John Deere 3520 3522 Sugar Cane Harvester Repair Technical Manual TM100419

Description

File Details

• Manual Type: Repair Technical Manual
• Document Number: TM100419
• Publication Date: 27 October 2011 (27OCT11)
• Models Covered: John Deere 3520 and 3522 Sugar Cane Harvesters
• Language: English
• Pages: 588
• File Format: PDF
• Publisher Note: John Deere Thibodaux, Litho in U.S.A.

What This Manual Covers

The John Deere 3520 3522 Sugar Cane Harvester Repair Technical Manual TM100419 is organized into fourteen major sections, each addressing a distinct machine system or assembly group. The table of contents runs deep — most sections are subdivided into multiple groups with their own tools lists, specifications, wear tolerances, and torque values before the repair procedures begin.

• Section 10 — General
  • Group 05: Safety (operation safety, service safety, accumulator safety, fire prevention, hazardous areas)
  • Group 10: Specifications — John Deere 6090 Engine PowerTech
  • Group 15: General Capacities (harvester fluid capacities, tire inflation pressures)
  • Group 20: Torque Specifications (component-specific torques, metric and unified inch bolt torque charts, fitting torque tables for SAE 37°/JIC, ORS, BSPP, four-bolt flange)
  • Group 25: Fluid Recommendations (engine coolant, hydraulic fluid, diesel fuel, engine oil, gear oils, grease)
  • Group 30: General Information (conversions, specialty tools, harvester specialty tool part numbers)
  • Group 35: Service Points (component locations, service point locations, grease point locations)
• Section 20 — Engine
  • Group 05: Pump Drive Gear Box
• Section 30 — Feed Roller System
  • Group 05: Knockdown Roller
  • Group 10: Buttlifter Roller (B1)
  • Group 15: Bottom Feed Roller
  • Group 20: Top Feed Roller
• Section 40 — Electrical
  • Group 10: Electrical Harness and Connectors (Weather Pack, Metric-Pack, Deutsch connector service; terminal extraction and installation procedures)
• Section 50 — Hydrostatic System
  • Group 05: Planetary Final Drive Bonfiglioli
  • Group 10: Planetary Final Drive Iberica
  • Group 15: Track
  • Group 20: Wheel
• Section 60 — Steering System
  • Group 05: Steering Column (Type A)
  • Group 10: Steering Column (Type B)
  • Group 15: Steering Wheel Position Input Assembly (Autotrac Ready Track Machines)
  • Group 20: Relief Valve
• Section 70 — Main Hydraulic System
  • Group 10A: Multiple Gear Pump
  • Group 10B: Piston Pump
  • Group 20A: Steering Cylinder
  • Group 20B: Crop Divider Cylinder
  • Group 20C: Crop Divider Tilt Cylinder
  • Group 20D: Topper Cylinder
  • Group 20E: Basecutter Cylinder
  • Group 20F: Elevator Cylinders
  • Group 20G: Height Indicator Cylinder
  • Group 20H: Cab Tilt Cylinder
  • Group 20I: Knockdown Tilt and Crop Divider Tilt Cylinder
  • Group 30A: Fixed Displacement Motor
  • Group 30B: Collector, Crop Divider, Feedroller and Elevator Motor
  • Group 30C: Topper and Secondary Extractor Motor
  • Group 30D: Basecutter and Primary Extractor Motors
  • Group 30E: Secondary Extractor Hood Rotate Motor
  • Group 30F: Cooling Package/Oil Cooler Motor
  • Group 30G: Variable Displacement Ground Drive Motor (Wheel)
  • Group 30H: Fixed Displacement Motor (Track)
  • Group 30I: Chopper Motor
  • Group 40A: Rear Feed Roller Valve
  • Group 40B: Steering Priority Valve (Wheel)
  • Group 40C: Steering Valve
• Section 80 — Topper System
  • Group 05: Collector, Crop Divider, Feed Roller and Elevator Motor
• Section 90 — Operator’s Station
  • Group 05: Cab
• Section 100 — Crop Divider System
  • Group 05: Crop Divider
• Section 110 — Basecutter System
  • Group 05: Basecutter Gearbox
  • Group 10: Basecutter Lift Cylinder Accumulators
• Section 120 — Chopper System
  • Group 05: Chopper Box
• Section 130 — Cleaning System
  • Group 05: Primary Extractor
• Section 140 — Elevator System
  • Group 05: Elevator Systems Installation

The John Deere 3520 3522 Sugar Cane Harvester Repair Technical Manual TM100419 gives a working technician a complete roadmap through the machine — from the pump drive gearbox behind the engine, through every hydraulic cylinder and motor on the main hydraulic circuit, to the planetary final drives, track and wheel configurations, basecutter gearbox, chopper box, primary extractor, and elevator installation. Each group begins with a consolidated summary of essential tools, service equipment, materials, service parts kits, specifications, wear tolerances, and torque values, so the information needed to start a job is gathered in one place rather than scattered across the text.

Key Systems and Repair Scope

The hydraulic section alone spans more than twenty subgroups covering every cylinder and motor on the machine. Cylinder disassembly and reassembly procedures include explicit cautions against using pneumatic or hydraulic pressure to remove rod assemblies, rod finish protection instructions, and step-by-step seal replacement. Motor groups address fixed displacement, variable displacement ground drive (wheel), and track-specific motor reconditioning — including bearing plate, valve segment, and cylinder block replacement procedures with inspection criteria for running surface condition, locating pinhole wear, and sealing surface integrity.

The planetary final drive sections cover both Bonfiglioli and Iberica units with detailed hub disassembly methods, lock-nut removal techniques including drill-and-split procedures where conventional removal is not possible, press procedures for bearing and hub housing separation, and assembly guidelines that specify when entire reduction stages — rather than individual gears — must be replaced. Threaded ring nut reuse is explicitly prohibited in the assembly instructions.

The electrical section addresses Weather Pack, Metric-Pack, and Deutsch connector types with terminal extraction tools specified by wire gauge, crimp type and crimp inspection criteria, and handling rules to prevent locking mechanism damage during service. Component-specific torque values in Section 10 include feed roller motor mounting bolts, top and bottom feed roller mounting studs, basecutter mounting bolts, basecutter disk mounting bolts, chopper flywheel nut, final drive mounting bolts, track shoe bolts, track segment sprockets, and swing table pin nuts — each with Araldite, Loctite 242, Loctite 271, or Anti-Seize adhesive call-outs where applicable.

Specifications and Capacity Data

Section 10 consolidates the 3520 and 3522 fluid capacities in a single comparative table: fuel tank 568 L (150 U.S. gal) for both models, hydraulic oil tank 397 L (105 U.S. gal), engine oil 29.5 L (7.8 U.S. gal), coolant 69.6 L (16.5 U.S. gal), chopper gearbox 11.01 L (2.9 U.S. gal), basecutter gearbox dry 8.97 L (2.37 U.S. gal) for the 3520 and 13.5 L (3.5 U.S. gal) for the 3522, pump drive gearbox 7.1 L (1.87 U.S. gal), and final drive 4.2 L (1.1 U.S. gal) for both wheel and track variants. Approximate operating weights are listed as 19,050 kg (42,000 lb) for the 3520 and 19,780 kg (43,600 lb) for the 3522. The engine specification table identifies the John Deere 6090H 9.0 L six-cylinder powerplant in two variants — model 609HT803 Tier III rated at 337 HP at 2100 RPM and model 609HT804 Non EGR Tier II at 375 HP at 2100 RPM — with turbocharger and air-to-air aftercooling noted. Preliminary service intervals call for oil and filter changes after the first 100 hours and every 250 hours thereafter.

Get This Manual — Instant PDF Download

The John Deere 3520 3522 Sugar Cane Harvester Repair Technical Manual TM100419 provides the procedure depth a technician needs to correctly disassemble, inspect, and reassemble every major system on both the wheel and track variants of these harvesters. Repair work attempted without the correct torque values, adhesive specifications, press procedures, and wear-limit data risks premature component failure and repeated downtime during harvest season — precisely when reliable machine operation matters most. This 588-page document puts the right procedures and specifications in your hands before the wrench goes on. Pay once, download instantly, read on any device, print as needed — no shipping, no waiting.