John Deere 449, 459 Standard Hay and Forage Round Balers All Inclusive Diagnosis & Repair Technical Manual (TM121019)
Complete Diagnostics and Repair Technical Manual for John Deere Hay and Forage Round Balers Models 449 Standard & 459 Standard, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
John Deere 449 Standard, 459 Standard workshop service & 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.
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TM121019 - John Deere Hay and Forage Round Balers 449 Standard, 459 Standard Technical Manual (Diagnosis Operation Test Repair Service).PDF
Total Pages/Size: 831 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
Delivery: instant download link displayed on page & emailed to you after checkout
Protection: DRM-free; without any restriction
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
Cylinder Repair
Optional Hydraulic Bale Ramp Repair
Twine Mechanism-Hydraulic
General Information
Diagnosing Malfunctions
Twine Wrap System Adjustments
Twine Wrap System Repair
Electrical System
General Information
Common Electrical Tests and Checks
Diagnosing Malfunctions
Tests and Adjustments
Tests and Adjustments-BALETRAK Pro System
Electrical Diagrams
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 (449 Only)
Miscellaneous
Miscellaneous
Wheel Repair
Gate Repair
Tension Arm Repair
Tongue Repair
Belt Repair
Main Frame Repair
TABLE OF CONTENTS....1
Section 10: General....15
Group 05: Safety....15
Recognize Safety Information....18
Understand Signal Words....19
Handle Fluids Safely—Avoid Fires....20
Prevent Battery Explosions....21
Prepare for Emergencies....22
Park Machine Safely....23
Operate Baler Safely....24
Protect Bystanders....25
Service Machine Safely—449 and 459 Standard....26
Support Machine Properly....30
Wear Protective Clothing....31
Work in Clean Area....32
Service Machines Safely....33
Work In Ventilated Area....34
Illuminate Work Area Safely....35
Replace Safety Signs....36
Use Proper Lifting Equipment....37
Avoid High-Pressure Fluids....38
Remove Paint Before Welding or Heating....39
Avoid Heating Near Pressurized Fluid Lines....40
Service Tires Safely....41
Practice Safe Maintenance....42
Use Proper Tools....43
Construct Dealer-Made Tools Safely....44
Dispose of Waste Properly....45
Precautions for Welding....46
Protect Against High Pressure Spray....48
Live With Safety....49
Group 10: Specifications....874
Machine Specifications—449 Round Baler....53
Machine Specifications—459 Standard Round Baler....56
Metric Bolt and Screw Torque Values....58
Unified Inch Bolt and Screw Torque Values....60
Service Recommendations For 37° Flare and 30° Cone Seat Connectors....62
Group 15: General Information....16
Machine Description....65
Group 20: Lubricants....16
Grease....68
Gear Case Oil....69
Alternative and Synthetic Lubricants....70
Mixing of Lubricants....71
Lubricant Storage....72
Perform Lubrication and Maintenance....73
Section 20: Drive Train....74
Group 05: General Information....74
Drive Train Operation....79
Operating RPM....81
Group 10: Diagnosing Malfunctions....510
PTO Driveline Difficulties....83
Slip Clutch Difficulties (If Equipped)....84
Shear Bolt Difficulties....85
Gear Case Difficulties....86
Drive Chain Difficulties....87
Group 15: Drive Train Protection....74
Service Parts Kits....377
Specifications....874
Replace Driveline Shear Bolt....91
Repair PTO Driveline Slip Clutch (If Equipped)....92
Adjust PTO Driveline Slip Clutch (If Equipped)....94
Slipping Seized PTO Driveline Slip Clutch (If Equipped)....96
Check Pickup Slip Clutch Torque (MegaWide™ Plus)....99
Replace Pickup Slip Clutch....102
Group 20: PTO Driveline....74
Essential or Recommended Tools....873
Other Material....727
Service Parts Kits....377
PTO Driveline Exploded View with Plastic Shields (Shear Bolt Type)....109
PTO Driveline Exploded View (Slip Clutch Type)....111
Repair Shields (Shear Bolt Type)....113
Install Shield....115
Repair U-Joint (Shear Bolt Type)....117
Assemble U-Joint....122
Repair PTO Lock-Back Collar Disconnect (Shear Bolt Type)....125
Repair PTO Lock-Back Collar Disconnect....128
Repair PTO Constant Velocity Joint....130
Repair PTO Constant Velocity Joint (Shear Bolt Type)....135
Disassemble and Assemble Constant Velocity Joint (Shear Bolt Type)....141
Replace Centralizer Bearing....145
Group 25: Remove and Install Gear Case....151
Other Material....727
Specifications....874
Remove Gear Case....149
Install Gear Case....151
Replace Hex Shaft from Gear Case-to-Sidesheet....155
Group 27: Gear Case Repair....75
Essential or Recommended Tools....873
Service Equipment and Tools....893
Other Material....727
Specifications....874
Disassemble Gear Case....172
Gear Case Exploded View....182
Assemble Gear Case....184
Group 30: Roll Drives....75
Specifications....874
Adjust Lower Drive Roll Chain....203
Adjust Upper Drive Roll Chain....204
Check Starter Roll Drive Chain....206
Adjust Starter Roll Drive Chain....207
Replace Starter Roll Drive Chain....213
Remove and Install Starter Roll Sprocket....214
Remove and Install Lower Drive Roll Sprocket....215
Check Upper Drive Roll Sprocket Alignment....216
Group 35: Rolls....75
Service Equipment and Tools....893
Specifications....874
Diagram of Rolls and Belt Routing—449....223
Diagram of Rolls and Belt Routing—459 Standard....224
Remove and Install Starter Roll....225
Remove and Install Belt Staggering Roll....229
Remove and Install Take-Up Arm Roll....232
Remove and Install Front Idler Roll—459 Standard....234
Remove and Install Top Idler Roll....236
Remove and Install Auxiliary Take-Up Roll....238
Remove and Install Upper Rear Gate Roll....239
Remove and Install Lower Rear Gate Roll....241
Remove and Install Lower Front Gate Roll....243
Remove and Install Rear Roll of Tension Arm....249
Remove and Install Center and Front Rolls of Tension Arm....251
Replace Tension Arm Roll Shaft....253
Replace Stationary Shaft Roll Bearings....256
Remove and Install Lower Drive Roll....259
Remove and Install Left-Hand Side Lower Drive Roll Bearing....287
Remove and Install Right-Hand Side Lower Drive Roll Bearing....296
Remove and Install Upper Drive Roll....302
Install Upper Drive Roll Bearings....309
Group 40: Miscellaneous....76
Service Equipment and Tools....893
Specifications....874
Adjusting Auger Scrapers (MegaWide™)....319
Adjust Lower Front Gate Roll Scraper....320
Adjust Starter Roll Scraper (If Equipped)....322
Adjust Idler Roll Scraper (If Equipped)....324
Section 30: Hydraulics....326
Group 05: General Information....326
Specifications....874
Hydraulic System Description and Diagram....330
Tensioning Valve....332
Non-Adjustable Relief Valve....333
Pilot-Operated Check Valve....334
Install Inline Orifice Correctly—459 STD....335
Group 10: Diagnosing Malfunctions....510
Diagnosing Hydraulic Malfunctions....338
Group 15: Operation and Tests....326
Essential or Recommended Tools....873
Specifications....874
Hydraulic System Operation....343
Low Pressure Relief Valve Test....346
High-Pressure Relief Valve Test—Field Test....348
High-Pressure Relief Valve Test—Shop Test....350
Test Tension/Gate Cylinder for Leakage....354
Test Hydraulic Twine Arm and Pickup Lift Cylinders for Leakage....356
Group 20: Tensioning Valve Repair....326
Remove and Install Tensioning Valve—449....360
Remove and Install Tensioning Valve—459 Standard....362
Disassemble and Inspect Tensioning Valve—449....365
Disassemble and Inspect Tensioning Valve—459 Standard....367
Assemble Tensioning Valve—449....370
Assemble Tensioning Valve—459 Standard....372
Check Condition of Valve Seat and Poppet....374
Group 25: Cylinder Repair....326
Service Parts Kits....377
Remove and Install Gate Cylinder....378
Disassemble and Assemble Tension Arm Cylinder....380
Disassemble and Assemble Gate Cylinder....390
Disassemble and Assemble Twine Arm Cylinder....404
Group 30: Optional Hydraulic Bale Ramp Repair....327
Repair Hydraulic System for Hydraulic Bale Ramp—459 Standard....413
Section 40: Twine Mechanism—Hydraulic....415
Group 05: General Information....415
Hydraulic Twine Wrap System Description....417
Operating Twine Wrap Control....418
Adjust Twine Spacing (Manual Hydraulic Tie)....420
Group 10: Diagnosing Malfunctions....510
Diagnosing Twine Wrap Malfunctions....432
Group 15: Twine Wrap System Adjustments....415
Specifications....874
Adjusting Twine Arm-to-Starter Roll, Cutter Link Support, and Twine Arm Stop....443
Adjust Twine Arm Distance from Right-Hand Sidesheet (Hydraulic Twine)....449
Adjust Twine Cutter-to-Twine Arm Clearance....451
Adjust Twine Cutter Knife....453
Adjust Twine Cutter Contact Tab....456
Adjust Clearance Between Cutter Link Support and Twine Arm....458
Adjust Twine Cutter Tension....460
Adjust Front Twine Arm (Double Twine Arms)....465
Adjust Twine Indicator Retaining Strap....467
Adjust Twine End Spacing with Mechanical Twine Guides (449 Only)....468
Group 20: Twine Wrap System Repair....415
Other Material....727
Specifications....874
Remove Hydraulic Twine Arm Cylinder....472
Install Hydraulic Twine Arm Cylinder....474
Attach Hydraulic Cylinder End Block to Twine Arm....476
Adjust Initial Length of Hydraulic Twine Arm Cylinder....478
Install Twine Arm Stop....480
Section 60: Electrical System....481
Group 05: General Information....481
Lighting Enhancement Module....486
Electrical System Description—BaleTrak Pro....487
Group 10: Common Electrical Tests and Checks....481
Service Equipment and Tools....893
Electromagnetic Interference (EMI)....494
Basic Informational Warnings for Machines Equipped with Computer Controlled Systems....495
Checks Before Testing....496
Electrical Circuit Definition....497
Electronic Circuit Definition....498
Common Circuit Test....499
Electrical Circuit Malfunctions....500
Probe Light Check—Voltage from Battery....504
Probe Light Check—Continuity to Ground....505
Seven-Step Electrical Test Procedure....506
Group 15: Diagnosing Malfunctions....510
Diagnosing Malfunctions....510
Activating BaleTrak™ Pro Monitor-Controller Alarms....512
BALETRAK Error Codes....513
BALETRAK Pro Monitor-Controller Difficulties....516
Group 16: Tests and Adjustments....481
Specifications....874
Adjust Bale Size Switch (with Hydraulic Twine)....525
Adjust Bale Size Link for Maximum Bale Size (Oversize Warning with Hydraulic Twine)....527
Test Microswitch....529
Group 20: Tests and Adjustments—BALETRAK Pro System....481
Specifications....874
Access BaleTrak Pro Customer, Setup, and Diagnostic Channels....532
BALETRAK Pro Monitor-Controller Customer Channels....534
BALETRAK™ Pro Monitor-Controller Channels....535
Channel 001: Reset BaleTrak Pro Monitor-Controller to Initial Settings....536
Channel 002: Dry Straw Twine Wrap Program....537
Channel 003: Set Twine Re-Extension....538
Channel 004: Set Cinch Wrap....539
Channel 005: Adjust Bale Diameter Sensor....540
Replace and Adjust Bale Diameter Sensor Mounting Bracket....542
Adjust Bale Diameter Display....544
Channel 008: Change Display to Metric or English Units....546
Channel 010: Set Near-Full Indicator Set Point....547
Channels 013 and 014: Gate Close and Oversize Bale Switches....548
Adjust Oversize Bale Switch....550
Adjust Bale Size Link for Maximum Bale Size (Oversize Warning 449 and 459 BaleTrak™ Pro)....552
Testing Twine or Net Wrap Actuator Current (Channel 018)....554
Channel 019: Test Tractor Convenience Outlet Voltage....556
Channel 020: Test LCD Panel....557
Channel 029: Calibrate Twine Arm....558
Channel 030: Twine Actuator Stroke....560
Channel 033: Adjust Delay of Twine Eject Icon....561
Checking Microswitches....562
Test Sensors....563
BALETRAK Pro Monitor-Controller Setup Channels....565
Channel 201: Change Baler Model....566
Channel 202: Enable Twine Feature....568
Channel 208: Activating Optional Variable Core Operation....570
BALETRAK Pro Monitor-Controller Diagnostic Channels....572
Channels 301—306: Diagnostic Trouble Codes and Bale Count Memory....573
Channel 307: View Minutes Counter....577
Channel 308: View Hours Counter....578
Channel 309: Lowest Battery Voltage Level Recorded....579
Channel 310: Highest Battery Voltage Level Recorded....581
Channel 311: Controller Software Version....583
Channel 312: Total Bale Counter....584
BaleTrak™ PRO System Component Locations....585
Group 25: Electrical Diagrams....483
Wire Color Chart....587
Baler Wiring Harness Diagram....588
Group 27: Electrical Diagrams—BaleTrak™ PRO System....483
Wiring Harness Diagram—449 and 459 Standard....595
BaleTrak Pro System Wiring Diagram....599
Wiring Harness Diagram—BALETRAK Pro Monitor-Controller....600
Group 30: BALETRAK Pro Monitor-Controller Operations....483
BaleTrak™ Pro Monitor-Controller Keys and Switches....604
BaleTrak™ PRO Monitor-Controller Displays and Indicators....605
BaleTrak™ Pro Monitor-Controller Operation....606
BaleTrak™ Pro Monitor-Controller Specifications....874
BaleTrak™ Pro Monitor-Controller Setup Values and Initial Settings (449)....609
BaleTrak™ Pro Monitor-Controller Setup Values and Initial Settings (459 Standard)....611
Viewing and Resetting Bale Counters....613
Adjusting Audible Alarm Volume....615
Setting Bale Diameter....616
Adjusting Bale Diameter Display....617
Twine Wrap Terms and Settings....619
Using Manual Actuator, Wrap, and Bypass Switches....621
Using Bypass Switch (Twine Wrap Only)....623
Group 35: Repair—BALETRAK Pro System....483
Specifications....874
Programming BaleTrak™ Pro....626
Resetting BaleTrak™ Pro Monitor-Controller to Initial Settings (Channel 001)....627
Replace BaleTrak™ Pro Computer Chip (EEPROM)....630
Replace Monitor-Controller LCD Backlight Bulbs....634
Replace Monitor-Controller LCD Panel....635
Replace BaleTrak™ Pro Monitor-Controller Faceplate....638
Replace Monitor-Controller Audible Alarm....641
Replace Bale Diameter Sensor....642
Adjusting Gate Close Switch....644
Replace Gate Closed Switch....645
Replace Oversize Bale Switch....646
Group 40: Connector Repair....484
Connector Repair—Use CTM....648
Section 70: Pickup....649
Group 05: General Information....649
Specifications....874
Pickup Description....653
Preliminary Checks....654
Check Pickup Tooth End Play....656
Group 10: Diagnosing Malfunctions....510
Pickup Difficulties....662
Feeding Difficulties....666
Feeding Difficulties with Roller Baffle....670
Group 15: Regular Pickup Repair....649
Other Material....727
Specifications....874
Replace Teeth (Pickup Installed)....759
Replace Cam Follower Bearings....763
Remove and Install Pickup....679
Disassemble Pickup....779
Inspect Pickup Components....786
Assemble Pickup....788
Pickup Drive Belt and Chain Alignment....714
Adjust Initial Length of Drive Belt Idler Spring....716
Adjust Drive Belt Idler....717
Adjust Pickup Float Springs (Regular Pickup)....718
Adjusting Pickup Float Springs (MegaWide™ Plus Pickup)....720
Remove and Install Compressor Rack Assembly....722
Adjusting Compressor Rack Assembly....724
Group 25: MEGAWIDE PLUS Pickup Repair (449 Only)....649
Service Equipment and Tools....893
Other Material....727
Specifications....874
Remove and Install Roller Baffle....730
Repair Roller Baffle....732
Balancing Roller Baffle....739
Remove and Install Compressor Rack Assembly—MegaWide Plus....741
Adjust Compressor Rods....742
Remove and Install Pickup/Rotor Assembly....744
MegaWide Plus Pickup and Rotor Exploded View....755
Pickup/Rotor Frame-to-Baler Frame Shimming Procedure....757
Replace Teeth (Pickup Installed)....759
Replace Cam Follower Bearings....763
Remove and Install Pickup Cam....765
Remove and Install Pickup—MegaWide Plus....772
Disassemble Pickup....779
Inspect Pickup Components....786
Assemble Pickup....788
Remove and Install Auger/Rotor Assembly....798
Disassemble and Assemble Auger/Rotor and Shaft Assembly....803
Pickup Drive Chains Alignment....805
Adjust Auger Scrapers....807
Adjust Pickup Drive Chains....808
Adjust Pickup Float Springs—MegaWide Plus....811
Group 30: Miscellaneous....650
Specifications....874
Adjust Initial Length of Hydraulic Lift Cylinder (If Equipped)....815
Repair Gauge Wheel—Exploded View....816
Remove and Install Gauge Wheel Arm Assembly....818
Section 80: Miscellaneous....820
Group 05: Wheel Repair....820
Service Equipment and Tools....893
Specifications....874
Remove Baler Wheel....825
Tire Installation and Wheel Nut Torque....826
Inspect and Replace Baler Wheel Bearings....829
Repair Gathering Wheel (If Equipped)....831
Remove Excessive Play from Gathering Wheel Pivot....834
Group 10: Gate Repair....820
Specifications....874
Straighten Gate....838
Remove and Install Gate....841
Attach Bale Shape Indicator Cables....845
Adjust Gate Lock Rod....849
Group 15: Tension Arm Repair....820
Specifications....874
Remove and Install Tension Arm....854
Adjust Take-Up Arm Spring (449)....857
Adjust Take-Up Arm Spring (459 Standard)....858
Adjust Bale Size Indicator....860
Inspect Tension Arm Wear Channel....861
Replace Tension Arm Wear Channel....863
Group 20: Tongue Repair....820
Specifications....874
Remove and Install Tongue....868
Group 25: Belt Repair....820
Essential or Recommended Tools....873
Specifications....874
Remove Belts....875
Install Belts....876
Prepare Belts for New Lacings....878
Install Belt Lacing....882
Check Belt Tracking....885
Adjust Belt Tracking....886
Belts Eligible for Warranty Replacement....888
Belts Not Eligible for Warranty Replacement....889
Group 30: Main Frame Repair....821
Service Equipment and Tools....893
Straighten Main Frame....894
John Deere 449, 459 Standard Hay and Forage Round Balers All Inclusive Diagnosis & Repair Technical Manual (TM121019)
