John Deere 459 Economy Hay and Forage Round Balers All Inclusive Service Technical Manual (TM140619)

TM140619 - John Deere 459 Economy Hay and Forage 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 Hay and Forage Round Balers Models 459 Economy, with all the shop information to maintain, diagnostic, repair, rebuild like professional mechanics.

459 Economy Hay and Forage 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: 1,225 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
      Cylinder Repair
      Hydraulic Bale Ramp (Optional)
   Twine Mechanism-Electric (If Equipped)
      General Information
      Diagnosing Malfunctions
      Twine Wrap System Adjustments
      Twine Wrap System Repair
   Net Wrap (If Equipped)
      General Information
      Diagnosing Malfunctions
      Net Wrap Repair
   Electrical System
      General Information
      Common Electrical Tests and Checks
      Diagnosing Malfunctions
      Tests and Adjustments
      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
      Miscellaneous
   Miscellaneous
      Wheel Repair
      Gate Repair
      Tension Arm Repair
      Tongue Repair
      Belt Repair
      Main Frame Repair
      Bale Ramp (If Equipped)
   Dealer Fabricated Tools
 

tm140619 - 459 Economy Round Baler

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

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—459E

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

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

Drivetrain Operation

Group 10: Diagnosing Malfunctions

PTO Driveline Difficulties

Shear Bolt Difficulties

Gear Case Difficulties

Drive Chain Difficulties

Group 15: Drive Train Protection

Specifications

Replace Driveline Shear Bolt

Group 20: PTO Driveline

Other Material

PTO Driveline Exploded View with Plastic Shields (Shear Bolt Type)

Repair Shields (Shear Bolt Type)

Install Shield

Repair U-Joint (Shear Bolt Type)

Repair PTO Lock-Back Collar Disconnect (Shear Bolt Type)

Repair PTO Lock-Back Collar Disconnect

Repair PTO Constant Velocity Joint (Shear Bolt Type)

Disassemble and Assemble Constant Velocity Joint (Shear Bolt Type)

Replace Centralizer Bearing

Group 25: Remove and Install Gear Case

Other Material

Specifications

Remove Gear Case

Install Gear Case

Replace Gear Case Hex Shaft

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

Specifications

Diagram of Rolls and Belt Routing

Remove and Install Starter Roll

Remove and Install Belt Staggering Roll

Remove and Install Take-Up Arm Roll

Remove and Install Front Idler Roll

Remove and Install Top Idler Roll

Remove and Install Auxiliary Take-Up Roll (If Equipped)

Remove and Install Upper Rear Gate Roll

Remove and Install Lower Rear Gate Roll

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 and Install Upper Drive Roll

Install Upper Drive Roll Bearings

Group 40: Miscellaneous

Service Equipment and Tools

Specifications

Adjust Lower Front Gate Roll Scraper

Section 30: Hydraulics

Group 05: General Information

Specifications

Tensioning Valve

Non-Adjustable Relief Valve

Pilot-Operated Check 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 Pickup Lift Cylinders for Leakage

Group 20: Tensioning Valve Repair

Remove and Install Tensioning Valve

Remove and Install Tensioning Valve with Options

Disassemble and Assemble Tensioning Valve

Check Condition of Valve Seat and Poppet

Group 25: Cylinder Repair

Service Parts Kits

Remove and Install Gate Cylinder

Disassemble and Assemble Gate or Tension Arm Cylinder

Disassemble and Assemble Upper Take-Up Arm Cylinder

Group 30: Hydraulic Bale Ramp (Optional)

Repair Hydraulic System with Hydraulic Bale Ramp

Section 50: Twine Mechanism—Electric (If Equipped)

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

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

Set Twine Cutter-to-Twine Arm

Check and Set Twine Cutter Knife

Set Twine Cutter Contact Tab

Set Clearance Between Cutter Link Support and Twine Arm

Set Twine Cutter Tension

Set Front Twine Arm

Set Twine Indicator Retaining Strap

Set Twine Tension

Set Twine End Wrap Distance

Set Twine Spacing

Group 20: Twine Wrap System Repair

Specifications

Remove and Install Twine Arm Actuator

Install Twine Arm Actuator, Adapter, and Pivot Assembly

Install Twine Arm Stop

Section 60: Net Wrap (If Equipped)

Group 05: General Information

Other Material

Specifications

System Description

Switch Description

Setting Number of Net Wraps

Monitor Display for B-Wrap Baling

Correct Feeding Problems

Prepare Net Wrap After Extended Storage

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

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 Feed Roll

Replace Upper Feed Roll Bearings

Remove and Install Lower 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 70: Electrical System

Group 05: General Information

Lighting Enhancement Module

Electrical System Description—BaleTrak Pro

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

Diagnosing Malfunctions

Activating BaleTrak Pro Monitor-Controller Alarms

BaleTrak Error Codes

BaleTrak Pro Monitor-Controller Difficulties

Group 20: Tests and Adjustments

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

Replace and Adjust Bale Diameter Sensor Mounting Bracket

Adjust Bale Diameter Display

Channel 006: Adjust Net Wrap Delay

Channel 008: Change Display to Metric or English Units

Channel 010: Set Near-Full Indicator Set Point

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

Testing Twine or Net Wrap Actuator Current (Channel 018)

Channel 019: Test Tractor Convenience Outlet Voltage

Channel 020: Test 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 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

BaleTrak Pro System Component Locations

Group 27: Electrical Diagrams—BaleTrak™ PRO System

Electrical Schematic

Baler Lighting Electrical Schematic

Wire Harness Diagram—BaleTrak™ Pro Monitor-Controller

Wiring Harness Connector Diagram

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

View and Reset Bale Counters

Adjusting Audible Alarm Volume

Setting Bale Diameter

Adjusting Bale Diameter Display

Twine Wrap Terms and Settings

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

Adjusting Gate Close Switch

Replace Gate Closed Switch

Replace Oversize Bale Switch

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 80: Pickup

Group 05: General Information

Specifications

Preliminary Checks

Group 10: Diagnosing Malfunctions

Pickup Difficulties

Feeding Difficulties

Group 15: Regular Pickup Repair

Other Material

Specifications

Replace Teeth (Pickup Installed)

Replace Cam Follower Bearings

Remove and Install Pickup

Disassemble Pickup

Inspect Pickup Components

Assemble Pickup

Check Pickup Tooth End Play

Pickup Drive Belt and Chain Alignment

Adjust Initial Length of Drive Belt Idler Spring

Adjust Drive Belt Idler

Adjust Pickup Float Springs

Adjusting Pickup Height

Remove and Install Compressor Rack Assembly

Adjusting Compressor Rack Assembly

Group 30: Miscellaneous

Specifications

Adjust Initial Length of Pickup Lift Cylinder (If Equipped)

Repair Gauge Wheel—Exploded View

Remove and Install Gauge Wheel Arm Assembly

Adjust Gauge Wheels

Section 90: Miscellaneous

Group 05: Wheel Repair

Service Equipment and Tools

Specifications

Remove Baler Wheel

Tire Installation and Wheel Nut Torque

Wheel Spindle Positions on 459 Economy Baler with Regular Pickup and 11L-14 Tires

Inspect and Replace Baler Wheel Bearings

Repair Converging Wheel (If Equipped)

Remove Excessive Play from Converging Wheel Pivot

Group 10: Gate Repair

Specifications

Straighten Gate

Remove and Install Gate

Adjust Gate Lock Rod

Group 15: Tension Arm Repair

Specifications

Remove and Install Tension Arm

Adjust Take-Up Arm Spring

Adjust Bale Size Indicator

Inspect 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

Specifications

Remove Belts

Install Belts

Check Belt Tracking

Adjust Belt Tracking without Net Wrap

Adjust Belt Tracking with Net Wrap

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

Group 35: Bale Ramp (If Equipped)

Remove and Install Bale Ramp

Section 99: Dealer Fabricated Tools

Group 05: Dealer Fabricated Tools

DFEX1874A Support Strap