of elevator, measure gap (C) between end of the wear strip and adjacent chain roller.

3. It may be necessary to adjust the idler sprocket (D) position to obtain proper tension readings.

• To lower sprocket (increases chain tension), tighten

Specification

adjustment nut (E).

Roller to Wear Strip—Gap..................................................................................... 25 mm (1 in.)

• Gap is less than specification — chain is too loose. • Gap is more than specification — chain is too tight. Add or release grease to adjust chain tension (see Adjusting Tension in this section).

D—Idler Sprocket E—Adjustment Nut

• To raise sprocket (decreases chain tension), loosen adjustment nut (E).

IMPORTANT: Always check chain tension after changing idler sprocket position. Position of idler sprocket will affect amount of chain tension applied. PW66162,00009A8 -19-27FEB13-2/2

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Elevator Systems Installation

Remove and Install Elevator Chain Slats 2. Remove cap screws and lock nuts (A) from both ends of slat (B). 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.

T8120002638 —UN—07JAN13

1. Shut OFF engine and remove ignition key.

A—Cap Screws and Lock Nuts (4 used) B—Slat (23 used)

T8120002411 —UN—03DEC12

Adding extra slats to elevator chain will decrease chain life. C—Chain Link D—Slat Edges

PW66162,00009A9 -19-27FEB13-1/1

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T8130000203 —UN—21JAN13

Remove and Install Elevator Wear Strips

A—Wear Strips (22 used)

The elevator chain follows a channel that is lined with replaceable wear strips (A). These strips can be replaced individually if necessary.

Wear strips are installed with socket-drive screws, washers, and lock nuts. PW66162,00009AA -19-27FEB13-1/1

Changing Chain and Sprockets If either the elevator chains or sprockets need changing, John Deere recommends that both are changed at the same time. A worn part mated to a new one will not operate at its optimal capacity.

2. Separate (break) both chains and remove them from the elevator. 3. Remove the two bolts securing each hydraulic motor to the bearing carrier assembly. Pull out the motors 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 1. Locate the position where the chain is to be broken, and grind the peened edge of both pins located in the link.

3. To rejoin the chain, the same link can be reused. Replace the link pins with 2 - 1/4 inch x 3/8 inch bolts and 2-3/8 inch nuts. Place them through the link to 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

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CM053510311 —UN—30SEP05

Elevator Sprocket and Chain

Continued on next page

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Elevator Systems Installation 1— Tailshaft 2— Tailshaft Mount 3— Sprocket Chain Adjuster 4— N/A 5— N/A 6— Direct Drive Adjuster 7— N/A 8— Floor Support 9— Elevator Chain Assembly 10— Slat Assembly 11— Sprocket Hub 12— Sprocket

A - In Seat Right Side

13— Sprocket 14— Sprocket 15— Sprocket Spindle 16— Lower Lift Link Spacer 17— Ball Bearing 18— Snap Ring 19— Retaining Ring 20— Bearing 21— Special Set Screw 22— Bearing Out Retainer 23— Zerk

24— Bearing In Retainer 25— O-ring 26— Lock Nut 27— Washer 28— Elevator Chain 29— Inner Link 30— Connecting Link 31— Bolt 32— Nut 33— Bolt 34— Washer 35— Washer 36— Lock Nut 37— Bolt

38— Bolt 39— Bolt 40— Lock Nut 41— Bolt 42— Bolt 43— Bolt 44— FMS - Floor Retainer 45— RMT- Spacer 46— Bolt 47— Washer 48— Lock Washer 49— Nut 50— Nut 51— Washer

B - In Seat Left Side PW66162,00007C9 -19-23OCT12-2/2

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CM053510312 —UN—30SEP05

Elevator Swing Table

Continued on next page

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Elevator Systems Installation 1— Lock Nut 2— Bolt 3— RMT- Spacer Swing 4— Washer 5— Swing Table Assembly 6— Trunnion Pin 7— Table Pin 8— Cylinder Pin 9— Ball Bushing 10— Bolt 11— Swing Table Pin Assembly

12— Lock Nut 13— Washer 14— Zerk 15— Washer 16— Lower Table Washer 17— Upper Table Washer 18— Zerk 19— Bolt 20— Lock Washer 21— Bushing 22— Elevator Sheave Assembly

Item (A) is welded to Item (5). Fill gaps (B) with shims, items (13 and 16). The elevator swing table is mounted to the main frame by two pins (7 and 11). The table pivots on two spherical

23— Sheave Pin Assembly 24— RMT - Spacer 25— Elevator Sheave Cable 26— Elevator Sheave 27— Bolt 28— N/A 29— Washer 30— Lock Nut 31— Cylinder Pin 32— Spacer 33— Washer

34— Washer 35— Bolt 36— Sheave Pin Cylinder Assembly 37— KLIK Pin 38— Washer 39— Elevator Block Plate 40— Bolt 41— Washer 42— Lubricant 43— Modified Bolt

bearings and is controlled by two opposing cylinders, which are pin attached. The two cylinders operate in opposition and turn the table through 180°. The two pivot pins secure the swing table to the main frame with nylon locknuts on each pin. PW66162,00007CA -19-23OCT12-2/2

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CM053510314 —UN—03OCT05

Standard Elevator

1— Upper Top Wearstrip 2— Upper Mid Wearstrip 3— Upper Bottom Wearstrip 4— Upper Left Hand Floor Assy

5— Upper Right Hand Floor Assy 6— Bolt 7— Washer 8— Lock Nut 9— Cart Guard Sheet 10— Cart Guard Clip

11— Bolt 12— Bolt 13— Direct Drive Mount Assy R 14— Direct Drive Mount Assy L 15— Bolt

Continued on next page

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16— Lock Washer 17— Wiper Belt 18— Bolt 19— Backing Plate

PW66162,00007CB -19-23OCT12-1/2

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Elevator Systems Installation A - The last set of studs on this end do not require nuts and washers until installation of drive components.

2. Install items 4 & 5.

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

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Contents

Section 199 Dealer Fabricated Tools

Page

Group 05—Dealer Fabricated Tools DFRW20—Compressor Holding Fixture...................................................... 199-05-1

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Contents

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Group 05

Dealer Fabricated Tools

RW13619 —UN—20SEP89

DFRW20—Compressor Holding Fixture

A—102 mm (4 in.) B—76 mm (3 in.) C—70 mm (2.75 in.)

D—6.4 mm (0.25 in.) E—19 mm (0.75 in.) F— 152 mm (6 in.)

G—254 mm (10 in.) H—114 mm (4.5 in.) I— 178 mm (7 in.)

J— Weld K—Two Holes

Material Required:

4—Matching Lock Washers and Nuts

2—Steel Plates (4 x 2.75 in.) and (10 x 6 in.) 2—Threaded Steel Rods (0.5 x 7 in.)

Tool is used to hold air conditioner compressor during disassembly and assembly. PW66162,00008C7 -19-03DEC12-1/1

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Index Page Page

A Accumulator Base cutter Charge............................................................ 70-30-2 Crop divider Charge............................................................ 70-30-2 Elevator Charge............................................................ 70-30-4 Topper Charge............................................................ 70-30-4 Adhesives Specifications..................................................... 10-10-4 Adhesives and sealants....................................... 10-10-15 Adjust elevator chain ........................................... 170-05-4 Adjusting tension.............................................. 170-05-4 Checking elevator chain tension ...................... 170-05-4 Adjust primary extractor chain tension ................ 160-05-1 Air cleaner Inlet assembly Remove and install......................................... 30-10-2 Air conditioning system Charge ............................................................. 90-05-10 Clutch hub clearance Check ........................................................... 90-05-20 Compressor Remove and install....................................... 90-05-14 Repair........................................................... 90-05-15 Compressor clutch Repair........................................................... 90-05-19 Compressor manifold Replace ........................................................ 90-05-20 Compressor oil Information ................................................... 90-05-11 Compressor relief valve Replace ........................................................ 90-05-13 Condenser Remove and install...........................20-20-1, 90-10-1 Discharge and recover system ........................ 90-05-24 Evacuate ............................................................ 90-05-9 Flush .................................................................. 90-05-6 High pressure switch Replace .......................................................... 90-10-2 Hose and tubing O-ring connection torque ............................................................... 90-05-3 Leak test with dye .............................................. 90-05-5 Oil Determine correct charge............................. 90-05-12 Purge ................................................................. 90-05-8 Refrigerant Proper handling .............................................. 90-05-4 R-134a precautions ........................................ 90-05-4 Refrigerant oil charge....................................... 90-05-10 Service information ............................................ 90-05-3 Service parts kits................................................ 90-05-2 System components Receiver dryer Replace....................................................... 90-10-1

Test shaft seal leakage .................................... 90-05-21 Test volumetric efficiency ................................. 90-05-22 Air filter Restriction switch Remove and install......................................... 40-20-7 Air intake system Air cleaner inlet assembly Remove and install......................................... 30-10-2 Turbocharger repair ........................................... 30-10-2 Alternator Remove and install ............................................ 40-40-1 Alternator repair Engine accessories............................................ 40-40-1 Auxiliary coolers Fuel Remove and install......................................... 20-20-1 Axle Maintenance ...................................................... 55-05-7

B Base cutter lift (track harvester) Cylinder Disassemble and assemble ......................... 70-20-28 Remove and install....................................... 70-20-26 Base cutter lift (wheel harvester) Cylinder Disassemble and assemble ......................... 70-20-20 Remove and install....................................... 70-20-17 Batteries Remove and install ............................................ 40-05-5 Battery Charging ............................................................ 40-05-3 Disconnect switch .............................................. 40-05-4 Fluid level........................................................... 40-05-2 Preventing damage............................................ 40-05-2 Servicing ............................................................ 40-05-1 Belt Tensioner ........................................................... 20-05-2 Bolt and screw torque values Metric ................................................................. 10-10-6 Unified inch ........................................................ 10-10-5 Bottom Feed Roller.............................................. 140-10-1 Repair .............................................................. 140-10-2 Break-in engine oil................................................. 10-15-1 Bushings and Pins............................................... 55-05-10 Butt-lifter Motor Disassemble and assemble ........................... 70-25-3 Buttlifter Roller ..................................................... 140-05-1

C Cab Remove and install .......................................... 90-20-15

Continued on next page

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Index-1

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Index

Page

Page

Cab door Disassemble and assemble ............................. 90-20-12 Latch striker Remove and install....................................... 90-20-13 Remove and install .......................................... 90-20-10 Cab inner roof Remove and install Style B ............................................................ 90-20-6 Cab roof Remove and install Style B ............................................................ 90-20-6 Cab tilt Cylinder Disassemble and assemble ........................... 70-20-6 Remove and install......................................... 70-20-3 Carrier Roller ....................................................... 55-05-16 Charging system Alternator Remove and install......................................... 40-40-1 Chopper Motor Remove and install....................................... 70-25-11 Chopper drum Exploded view.................................................. 150-05-5 Chopper system Assembly Remove and install....................................... 150-05-6 Blades and kicker plates Remove and install..................................... 150-05-25 Drum Exploded view .............................................. 150-05-5 Flywheel clutch Adjust ......................................................... 150-05-29 Gear case Disassemble and assemble ....................... 150-05-23 Exploded view .............................................. 150-05-3 Timing ............................................................ 150-05-27 Cleaning system Fan blades, doubler plates, and backing plates Install ............................................................ 160-05-3 Primary extractor Fan assembly Exploded view........................................... 160-05-2 Condenser Air conditioning Remove and install......................................... 20-20-1 Repair ................................................................ 90-10-1 Connector repair R-A repair procedure ......................................... 40-10-3 R-B repair procedure ......................................... 40-10-6 R-C repair procedure ......................................... 40-10-9 R-D repair procedure ....................................... 40-10-12 R-E repair procedure ....................................... 40-10-14 R-F repair procedure........................................ 40-10-16 R-G repair procedure ....................................... 40-10-19 R-I repair procedure......................................... 40-10-20 R-J repair procedure ........................................ 40-10-22

R-K repair procedure ....................................... 40-10-27 R-M repair procedure....................................... 40-10-29 R-N repair procedure ....................................... 40-10-31 Connectors Handling and repair............................................ 40-10-2 Coolant Additional information ........................................ 10-15-6 Diesel engine ..................................................... 10-15-4 John Deere Cool-Gard II Coolant Extender........................................................... 10-15-5 Supplemental additives...................................... 10-15-7 Testing................................................................ 10-15-8 Warm temperature climates ............................... 10-15-7 Cooling system Surge tank cap Test................................................................. 20-10-2 Test radiator ....................................................... 20-10-2 Test radiator cap ................................................ 20-10-1 Test surge tank................................................... 20-10-2 Critical torque Specifications..................................................... 10-10-4 Crop divider Disassemble and assemble ............................. 110-05-2 Guage wheel Exploded view .............................................. 110-05-3 Position sensor (if equipped) Remove and install......................................... 40-20-6 Crop Divider Removal........................................................... 110-05-2 Crop divider lift Cylinder Disassemble and assemble ......................... 70-20-13 Remove and install....................................... 70-20-11 Crop divider linkage Exploded view.................................................. 110-05-1 Crop divider shoe Remove and install .......................................... 110-05-2 Crop Divider System Buttlifter............................................................ 140-05-1 Crop divider tilt Cylinder Disassemble and assemble ......................... 70-20-35 Remove and install....................................... 70-20-33 Crop divider valve, floating Remove and install ............................................ 70-15-2

D Dealer fabricated tools Compressor holding fixture DFRW20....................................................... 199-05-1 Diesel fuel.............................................................. 10-15-3 Diesel fuel system Cooler Remove and install......................................... 30-05-9 Filters Remove and install......................................... 30-05-2 Continued on next page

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Index

Page

Page

Fuel tank Remove and install......................................... 30-05-4 Drum and Topper................................................. 100-05-3 Drum and Topper Assembly ................................ 100-05-1

Repair ................................................................ 20-05-1 Specifications..................................................... 10-10-2 Thermostat repair............................................... 20-10-3 Water pump repair ............................................. 20-10-3 Engine oil Break-In ............................................................. 10-15-1

E Electrical Air filter restriction switch Remove and install......................................... 40-20-7 Component handling precautions ...................... 40-10-1 Engine Replace sensors and switches....................... 40-20-1 Position sensor (if equipped) Crop divider Remove and install ..................................... 40-20-6 Starting motor Remove and install......................................... 40-45-1 Visual inspection ................................................ 40-10-1 Electrical system Batteries Remove and install......................................... 40-05-5 Switch Engine access door Remove and install ..................................... 40-20-2 Elevator Motor Disassemble and assemble ........................... 70-25-3 Sprocket Tightening ........................................... 55-05-7 Elevator discharge flap Cylinder Disassemble................................................. 70-20-47 Remove and install....................................... 70-20-46 Elevator lift Cylinder Disassemble and assemble ......................... 70-20-41 Remove and install....................................... 70-20-39 Elevator swing Cylinder Disassemble and assemble ........................... 70-20-6 Remove and install......................................... 70-20-5 Elevator System Chain and Sprockets........................................ 170-05-7 Elevator Floor................................................... 170-05-1 Extension ......................................................... 170-05-3 Standard ........................................................ 170-05-12 Swing Table.................................................... 170-05-10 Wearstrips........................................................ 170-05-1 Elevator valve Remove and install .......................................... 70-15-15 Emergency exit...................................................... 10-05-2 Engine Air filters Remove and install......................................... 30-10-1 Electrical Replace sensors and switches....................... 40-20-1 Primary filter Clean and inspect........................................... 30-10-1

F Feed roller Motor Disassemble and assemble ........................... 70-25-3 Feed roller system Butt-lifter Remove and install....................................... 140-05-2 Feed Roller System Bottom Feed Roller .......................................... 140-10-1 Top Floating Feed Roller.................................. 140-15-1 Filter Engine air Remove and install......................................... 30-10-1 Primary engine air Clean and inspect........................................... 30-10-1 Filters Fuel Remove and install......................................... 30-05-2 Final drive Assemble (S.N. --100986)............................................. 55-10-36 (S.N. 120701--)............................................. 55-10-12 Disassemble (S.N. --100986)............................................. 55-10-27 (S.N. 120701-- ).............................................. 55-10-5 Gear oil ............................................................ 10-15-10 Lifetime seal Assemble (S.N. --100986) ......................................... 55-10-48 (S.N. 120701-- ) View................................................................ 55-10-4 Final Drive (S.N. --100986) View.............................................................. 55-10-26 Flange Fittings ............................................................. 10-10-12 Four bolt Flange fittings................................................... 10-10-12 Front axle Toe-in Adjust ............................................................. 60-15-4 Check ............................................................. 60-15-3 Front wheel Bearings Remove and install......................................... 57-05-3 Fuel Diesel ................................................................. 10-15-3 Lubricity.............................................................. 10-15-3 Fuel and lubricants Lubricate machine properly................................ 10-15-1 Continued on next page

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Index

Page

Page

Fuel cooler Remove and install ..............................20-20-1, 30-05-9 Fuel level sensor Remove and install ............................................ 40-20-3 Fuel system Bleed.................................................................. 30-05-3 Repair ................................................................ 30-05-1 Fuel tank Remove and install ............................................ 30-05-4 Fuse and relay Identification....................................................... 40-30-2 Fuse and relay panel Location ............................................................. 40-30-1 Fuses Replacing ........................................................... 40-30-1

Remove and Install ................................... 70-20-17 Cab tilt Disassemble and assemble........................ 70-20-6 Remove and install ..................................... 70-20-3 Crop divider lift Disassemble and assemble...................... 70-20-13 Remove and install ................................... 70-20-11 Crop divider tilit Remove and install ................................... 70-20-33 Crop divider tilt Disassemble and assemble...................... 70-20-35 Elevator discharge flap Disassemble and assemble...................... 70-20-47 Remove and install ................................... 70-20-46 Elevator lift Disassemble and assemble...................... 70-20-41 Remove and install ................................... 70-20-39 Elevator swing Disassemble and assemble........................ 70-20-6 Remove and install ..................................... 70-20-5 Knockdown tilt Disassemble and assemble...................... 70-20-35 Remove and install ................................... 70-20-31 Steering (wheel harvester) Disassemble and assemble........................ 70-20-8 Remove and install ..................................... 70-20-7 Topper Disassemble and assemble........................ 70-20-6 Remove and install ..................................... 70-20-2 Elevator Accumulator Charge ........................................................ 70-30-4 Fixed displacement ground drive motor (Track harvester) Repair ....................................................... 70-25-84 Motor Chopper Remove and install ................................... 70-25-11 Cooling package........................................... 70-25-58 Secondary extractor rotate Disassemble and assemble...................... 70-25-65 Topper severing disk (whole topper) and secondary extractor fan Disassemble and assemble...................... 70-25-30 Exploded view........................................... 70-25-29 Motors Variable displacement ground drive motor (optional) Exploded view........................................... 70-25-86 Mulitple gear pump Repair............................................................. 70-10-2 Topper Accumulator Charge ........................................................ 70-30-4 Valve Improved height control Remove and install ..................................... 70-15-4

G Gauge wheel Exploded view.................................................. 110-05-3 Gear oil Final drive ........................................................ 10-15-10 Grease................................................................. 10-15-10

H Hardware torque values Metric ................................................................. 10-10-6 Unified inch ........................................................ 10-10-5 Headliner Remove and install Style B .......................................................... 90-20-10 High pressure switch Replace.............................................................. 90-10-2 Hydraulic oil ....................................................................... 10-15-9 Hydraulic filter assemblies Remove and install ............................................ 70-05-2 Hydraulic reservoir Drain .................................................................. 70-05-1 Level switch Remove and install......................................... 40-20-5 Hydraulic system Base cutter Accumulator Charge ........................................................ 70-30-2 Chopper motor Disassemble and assemble ......................... 70-25-15 Crop divider Accumulator Charge ........................................................ 70-30-2 Cylinder Base cutter lift (track harvester) Disassemble and assemble...................... 70-20-28 Remove and install ................................... 70-20-26 Base cutter lift (wheel harvester) Disasseble and assemble......................... 70-20-20

Continued on next page

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Index

Page

Page

Valves Control Repair ......................................................... 70-15-5 Elevator Remove and install ................................... 70-15-15 Floating crop divider Remove and install ..................................... 70-15-2 Variable displacement ground drive motor (wheel harvester) Repair........................................................... 70-25-88 Hydraulic System Filter assemblies Remove and install......................................... 70-05-2

Miscellaneous Rails and platform Left-hand ladder Remove and install ..................................... 80-05-1 Motor Butt-lifter Disassemble and assemble ........................... 70-25-3 Chopper Remove and install....................................... 70-25-11 Elevator Disassemble and assemble ........................... 70-25-3 Feed roller Disassemble and assemble ........................... 70-25-3 Scroll Disassemble and assemble ........................... 70-25-3 Side knife Disassemble and assemble ........................... 70-25-3 Topper gathering disk Disassemble and assemble ........................... 70-25-3 Whole topper Remove and install ..................................... 70-25-2

I Idler Lubrication ......................................................... 55-05-3 Improved height control valve Remove and install ............................................ 70-15-4 Instructional seat Remove and install ............................................ 90-15-1

O J Jack locations ........................................................ 57-05-1

Oil Hydraulic ............................................................ 10-15-9

K

P

Knockdown roller Disassemble and assemble ............................. 120-05-3 Exploded view.................................................. 120-05-2 Remove and install .......................................... 120-05-3 Knockdown tilt Cylinder Disassemble and assemble ......................... 70-20-35 Remove and install....................................... 70-20-31

Pitch.....................................................55-05-12, 55-05-13 Power train Pump drive Gear case Exploded view............................................. 50-05-2 Pump drive gear case Disassemble and assemble ........................... 50-05-5 Remove and install......................................... 50-05-3 Pump drive gear case Disassemble and assemble ............................... 50-05-5 Exploded view.................................................... 50-05-2 Remove and install ............................................ 50-05-3

L Ladder Left-hand Remove and install......................................... 80-05-1 Link Rail Wear ....................................................... 55-05-9 Lubricants, Safety Safety, Lubricants ............................................ 10-15-10 Lubrication Idler .................................................................... 55-05-3 Lubricity of diesel fuel ............................................ 10-15-3

M Metric bolt and screw torque values ...................... 10-10-6 Metric O-Ring Torque Chart Torque Chart O-Ring Metric ............................... 10-10-8

R Radiator Test .................................................................... 20-10-2 Radiator cap Test .................................................................... 20-10-1 Recoil Spring Repair.............................................. 55-05-8 Remove and install Elevator chain slats.......................................... 170-05-6 Elevator wear strips ......................................... 170-05-7 Reservoir Hydraulic Drain............................................................... 70-05-1 Roller Lubrication................................................... 55-05-2

Continued on next page

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Index

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Page

Roller wear Specifications................................................... 55-05-19

Steering (wheel harvester) Cylinder Disassemble and assemble ........................... 70-20-8 Remove and install......................................... 70-20-7 Steering and brakes Relief valve Steering Adjust.......................................................... 60-10-8 Steering linkage Exploded view ................................................ 60-15-2 Steering valve (wheel harvester) Exploded view ................................................ 60-10-2 Steering relief valve Adjust ................................................................. 60-10-8 Steering valve (wheel harvester) Exploded view.................................................... 60-10-2 Surge tank Cap Test................................................................. 20-10-2 Test .................................................................... 20-10-2 Swing Table ....................................................... 170-05-10 Switch Air filter restriction Remove and install......................................... 40-20-7 Engine access door Remove and install......................................... 40-20-2 System components Condenser Remove and install......................................... 90-10-1 Receiver dryer Replace .......................................................... 90-10-1

S Safety Transport.......................................................... 10-05-11 Safety, Avoid High-Pressure Fluids Avoid High-Pressure Fluids ............................. 10-05-12 Safety, Handle Fuel Safely, Avoid Fires Avoid Fires, Handle Fuel Safely......................... 10-05-9 Safety, Steps and Handholds Use Steps and Handholds Correctly.................. 10-05-8 Scroll Motor Disassemble and assemble ........................... 70-25-3 Seal fittings Assembly and installation .................................. 10-10-7 Seat Instructional Remove and install......................................... 90-15-1 Secondary extractor fan Motor Disassemble and assemble ......................... 70-25-30 Exploded view .............................................. 70-25-29 Senors and switches Fuel level sensor Remove and install......................................... 40-20-3 Sensor Hydraulic oil temperature Remove and install......................................... 40-20-4 Sensors and switches Hydraulic reservoir level switch Remove and install......................................... 40-20-5 Service Adjust elevator chain........................................ 170-05-4 Adjust primary extractor chain tension............................................................ 160-05-1 Remove and install elevator chain slats................................................................ 170-05-6 Remove and install elevator wear strips............................................................... 170-05-7 Shredder Topper.................................................. 100-05-2 Side knife Motor Disassemble and assemble ........................... 70-25-3 Specifications Adhesives .......................................................... 10-10-4 Critical torque..................................................... 10-10-4 Engine................................................................ 10-10-2 Sprocket Wear Patterns .................................................. 55-05-18 Sprocket Tightening............................................... 55-05-7 Starting motor Remove and install ............................................ 40-45-1 Repair ................................................................ 40-45-1

T Thermostat Repair ................................................................ 20-10-3 Toe-in Front axle Adjust ............................................................. 60-15-4 Check ............................................................. 60-15-3 Top Floating Feed Roller ..................................... 140-15-1 Topper Blades Replace ........................................................ 100-05-1 Cylinder Disassemble and assemble ........................... 70-20-6 Remove and install......................................... 70-20-2 Gathering disk motor Whole topper Remove and install ..................................... 70-25-2 Topper gathering disk Motor Disassemble and assemble ........................... 70-25-3 Topper severing disk (whole topper) Motor Disassemble and assemble ......................... 70-25-30 Exploded view .............................................. 70-25-29 Continued on next page

TM100419 (02APR13)

Index-6

3520 and 3522 Sugar Cane Harvester Repair 040213 PN=6

Index

Page

Page

Topper system Assembly Removal ....................................................... 100-05-1 Topper System Assembly ......................................................... 100-05-3 Drum and Topper Assembly............................. 100-05-1 Shredder Topper .............................................. 100-05-2 Torque charts Metric ................................................................. 10-10-6 Unified inch ........................................................ 10-10-5 Track Adjust tension .................................................... 55-05-7 Alignment ........................................................... 55-05-2 Assembly ........................................................... 55-05-1 Bushing ............................................................ 55-05-11 Bushings and Pins ........................................... 55-05-10 Link Rail Wear.................................................... 55-05-9 Recoil Spring Repair .......................................... 55-05-8 Roller Lubrication ............................................... 55-05-2 Roller wear....................................................... 55-05-19 Rollers.............................................................. 55-05-13 Track shoes ........................................................... 55-05-4 Track tension Adjust ................................................................. 55-05-7 Tune-up and adjustments...................................... 10-20-1 Turbocharger repair Air intake system................................................ 30-10-2

Unified inch bolt and screw torque values .................................................................. 10-10-5

U

V Valve Elevator Remove and install....................................... 70-15-15 Floating crop divider Remove and install......................................... 70-15-2 Improved height control Remove and install......................................... 70-15-4

W Water pump, repair................................................ 20-10-3 Welding precautions, Safety.................................. 10-05-5 Wheel Remove and Mount Tire .................................... 57-05-4 Wheel assembly Remove and install ............................................ 57-05-2 Wheel bearings Remove and install ............................................ 57-05-3 Whole topper Gathering disk motor Remove and install......................................... 70-25-2 Windshield, cab Remove and install 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