John Deere 459s, 559s Silage Special; 459, 559 Round Balers All Inclusive Service Technical Manual (TM121119)

TM121119 - John Deere 459s, 559s Silage Special; 459, 559 Round Balers All Inclusive Service Technical Manual (Diagnosis Operation Tests Repair Service).PDF

Complete Diagnostics and Repair Technical manual with Electrical Wiring Diagrams for John Deere Silage Special Models 459s, 559s; Round Balers Models 559, 559, with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics.

John Deere 459s, 559s Silage Special & 459, 559 Round Balers workshop Diagnosis & 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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: 1,505 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   General
      Safety
      Specifications
      General Information
      Lubricants
   Drive Train
      General Information
      Diagnosing Malfunctions
      Drive Train Protection
      PTO Driveline
      Remove and Install Gear Case
      Gear Case Repair
      Roll Drives
      Rolls
      Miscellaneous
   Hydraulics
      General Information
      Diagnosing Malfunctions
      Operation and Tests
      Tensioning Valve Repair
      Gate Lock Valve Repair
      Cylinder Repair
      Optional Hydraulic Bale Ramp Repair
   Twine Mechanism-Electric
      General Information
      Diagnosing Malfunctions
      Twine Wrap System Adjustments
      Twine Wrap System Repair
   COVEREDGE Net Wrap System (If Equipped)
      General Information
      Diagnosing Malfunctions
      Net Wrap Repair
   Electrical System
      General Information
      Common Electrical Tests and Checks
      Diagnosing Malfunctions-BALETRAK Pro System
      Tests and Adjustments-BALETRAK Pro System
      Electrical Diagrams-BALETRAK Pro System
      BALETRAK Pro Monitor-Controller Operations
      Repair-BALETRAK Pro System
      Connector Repair
   Pickup
      General Information
      Diagnosing Malfunctions
      Regular Pickup Repair
      MEGAWIDE PLUS Pickup Repair
      Miscellaneous
   Miscellaneous
      Wheel Repair
      Gate Repair
      Tension Arm Repair
      Tongue Repair
      Belt Repair
      Main Frame Repair
   Dealer Fabricated Tools
      Dealer Fabricated Tools
 

tm121119 - 459, 459 Silage Special, 559, and 559 Silage Special Round Balers

Table of Contents

Foreword

Section 10: General

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Park Machine Safely

Operate Baler Safely

Protect Bystanders

Service Machine Safely—459, 459S, 559, 559S

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Avoid High-Pressure Fluids

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Service Tires Safely

Practice Safe Maintenance

Use Proper Tools

Construct Dealer-Made Tools Safely

Dispose of Waste Properly

Precautions for Welding

Protect Against High Pressure Spray

Live With Safety

Group 10: Specifications

Machine Specifications—459, 459 Silage Special, 559, and 559 Silage Special

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Service Recommendations For 37° Flare and 30° Cone Seat Connectors

Group 15: General Information

Machine Description—459, 459 Silage Special, 559, and 559 Silage Special

Group 20: Lubricants

Grease

Gear Case Oil

Alternative and Synthetic Lubricants

Mixing of Lubricants

Lubricant Storage

Perform Lubrication and Maintenance

Section 20: Drive Train

Group 05: General Information

Drive Train Operation

Operating RPM

Group 10: Diagnosing Malfunctions

PTO Driveline Difficulties

Slip Clutch Alert Feature (If Equipped)

Slip Clutch Difficulties (If Equipped)

Gear Case Difficulties

Drive Chain Difficulties

Group 15: Drive Train Protection

Service Parts Kits

Specifications

Turn Slip Clutch Alert System On/Off

Replace PTO Slip Clutch Alert Sensor

Replace Pickup Slip Clutch Alert Sensor

Adjust PTO and Pickup Slip Clutch Alert Sensors (MegaWide™ Plus and MegaTooth™ Pickups)

Check Pickup Slip Clutch Torque (MegaWide™ Plus)

Replace Pickup Slip Clutch

Repair PTO Driveline Hub—Slip Clutch Type

Repair PTO Driveline Slip Clutch (If Equipped)

Adjust PTO Driveline Slip Clutch (If Equipped)

Slipping Seized PTO Driveline Slip Clutch (If Equipped)

Group 20: PTO Driveline

Service Parts Kits

PTO Driveline Exploded View—Slip Clutch Type

Repair PTO Lock-Back Collar Disconnect

Repair PTO Constant Velocity Joint

Group 25: Remove and Install Gear Case

Other Material

Specifications

Remove Gear Case

Install Gear Case

Replace Hex Shaft from Gear Case-to-Sidesheet

Group 27: Gear Case Repair

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Disassemble Gear Case

Gear Case Exploded View

Assemble Gear Case

Group 30: Roll Drives

Specifications

Adjust Lower Drive Roll Chain

Adjust Upper Drive Roll Chain

Check Starter Roll Drive Chain

Adjust Starter Roll Drive Chain

Replace Starter Roll Drive Chain

Remove and Install Starter Roll Sprocket

Remove and Install Lower Drive Roll Sprocket

Check Upper Drive Roll Sprocket Alignment

Group 35: Rolls

Service Equipment and Tools

Other Material

Specifications

Diagram of Rolls and Belt Routing—459 and 559

Diagram of Rolls and Belt Routing—459S and 559S

Remove and Install Starter Roll

Remove and Install Belt Staggering Roll

Remove and Install Cleaning Auger Roll 459S and 559S

Checking and Adjusting Clearance Between Cleaning Auger and Staggered Belt Roll

Remove and Install Front Idler Roll

Remove and Install Take-Up Arm Roll

Remove and Install Top Idler Roll

Remove and Install Auxiliary Take-Up Roll

Remove and Install Upper Rear Gate Roll

Remove and Install Lower Rear Gate Roll—without CoverEdge™ Net Wrap

Remove and Install Lower Rear Gate Roll—with CoverEdge™ Net Wrap

Remove and Install Lower Front Gate Roll

Remove and Install Rear Roll of Tension Arm

Remove and Install Center and Front Rolls of Tension Arm

Replace Tension Arm Roll Shaft

Replace Stationary Shaft Roll Bearings

Remove and Install Lower Drive Roll

Remove and Install Left-Hand Side Lower Drive Roll Bearing

Remove and Install Right-Hand Side Lower Drive Roll Bearing

Remove Upper Drive Roll

Install Upper Drive Roll

Install Upper Drive Roll Bearings

High-Moisture Kit (Silage Baling) Difficulties

Group 40: Miscellaneous

Service Equipment and Tools

Specifications

Adjust Lower Front Gate Roll Scraper

Adjust Starter Roll Scraper (If Equipped)

Adjust Idler Roll Scraper (If Equipped)

Check Belt Tracking

Adjust Belt Tracking without COVEREDGE Net Wrap

Adjust Belt Tracking with COVEREDGE Net Wrap

Section 30: Hydraulics

Group 05: General Information

Hydraulic System Description and Diagram

Tensioning Valve

Non-Adjustable Relief Valve

Pilot-Operated Check Valve

Optional Variable Soft Core Solenoid Valve

Install Inline Orifice Correctly

Group 10: Diagnosing Malfunctions

Diagnosing Hydraulic Malfunctions

Group 15: Operation and Tests

Essential or Recommended Tools

Specifications

Hydraulic System Operation

Low Pressure Relief Valve Test

High-Pressure Relief Valve Test—Field Test

High-Pressure Relief Valve Test—Shop Test

Test Tension/Gate Cylinder for Leakage

Test Hydraulic Twine Arm and Pickup Lift Cylinders for Leakage

Test Take-Up Arm Cylinder

Test Gate Lock Valve for Leakage

Group 20: Tensioning Valve Repair

Remove and Install Tensioning Valve

Disassemble and Inspect Tensioning Valve

Assemble Tensioning Valve

Check Condition of Valve Seat and Poppet

Group 25: Gate Lock Valve Repair

Specifications

Repair Gate Lock Valve

Adjust Gate Lock Valve Interlock Lever (If Equipped)

Group 30: Cylinder Repair

Service Parts Kits

Remove and Install Gate Cylinder

Disassemble and Assemble Tension Arm Cylinder

Disassemble and Assemble Gate Cylinder

Disassemble and Assemble Twine Arm Cylinder

Group 35: Optional Hydraulic Bale Ramp Repair

Repair Hydraulic System for Hydraulic Bale Ramp

Section 40: Twine Mechanism—Electric

Group 05: General Information

Twine Wrap System Description

Understanding Twine Wrap Terms and Settings

Group 10: Diagnosing Malfunctions

Twine Wrap Difficulties

BALETRAK Pro Monitor-Controller Difficulties

Group 15: Twine Wrap System Adjustments

Specifications

Adjust Twine Arm-to-Starter Roll, Cutter Link Support, and Twine Arm Stop

Adjust Twine Cutter-to-Twine Arm

Check and Adjust Twine Cutter Knife

Adjust Twine Cutter Contact Tab

Adjust Clearance Between Cutter Link Support and Twine Arm

Adjust Twine Cutter Tension

Adjust Front Twine Arm

Adjust Twine Indicator Retaining Strap

Set Twine End Wrap Distance

Set Twine Spacing

Group 20: Twine Wrap System Repair

Specifications

Remove and Install Twine Arm Actuator—459 and 459S

Install Twine Arm Actuator, Adapter, and Pivot Assembly—459 and 459S

Remove and Install Twine Arm Actuator—559 and 559S

Install Twine Arm Actuator, Adapter, and Pivot Assembly—559 and 559S

Install Twine Arm Stop—459 and 459S

Install Twine Arm Stop—559 and 559S

Section 50: Net Wrap System (If Equipped)

Group 05: General Information

Other Material

Specifications

System Description

Switch Description

Setting Number of Net Wraps (If Equipped)

Monitor Display for B-Wrap Baling

Correct Feeding Problems

Check and Adjust Net Wrap Pan

Check and Straighten Net Pan Angle

Checking and Adjusting Net Pan Pressure without Leaf Spring

Group 10: Diagnosing Malfunctions

High-Moisture Kit Difficulties—Silage Baling

Net Wrap Difficulties

BALETRAK Pro Monitor-Controller Difficulties

Group 15: Net Wrap Repair

Specifications

Remove and Install Net Wrap Assembly

Repair Cuts on Feed Roll

Remove and Install Upper (Rubber) Feed Roll

Replace Upper Feed Roll Bearings

Remove and Install Lower (Steel) Feed Roll

Check Net Pan Pressure

Adjust Lower Net Wrap Guide

Replace Lower Front Gate Roll Belt Guide

Replace Cover Hinge Seal

Check Cover Gas Springs

Check and Adjust Cover Latch

Remove Net Wrap Actuator

Install Net Wrap Actuator

Remove and Install Net Wrap V-Belt

Check and Adjust Net Wrap V-Belt Idler Tension

Check and Adjust Net Wrap Switch

Final Adjustment of Net Wrap Switch—In Field

Replace Net Wrap Switch or Switch Arm

Remove and Install Cutoff Knife

Sharpen Cutoff Knife

Adjust Net Wrap Counterknife

Install and Adjust Net Wrap Brush

Adjusting Net Wrap Feed Roll Pressure

Checking Rubber Roll Bearing Support Clearance

Checking and Adjusting Net Wrap Feed Roll Brake Spring

Checking and Adjusting Brake Pad

Checking and Adjusting Net Wrap Feed Roll Brake

Adjusting Net Wrap Stretch

Section 60: Electrical System

Group 05: General Information

Electrical System Description—BALETRAK™ Pro

Slip Clutch Alert

Lighting Enhancement Module Operation

Group 10: Common Electrical Tests and Checks

Service Equipment and Tools

Electromagnetic Interference (EMI)

Basic Informational Warnings for Machines Equipped with Computer Controlled Systems

Checks Before Testing

Electrical Circuit Definition

Electronic Circuit Definition

Common Circuit Test

Electrical Circuit Malfunctions

Probe Light Check—Voltage from Battery

Probe Light Check—Continuity to Ground

Seven-Step Electrical Test Procedure

Group 15: Diagnosing Malfunctions—BALETRAK Pro System

Activating BaleTrak Pro Monitor-Controller Alarms

BALETRAK Error Codes

BALETRAK Pro Monitor-Controller Difficulties

Group 20: Tests and Adjustments—BALETRAK Pro System

Specifications

Access BaleTrak Pro Customer, Setup, and Diagnostic Channels

BaleTrak™ Pro Monitor-Controller Channels

Channel 001: Reset BaleTrak Pro Monitor-Controller to Initial Settings

Channel 002: Dry Straw Twine Wrap Program

Channel 003: Set Twine Re-Extension

Channel 004: Set Cinch Wrap

Channel 005: Adjust Bale Diameter Sensor

Adjust Bale Diameter Display

Channel 006: Adjust Net Wrap Delay

Channels 007 and 009: Adjust Bale Shape Sensor

Channels 007 and 009: Adjust Bale Shape Bar Display—Field Procedure

Channel 008: Change Display to Metric or English Units

Channel 010: Set Near-Full Indicator Set Point

Channel 011: Set Bale Shape Sensitivity

Channel 012: Test Net Wrap Switch

Channel 013: B-Wrap Sensor (when enabled)

Adjust B-Wrap Sensor

Channels 013 and 014: Gate Close and Oversize Bale Switches

Adjust Oversize Bale Switch

Channels 016 and 017: Checking PTO and Pickup Speed

Channel 018: Test Twine or Net Wrap Actuator Current

Channel 019: Test Tractor Convenience Outlet Voltage

Channel 020: Test Liquid Crystal Display (LCD) Panel

Channel 029: Calibrate Twine Arm

Channel 030: Twine Actuator Stroke

Channel 033: Adjust Delay of Twine Eject Icon

Channel 034: Adjust Cut Position

Channel 035: Adjust Bale Orientation

Checking Microswitches

Test Sensors

BALETRAK Pro Monitor-Controller Setup Channels

Channel 201: Change Baler Model

Channel 202: Enable Twine Feature

Channel 203: Enable Net Wrap and B-Wrap Feature

Channel 204: Slip Clutch Alert PTO Speed Sensor

Channel 205: Slip Clutch Alert Pickup RPM Sensor

Channels 206 and 207: Calibrate Slip Clutch Alert PTO and Pickup RPM Sensors

Channel 208: Activating Optional Variable Core Operation

BALETRAK Pro Monitor-Controller Diagnostic Channels

Channels 301—306: Diagnostic Trouble Codes and Bale Count Memory

Channel 307: View Minutes Counter

Channel 308: View Hours Counter

Channel 309: Lowest Battery Voltage Level Recorded

Channel 310: Highest Battery Voltage Level Recorded

Channel 311: Controller Software Version

Channel 312: Total Bale Counter

Group 25: Electrical Diagrams—BALETRAK Pro System

BaleTrak™ Pro System Component Locations

BaleTrak Pro Control System Wiring Diagram 459, 459S, 559, and 559S

Baler Lighting Electrical Schematic

Wiring Harness Diagram—BALETRAK Pro Monitor-Controller

Wiring Harness Diagram—Baler 459, 459S, 559, and 559S

Wiring Harness Diagram—B-Wrap Sensor Extension

Group 30: BALETRAK Pro Monitor-Controller Operations

BaleTrak™ Pro Monitor-Controller Keys and Switches

BaleTrak™ Pro Monitor-Controller Displays and Indicators

BaleTrak™ Pro Monitor-Controller Operation

BaleTrak™ Pro Monitor-Controller Specifications

BaleTrak™ Pro Monitor-Controller Setup Values and Initial Settings

Viewing and Resetting Bale Counters

Adjusting Audible Alarm Volume

Using Manual Actuator, Wrap, and Bypass Switches

Using Bypass Switch (Twine Wrap Only)

Group 35: Repair—BALETRAK Pro System

Specifications

Programming BaleTrak™ Pro

Resetting BaleTrak™ Pro Monitor-Controller to Initial Settings (Channel 001)

Replace BaleTrak™ Pro Computer Chip (EEPROM)

Replace Monitor-Controller LCD Backlight Bulbs

Replace Monitor-Controller LCD Panel

Replace BaleTrak™ Pro Monitor-Controller Faceplate

Replace Monitor-Controller Audible Alarm

Replace Bale Diameter Sensor

Replace and Adjust Bale Diameter Sensor Mounting Bracket

Replace Bale Shape Sensor

Adjusting Gate Close Switch

Replace Gate Closed Switch

Replace Oversize Bale Switch

Replace Variable (Soft) Core Solenoid Coil (If Equipped)

Group 40: Connector Repair

Essential or Recommended Tools

Other Material

Using High-Pressure Washers

Electrical System Visual Inspection

Electrical Connector Handling

Installation of Repair Wire Assembly (RWA)

Use Electrical Insulating Compound

Use Terminal Cleaner and Di-Electric Grease

Harness Repair—Splice Connector

Repair Procedure R-A

Repair Procedure R-B

Repair Procedure R-E

Repair Procedure R-J

Section 70: Pickup

Group 05: General Information

Pickup Description

Preliminary Checks

Check Pickup Tooth End Play

Group 10: Diagnosing Malfunctions

Pickup Difficulties

Feeding Difficulties

Feeding Difficulties with Roller Baffle

General Baler Difficulties—BaleTrak Pro System

Group 15: Regular Pickup Repair

Other Material

Specifications

Replace Cam Follower Bearings

Remove and Install Pickup

Disassemble Pickup

Inspect Pickup Components

Assemble Pickup

Pickup Drive Belt and Chain Alignment

Adjust Initial Length of Drive Belt Idler Spring

Adjust Drive Belt Idler

Adjust Pickup Float Springs

Remove and Install Compressor Rack Assembly (Regular Pickup)

Adjusting Compressor Rack Assembly (Regular Pickup)

Group 25: MEGAWIDE PLUS Pickup Repair

Service Equipment and Tools

Other Material

Specifications

Remove and Install Roller Baffle

Repair Roller Baffle

Balancing Roller Baffle

Remove and Install Compressor Rack Assembly (MEGAWIDE PLUS)

Adjust Compressor Rods (MEGAWIDE PLUS)

Remove and Install MEGAWIDE PLUS Pickup/Rotor Assembly

MegaWide Plus Pickup and Rotor Exploded View

MEGAWIDE PLUS Pickup/Rotor Frame-to-Baler Frame Shimming Procedure

Replace Teeth (Pickup Installed)

Replace Cam Follower Bearings

Remove and Install Pickup Cam

Remove and Install Pickup—MegaWide Plus

Disassemble Pickup

Inspect Pickup Components

Assemble Pickup

Remove and Install Auger/Rotor Assembly

Disassemble and Assemble Auger/Rotor Assembly

Pickup Drive Chains Alignment

Adjust Auger Scrapers

Adjust Pickup Drive Chains

Adjust Pickup Float Springs—MegaWide Plus

Group 30: Miscellaneous

Specifications

Adjust Initial Length of Hydraulic Lift Cylinder (If Equipped)

Repair Gauge Wheel—Regular Pickups

Repair Gauge Wheel—MEGAWIDE PLUS Pickup

Remove and Install Gauge Wheel Arm Assembly MegaWide Plus Pickup

Section 80: Miscellaneous

Group 05: Wheel Repair

Service Equipment and Tools

Specifications

Remove Baler Wheel

Tire Installation and Wheel Nut Torque

Inspect and Replace Baler Wheel Bearings

Repair Gathering Wheel (If Equipped)

Remove Excessive Play from Gathering Wheel Pivot

Group 10: Gate Repair

Specifications

Straighten Gate

Remove and Install Gate

Group 15: Tension Arm Repair

Specifications

Remove and Install Tension Arm

Adjust Take-Up Arm Compression Spring

Adjusting Upper Tension (Take-Up) Arm Cylinder

Adjust Bale Size Indicator

Checking Tension Arm Wear Channel

Replace Tension Arm Wear Channel

Group 20: Tongue Repair

Specifications

Remove and Install Tongue

Group 25: Belt Repair

Essential or Recommended Tools

Service Equipment and Tools

Remove Belts

Install Belts

Prepare Belts for New Lacings

Install Belt Lacing

Belts Eligible for Warranty Replacement

Belts Not Eligible for Warranty Replacement

Group 30: Main Frame Repair

Service Equipment and Tools

Straighten Main Frame

Section 99: Dealer Fabricated Tools

Group 05: Dealer Fabricated Tools

DFEX1874A Support Strap