John Deere Sugar Cane Harvester 3520, 3522 Repair Service Manual (TM100419)

TM100419 - John Deere Sugar Cane Harvester 3520, 3522 Technical Manual (Repair).PDF

Complete Repair manual for John Deere 3520, 3522 Sugar Cane Harvesters PIN Prefix NW, with all the service information to maintain, diagnostic, repair, rebuild like professional mechanics.

John Deere Track & Wheel Sugar Cane Harvesters 3520, 3522 workshop Repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 2,340 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
   Foreword
   General
      Safety
      General Specifications
      Fuels and Lubricants
      Tune-Up and Adjustments
   Engine
      Component Removal and Installation
      Cooling System
      Exhaust System
      Auxiliary Coolers
   Fuel and Air
      Diesel Fuel System
      Air Intake System
   Electrical
      Batteries
      Electrical Harness and Connectors
      Wire Harness Routings
      Sensors and Switches
      Lighting
      Fuses and Relays
      Operator Station
      Charging System
      Starting System
   Power Train
      Pump Drive
      Hydrostatic Drive Pumps
      Hydrostatic Drive Motors
      Final Drive Repair
   Track
      Ground Conditions
      Operating Conditions
      Undercarriage Wear
      Glossary
      Track Repair
   Wheel
      Wheel
   Steering and Brakes
      Steering Column
      Steering Valve and Control Unit
      Steering Arms and Pivots
      Brakes
   Hydraulic System
      Hydraulic Reservoir
      Hydraulic Pumps
      Hydraulic Valves
      Hydraulic Cylinders
      Hydraulic Motors
      Accumulators
   Miscellaneous
      Handrails and Platform
      Shields and Doors
   Operator Station
      Air Conditioning System
      System Components
      Seats
      Cab
   Topper System
      Topper
   Crop Divider System
      Crop Divider
   Knockdown Rollers
      Knockdown Rollers
   Base Cutter System
      Base Cutter
   Feed Roller System
      Rollers
   Chopper System
      Chopper
   Cleaning System
      Primary Extractor
      Secondary Extractor
   Elevator System
      Elevator
   Dealer Fabricated Tools
      Dealer Fabricated Tools

tm100419 - 3520 and 3522 Sugar Cane Harvester Repair Manual

Table of Contents

Foreword

Section 10: General

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Work in Clean Area

Service Machines Safely

Emergency Exit

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Support Machine Properly

Avoid Heating Near Pressurized Fluid Lines

Handle Fluids Safely—Avoid Fires

Remove Paint Before Welding or Heating

Precautions for Welding

Live With Safety

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Construct Dealer-Made Tools Safely

Seat Safety Switch

Tilting the Cab

Protect Bystanders

Use Steps and Handholds Correctly

Wear Protective Clothing

Handle Fuel Safely—Avoid Fires

Avoid Static Electricity Risk When Refueling

Service Accumulator Systems Safely

Service Cooling System Safely

Prepare for Emergencies

Use Safety Lights and Devices

Using Cylinder Safety Stops

Safe Transport of Harvester

Avoid High-Pressure Fluids

Wait Before Opening High-Pressure Fuel System

Use Caution on Hillsides

Use Caution On Slopes When Turning

Stopping and Parking

Park Machine Safely

Service Tires Safely

Service Tires Safely

Avoid Electrical Power Lines

Keep Hands Away from Knives

Decommissioning: Proper Recycling and Disposal of Fluids and Components

Prevent Battery Explosions

Handling Batteries Safely

Fire Prevention

In Case of Fire

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Stay Clear of Harvesting Units

Stay Clear of Rotating Drivelines

Keep Riders and Children Off Machine

Instructional Seat

Install All Guards

Avoid Hot Exhaust

Group 10: General Specifications

Dimensions

Weight

Component Specifications

Engine Specifications

Capacities

Travel Speeds

Interpreting Machine Serial Number

Machine Serial Number

Engine Serial Number

Pump Drive Gear Case Serial Number

Critical Torque Specifications

Identifying Zinc-Flake Coated Fasteners

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Face Seal Fittings Assembly and Installation—All Pressure Applications

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures

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

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures

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

Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications

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

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

Sealants and Adhesives Cross-Reference Chart

Group 15: Fuels and Lubricants

Lubricate Machine Properly

Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III

Diesel Engine Oil — Tier 2 and Stage II

Diesel Engine Oil — Tier 3 and Stage III

Diesel Fuel

Lubricity of Diesel Fuel

Diesel Engine Coolant

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

John Deere COOL-GARD™ II Coolant Extender

Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender

Operating in Warm Temperature Climates

Supplemental Coolant Additives

Testing Diesel Engine Coolant

Pump Drive, Base Cutter, and Chopper Gear Case Oil

Hydraulic Oil

Final Drive Gear Oil

Grease

Alternative and Synthetic Lubricants

Group 20: Tune-Up and Adjustments

Tune-Up and Adjustment

Check Oil Lines And Fittings

Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems

Programming Control Units

Section 20: Engine

Group 05: Component Removal and Installation

Special Tools

Other Material

Specifications

John Deere Engine Repair—Use CTM

Remove and Install Engine

Remove and Install Serpentine Belt

Inspect Belt Tensioner

Replace Engine Isolators

Group 10: Cooling System

Special Tools

Other Material

Specifications

Test Surge Tank Cap

Test Radiator and Surge Tank

Remove and Install Radiator

Drain, Flush, and Fill Cooling System

Remove and Install Fan

Thermostat Repair—Use CTM

Engine Water Pump Repair—Use CTM

Group 15: Exhaust System

Remove and Install Muffler

Group 20: Auxiliary Coolers

Specifications

Remove and Install Air Conditioning Condenser-Fuel Cooler

Remove and Install Hydraulic Oil Cooler

Remove and Install Charge Air Cooler

Cleaning Charge Air Cooler

Section 30: Fuel and Air

Group 05: Diesel Fuel System

Other Material

John Deere Fuel System Repair—Use CTM

Remove and Install Fuel Filters

Bleed Fuel System—Use CTM

Remove and Install Fuel Tank

Remove and Install Fuel Cooler

Group 10: Air Intake System

Remove and Install Engine Air Filters

Clean and Inspect Primary Air Filter

Remove and Install Air Cleaner Inlet Assembly

Turbocharger Repair—Use CTM

Section 40: Electrical

Group 05: Batteries

Specifications

Servicing Battery

Checking Battery Fluid Level

Preventing Battery Damage

Charging Battery

Battery Disconnect Switch

Remove and Install Batteries

Group 10: Electrical Harness and Connectors

Use Electrical Insulating Compound

Electrical System Visual Inspection

Using High-Pressure Washers

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

Electrical Connector / Wiring Harness Handling and Repair

Repair Procedure R-A

Repair Procedure R-B

Repair Procedure R-C

Repair Procedure R-D

Repair Procedure R-E

Repair Procedure R-F

Repair Procedure R-G

Repair Procedure R-I

Repair Procedure R-J

Repair Procedure R-K

Repair Procedure R-M

Repair Procedure R-N

Harness Repair — Splice Connector

Group 15: Wire Harness Routings

Cab Harness Routing

Armrest Harness Routing

Front Chassis Harness Routing

Engine Harness Routing

Battery Harness Routing

Rear Chassis Harness Routing

Main Track Harness Routing

Elevator Harness Routing

Group 20: Sensors and Switches

Other Material

Specifications

Replace Engine Sensors and Switches—Use CTM

Remove and Install Engine Access Door Switch

Remove and Install Fuel Level Sensor

Remove and Install Hydraulic Oil Temperature Sensor

Remove and Install Hydraulic Reservoir Level Switch

Remove and Install Hydraulic Reservoir Pressure Switch

Remove and Install Crop Divider Position Sensor (If Equipped)

Remove and Install Base Cutter Position Sensor (Wheel Harvester)

Remove and Install Base Cutter Position Sensor (Track Harvester)

Remove and Install Base Cutter Motor Pressure Sensor

Remove and Install Chopper/Base Cutter Pump Pressure Sensor

Steering Input Device (SID) (Track Harvester)

Remove and Install Primary Extractor Fan Speed Sensor

Remove and Install Air Filter Restriction Switch

Remove and Install Hydrostatic Drive Motor Speed Sensor—Single Speed (Track Harvester)

Remove and Install Hydrostatic Drive Motor Speed Sensor—Two-Speed (Track Harvester)

Remove and Install Hydrostatic Drive Motor Speed Sensor (Wheel Harvester)

Remove and Install Park Brake Valve Pressure Sensor

Group 25: Lighting

Remove and Install Cab Dome Light Assembly

Remove and Install Tail Lights

Remove and Install Engine Compartment Work Light

Remove and Install Front Turn Signals

Remove and Install Side Lights

Remove and Install Elevator Lights

Remove and Install Cab Roof Lights

Group 30: Fuses and Relays

Replacing Fuses

Fuse and Relay Panel Location

Fuse and Relay Identification

Group 35: Operator Station

Special Tools

Other Material

Specifications

Remove and Install Wiper Motor

Armrest Console Controls

Remove and Install CommandTouch™ Console

Remove and Install Multi-Function Lever

Remove And Install Multi-Function Lever Position Sensor

Replace Neutral Safety Switch

Overhead Console Control Identification

Remove and Install Overhead Console Switches

Remove and Install Radio

Remove and Install Radio Speaker

Floor Pedal Identification

Remove and Install Floor Pedals

Remove and Install Key Switch

Remove and Install Turn Signal Switch

Remove and Install CommandCenter™ (VTI) Display Unit

Replace Primary Display Unit (PDU)

Group 40: Charging System

Special Tools

Other Material

Specifications

Remove and Install Alternator

Remove and Install Alternator Pulley

John Deere Engine Accessories—Alternator Repair

Group 45: Starting System

Special Tools

Other Material

Specifications

Remove and Install Starting Motor

John Deere Starting Motor Repair

Section 50: Power Train

Group 05: Pump Drive

Special Tools

Other Material

Specifications

Remove and Install Pump Drive Gear Case

Remove and Install Drive Coupling Assembly

John Deere Pump Drive Gear Case Repair—Use CTM

Group 10: Hydrostatic Drive Pumps

Special Tools

Other Material

Specifications

Remove and Install Hydrostatic Drive Pumps

Hydrostatic Drive Pump Exploded View

Remove and Install Hydrostatic Drive Pump Shaft Seal

Remove and Install Hydrostatic Drive Pump Multi-Function Cartridge Valves

Engage and Disengage Drive Pump Bypass Actuators

Remove and Install Hydrostatic Drive Pump Charge Pressure Relief Valve

Repair Charge Pump

Remove and Install Hydrostatic Drive Pump Electronic Displacement Control

Remove and Install Pressure Control Pilot

Disassemble and Assemble Hydrostatic Drive Pump

Hydraulic-Hydrostatic System Flushing Procedure

Start-up Procedure After Hydrostatic Repair

Group 15: Hydrostatic Drive Motors

Special Tools

Other Material

Specifications

Remove and Install Hydrostatic Drive Motor (Wheel Harvester)

Remove and Install Hydrostatic Motor (Track Harvester)

Hydrostatic Drive Motor—Single Speed (Style A) Exploded View

Remove and Install Hydrostatic Drive Motor Shaft Seal—Single Speed (Style A)

Disassemble and Assemble Hydrostatic Drive Motor—Single Speed (Style A)

Remove and Install Hydrostatic Drive Motor Shaft Seal—Single Speed (Style B)

Remove and Install Hydrostatic Drive Motor End Cover O-Ring—Single Speed (Style B)

Remove and Install Hydrostatic Drive Motor Flushing Valve—Single Speed (Style B)

Disassemble and Assemble Hydrostatic Drive Motor—Two-Speed (Style A)

Disassemble and Assemble Hydrostatic Drive Motor—Two-Speed (Style B)

Disassemble and Assemble Hydrostatic Drive Motor Port Plate—Two-Speed

Group 20: Final Drive Repair

Special Tools

Other Material

Specifications

Remove and Install Final Drive (Wheel Harvester)

Remove and Install Final Drive (Track Harvester)

Final Drive Exploded View (S.N. 120701— )

Disassemble Final Drive (S.N. 120701— )

Assemble Final Drive (S.N. 120701— )

Final Drive Exploded View (S.N. —100986)

Disassemble Final Drive (S.N. —100986)

Assemble Final Drive (S.N. —100986)

Section 55: Track

Group 05: Ground Conditions

Ground Conditions

Abrasion

Impact

Packing

Moisture

Temperature

Chemicals

Group 10: Operating Conditions

Operating Conditions

Avoid Impacts When Possible

Do Not Spin Tracks

Avoid Excessive Speed

Avoid Unnecessary Reverse Operation

Use Counter-Rotation Wisely

Store the Machine Properly

Use Proper Maintenance Procedures

Keep Good Undercarriage Records

Track Bouncing

Sprocket Ratchet

Vibration

Pin and Bushing Retention Life

Sealed and Lubricated Track Chain Pin and Bushing Joint Life

Group 15: Undercarriage Wear

Link Rail Surface Wear

Link Rail Top Wear Uneven (Scalloped)

Link Roll-Over

Link Face Wear

Rail Side Wear

Pin Boss Wear

Link Counterbore Wear

Link Cracking

Rail Chipping

Track Link Wear Measurement

Internal Wear

Pin Breakage

Master Pin and Bushing Wear

Pin End Wear

Forward Drive Side Contact

Reverse Drive Side Contact

Pitch Wear

Forward Drive Side Tooth Wear

Forward Drive Side Bushing Wear

Reverse Operation

Reverse Drive Side Tooth Wear

Reverse Drive Side Bushing Wear

Bushing Cracks

Sprocket Root Wear

Bushing Radial Wear

Reverse Drive Side Tip Wear

Back Jamming

Forward Drive Side Tip Wear

Sprocket Side Wear

Tooth Corner Breakage

Tooth Tip Breakage

Sprocket Mounting

Sprocket Identification

Bushing and Link Counterbore Wear

Bushing End Cracks

Bushing End Wear

Bushing Seal Face—Sealed and Lubricated Track Chain

Track Link Bushing Wear Measurement

Roller Tread Wear

Roller Flange Top Wear

Roller Flat Spots

Roller Flange Side Wear

Track Roller Wear Measurement

Idler Tread Wear

Idler Tread Cracks

Idler Flange Side Wear

Idler Flange Top Wear

Idler Sidewall Wear and Cracking

Idler Wear Measurement

Carrier Roller Tread Wear

Carrier Roller Flange Wear

Carrier Roller Flange Top Wear

Carrier Roller Wear Measurement

Grouser Wear

Shoe Bending

Leading and Trailing Edge Wear

Shoe Contact with Rock Guard

Loose Hardware Damage

Track Shoe Wear Measurement

Track Guide Wear

Group 20: Glossary

Undercarriage

Carrier Roller

Front Idler

Ground Conditions

Grouser

Link

Sealed and Lubricated Track Chain

Master Bushing

Master Track Shoe

Sealed Track Chain

Pin Boss

Basecutter Guards

Track Guides

Sprocket

Track Adjuster

Track Bushing

Track Frame

Track Chain Pin

Track Roller

Track Seals—Sealed and Lubricated Track Chain

Track Shoes

Group 25: Track Repair

Special Tools

Other Material

Specifications

Adjust Track Chain Tension

Remove and Install Track Shoe

Remove and Install Track Assembly

Remove and Install Axle

Remove and Install Track Chain

Remove and Install Tension Idler

Remove and Install Track Idler

Remove and Install Track Sprocket

Remove and Install Track Rollers

Remove and Install Track Guides

Disassemble, Inspect, Lubricate, and Assemble Track Chain

Section 57: Wheel

Group 05: Wheel

Other Material

Specifications

Jack Locations

Remove and Install Wheel Assembly

Remove and Install Front Wheel Bearings

Remove and Install Tire

Section 60: Steering and Brakes

Group 05: Steering Column

Specifications

Steering Column Components (Style A)

Steering Column Components (Style B)

Disassemble And Assemble Steering Column (Style B)

Replace Telescoping Shaft Bearings

Group 10: Steering Valve and Control Unit

Other Material

Specifications

Remove and Install Steering Valve (Wheel Harvester)

Steering Valve Exploded View (Wheel Harvester)

Disassemble and Assemble Steering Valve (Wheel Harvester)

Remove and Install Steering Control Unit (Track Harvester)

Remove and Install Steering Input Device (SID) (Track Harvesters)

Group 15: Steering Arms and Pivots

Specifications

Steering Linkage Exploded View

Check and Adjust Front Wheel Toe-In

Group 20: Brakes

Park Brake Repair

Section 70: Hydraulic System

Group 05: Hydraulic Reservoir

Other Material

Specifications

Drain and Fill Hydraulic Reservoir

Replace Hydraulic Reservoir Sight Gauge Assembly

Remove and Install Hydraulic Filter Assemblies

Remove and Install Hydraulic Reservoir

Connecting Vacuum Pump to Hydraulic Reservoir

Group 10: Hydraulic Pumps

Special Tools

Other Material

Specifications

Pump Identification

Base Cutter and Chopper Pumps Exploded View

Remove and Install Base Cutter Pump (Optional)

Remove and Install Chopper/Base Cutter Pump

Remove and Install Primary Extractor Pump

Remove and Install Multi-Function Gear Pump

Remove and Install Feed System Gear Pump

Remove and Install Base Cutter and Chopper Pump Electronic Control

Disassemble and Assemble Base Cutter and Chopper Pumps

Remove and Install Primary Extractor Pump Electronic Displacement Control

Disassemble and Assemble Primary Extractor Pump

Multi-Function Gear Pump Exploded View

Feed System Gear Pump Exploded View

Repair Multiple Gear Pumps

Remove and Install Cab Tilt Hand Pump

Fill and Bleed Cab Tilt Hand Pump

Start-Up Procedure After Hydraulic Pump Repair

Group 15: Hydraulic Valves

Other Material

Specifications

Remove and Install Topper Valve

Disassemble and Assemble Topper Valve

Remove and Install Floating Crop Divider Valves

Disassemble and Assemble Floating Crop Divider Valve

Remove and Install Improved Height Control Valve

Remove and Install Suspension Control Valve (Track Harvester)

Disassemble and Assemble Suspension Control Valve (Track Harvester)

Remove and Install Front Feed Pilot Control Valve

Remove and Install Front Feed Pilot Control Valve (Optional Valve)

Remove and Install Rear Feed Pilot Control Valve

Pilot Control Valve Exploded View

Disassemble and Assemble Front Feed, Front Feed (Optional Valve), and Rear Feed Pilot Control Valves

Remove and Install Feed System Solenoid Valve

Remove and Install Flow Divider Valve

Disassemble and Assemble Flow Divider Valve

Remove and Install Steering Priority Valve (Wheel Harvester)

Disassemble and Assemble Steering Priority Valve (Wheel Harvester)

Remove and Install Chopper Curtain Agitator Valve

Remove and Install Cooling System Reversible Motor Valve

Disassemble and Assemble Cooling System Reversible Motor Valve

Remove and Install Swing Table Holding Valve

Remove and Install Elevator Speed Control Valve

Disassemble and Assemble Billet Length and Elevator Speed Control Valves (Manual Adjust)

Remove and Install Triple Relief Valve

Disassemble and Assemble Triple Relief Valve

Remove and Install Elevator Valve

Disassemble and Assemble Elevator Valve

Remove and Install Cylinder Function Valve (6 Bank)

Disassemble and Assemble Cylinder Function Valve (6 Bank)

Remove and Install Auxiliary Tilt Function Valve (4 Bank)

Remove and Install Park Brake Valve

Disassemble and Assemble Park Brake Valve

Remove and Install Remote Flushing Valve

Remove and Install Varitorq Valve (Wheel Harvester)

Remove and Install Ground Drive High/Low Valve (Track Harvester)

Remove and Install Positive Traction Valve (Wheel Harvester)

Group 20: Hydraulic Cylinders

Other Material

Specifications

Test Double Action Cylinders

Remove and Install Topper Cylinder

Remove and Install Cab Tilt Cylinder

Remove and Install Elevator Swing Cylinders

Disassemble and Assemble Topper, Cab Tilt, and Elevator Swing Cylinders—Use CTM

Remove and Install Steering Cylinders (Wheel Harvester)

Disassemble and Assemble Steering Cylinders (Wheel Harvester)

Remove and Install Crop Divider Lift Cylinders

Disassemble and Assemble Crop Divider Lift Cylinders

Remove and Install Base Cutter Lift Cylinders (Wheel Harvester)

Disassemble and Assemble Base Cutter Lift Cylinders (Wheel Harvester)

Remove and Install Base Cutter Lift Cylinders (Track Harvester)

Disassemble and Assemble Base Cutter Lift Cylinders (Track Harvester)

Remove and Install Knockdown Tilt Cylinder (Optional)

Remove and Install Crop Divider Tilt Cylinders (Optional)

Disassemble and Assemble Knockdown Tilt and Crop Divider Tilt Cylinder (Optional)

Remove and Install Elevator Lift Cylinders

Disassemble and Assemble Elevator Lift Cylinders

Remove and Install Elevator Discharge Flap Cylinder

Disassemble and Assemble Elevator Discharge Flap Cylinder

Group 25: Hydraulic Motors

Special Tools

Other Material

Specifications

Remove and Install Topper Gathering Disk Motor (Whole Topper)

Remove and Install Topper Gathering Disk Motor (Shredder Topper)

Remove and Install Topper Severing Disk Motor (Whole Topper)

Remove and Install Topper Drum Motor (Shredder Topper)

Topper Severing Disk (Whole Topper) and Secondary Extractor Fan Motors Exploded View

Disassemble and Assemble Topper Severing Disk (Whole Topper) and Secondary Extractor Fan Motors

Remove and Install Crop Divider Scroll Motor

Remove and Install Outer Scroll Motor

Remove and Install Side Knife Motor

Remove and Install Crop Divider Knockdown Roller Motor

Remove and Install Adjustable Knockdown Roller Motor

Remove and Install Fixed Knockdown Roller Motor

Remove and Install Base Cutter Motor

Remove and Install Feed Roller Motors

Remove and Install Butt-Lifter Roller Motors

Disassemble and Assemble Topper Gathering Disk, Scroll, Side Knife, Crop Divider Knockdown Roller, Fixed and Adjustable Knockdown Rollers, Butt-Lifter, Feed Roller, Sill Roller, and Elevator Motors

Remove and Install Chopper Motor

Chopper Motor Exploded View

Disassemble and Assemble Chopper Motor

Base Cutter and Primary Extractor Fan Motors Exploded View

Disassemble and Assemble Base Cutter and Primary Extractor Fan Motors

Remove and Install Primary Extractor Fan Motor

Remove and Install Primary Extractor Swing Motor

Remove and Install Secondary Extractor Fan Motor

Remove and Install Secondary Extractor Rotate Motor

Remove and Install Chopper Curtain Agitator Motor

Remove and Install Sill Motor

Primary Extractor Swing, Secondary Extractor Rotate, and Chopper Curtain Agitator Motors Exploded View

Disassemble and Assemble Primary Extractor Swing, Secondary Extractor Rotate, and Chopper Curtain Agitator Motors

Remove and Install Elevator Motor

Remove and Install Cooling System Motor

Cooling System Motor Exploded View

Disassemble and Assemble Cooling System Motor

Group 30: Accumulators

Special Tools

Specifications

Charge Crop Divider and Base Cutter Accumulators

Charge Topper and Elevator Accumulators

Section 80: Miscellaneous

Group 05: Handrails and Platform

Specifications

Remove and Install Left-Hand Ladder

Remove and Install Right-Hand Ladder

Remove and Install Handrail System

Remove and Install Left-Hand Platform

Remove and Install Right-Hand Platform

Remove and Install Center Platform

Remove and Install Cab Brush Guard

Group 10: Shields and Doors

Remove and Install Engine Compartment Doors

Remove and Install Base Cutter Shields (Wheel Harvester)

Section 90: Operator Station

Group 05: Air Conditioning System

Special Tools

Other Material

Specifications

Service Parts Kits

Service Information

Hose and Tubing O-Ring Connection Torques

Proper Refrigerant Handling

R-134a Refrigerant Precautions

Leak Test With Dye

Flush Air Conditioning System

Purge Air Conditioning System

Evacuate Air Conditioning System

Charge Air Conditioning System

Check Refrigerant Oil Charge

Compressor Oil Information

Determine Correct Oil Charge

Replace Compressor Relief Valve

Remove and Install Compressor

Repair Compressor

Repair Compressor Clutch

Check Clutch Hub Clearance

Inspect Compressor Manifold

Test Shaft Seal Leakage

Test Volumetric Efficiency

Discharge and Recover Air Conditioning System

Group 10: System Components

Specifications

Remove and Install Blower Motor

Replace Receiver Dryer

Remove and Install Condenser

Repair Condenser

Replace Low Pressure Switch

Replace High Pressure Switch

Replace Expansion Valve

Group 15: Seats

Remove and Install Operator Seat

Remove and Install Operator Seat Presence Switch

Operator Seat Exploded View

Operator Seat Air Suspension Assembly Exploded View

Disassemble and Assemble Operator Seat Air Suspension Assembly

Remove and Install Instructional Seat

Group 20: Cab

Special Tools

Specifications

Remove and Install Cab Windshield

Remove and Install Rear Window

Remove and Install Side Window

Remove and Install Cab Outer Roof

Remove and Install Cab Inner Roof

Remove and Install Front Cab Headliner

Remove and Install Rear Cab Headliner

Remove and Install Cab Door

Disassemble and Assemble Cab Door

Cab Door Latch Striker

Cab Tilt Procedure

Remove and Install Cab

Section 100: Topper System

Group 05: Topper

Special Tools

Other Material

Specifications

Replace Topper Blades

Remove and Install Topper Gathering Disk (Whole Topper)

Remove and Install Topper Gathering Disk Extensions (Whole Topper)

Remove and Install Topper Severing Disk, Hub, and Drum (Whole Topper)

Remove and Install Topper Assembly

Remove and Install Topper Boom Arms

Shredder Topper Exploded View

Adjust Shredder Topper Shear Plates

Remove and Install Topper Gathering Disk (Shredder Topper)

Disassemble and Assemble Shredder Topper

Section 110: Crop Divider System

Group 05: Crop Divider

Special Tools

Other Material

Specifications

Remove and Install Crop Divider Assembly

Remove and Install Crop Divider Scroll and Bearing Assembly

Remove and Install Outer Scrolls

Remove and Install Outer Scroll Upper Brackets

Replace Outer Scroll Bearing Assembly

Remove and Install Floating Shoes

Replace Side Knife Blades

Remove and Install Side Knife Assembly

Remove and Install Vine Cutter Knives

Remove and Install Crop Divider Knockdown Roller Assembly

Gauge Wheel Exploded View (If Equipped)

Section 120: Knockdown Rollers

Group 05: Knockdown Rollers

Special Tools

Other Material

Specifications

Remove and Install Fixed Knockdown Roller Assembly

Disassemble and Assemble Fixed Knockdown Roller

Remove and Install Adjustable Knockdown Roller Assembly

Disassemble and Assemble Adjustable Knockdown Roller Assembly

Section 130: Base Cutter System

Group 05: Base Cutter

Special Tools

Other Material

Specifications

Base Cutter Gear Case Exploded View—3520

Base Cutter Gear Case Exploded View—3522

Remove, Service, and Install Base Cutter Blades

Remove and Install Base Cutter Disks

Repair Base Cutter Breakaway Legs (Optional)

Remove and Install Base Cutter Assembly (Wheel Harvester)

Remove and Install Base Cutter Assembly (Track Harvester)

Disassemble and Assemble Base Cutter Gear Case

Section 140: Feed Roller System

Group 05: Rollers

Special Tools

Other Material

Specifications

Feed Roller Identification

Remove and Install Butt-Lifter Roller (B1)

Remove and Install Bottom Feed Rollers (B2, B3, B4, and B5)

Remove and Install Top Feed Rollers (T1, T2, T3, T4, and T5)

Check and Adjust Feed Motor Mount Axial Alignment

Remove and Install Sill Roller Assembly

Section 150: Chopper System

Group 05: Chopper

Special Tools

Other Material

Specifications

Chopper Timing

Remove and Install Chopper Blades and Kicker Plates

Adjust Chopper Flywheel Clutch

Chopper Flywheel and Clutch Exploded View

Remove and Install Chopper Flywheel and Clutch

Remove and Install Left-Hand Chopper Bearings (Style A)

Remove and Install Left-Hand Chopper Bearings (Style B)

Remove and Install Chopper Assembly

Chopper Gear Case Exploded View

Disassemble and Assemble Chopper Gear Case

Remove and Install Chopper Curtain Agitator Assembly

Section 160: Cleaning System

Group 05: Primary Extractor

Other Material

Specifications

Adjust Primary Extractor Chain Tension

Remove and Install Primary Extractor

Remove and Install Primary Extractor Hood

Remove and Install Primary Extractor Fan

Start-up Procedure After Fan Installation

Group 10: Secondary Extractor

Special Tools

Other Material

Specifications

Remove and Install Secondary Extractor

Remove and Install Secondary Extractor Hood

Remove and Install Secondary Extractor Fan and Hub Assembly

Check and Adjust Secondary Extractor Fan Assembly Balance

Adjust Secondary Extractor Chain Tension

Section 170: Elevator System

Group 05: Elevator

Special Tools

Other Material

Specifications

Remove and Install Elevator

Remove and Install Elevator Chain

Check and Adjust Elevator Sprockets and Chain Tension

Remove and Install Elevator Chain Slats

Remove and Install Elevator Wear Strips

Replace Elevator Idler Sprocket Bearings

Replace Elevator Tail Shaft Bearing Assemblies

Remove and Install Tail Shaft

Remove and Install Elevator Swing Table

Remove and Install Elevator Discharge Flap

Elevator Bypass Procedure

Section 199: Dealer Fabricated Tools

Group 05: Dealer Fabricated Tools

DFRW20—Compressor Holding Fixture

DFEXT4—Sizing Arbor

DFT8T2—Bearing Stop Limit Driver

DFT8T3—Cab Lifting Bracket

DFT8T4—Front Wheel Removal and Installation Tool

DFT8T5—Rear Wheel Removal and Installation Tool

DFT8T6—Final Drive Cover Removal Tool