John Deere 458 558 458 Baler Service Repair Manual
458, 458 Silage Special and 558 Round Balers Repair
REPAIR TECHNICAL MANUAL
Round Balers models 458, 458s, 558
TM1735 29 DEC 13 (ENGLISH)
John Deere Agriculture Pinted by Belgreen
Table of contents
FOREWORD
Section 10 - GENERAL
Group 05 - Safety
Group 10 - Specifications
Group 15 - General Information
Group 20 - Lubricants
Section 20 - DRIVE TRAIN
Group 05 - General Information
Group 10 - Diagnosing Malfunctions
Group 15 - Drive Train Protection
Group 20 - PTO Driveline
Group 25 - Remove and Install Gear Case
Group 26 - Gear Case Repair Iberica
Group 27 - Gear Case Repair Comer
Group 30 - Roll Drives
Group 35 - Rolls
Group 40 - Miscellaneous
Section 30 - HYDRAULICS
Group 05 - General Information
Group 10 - Diagnosing Malfunctions
Group 15 - Operation and Tests
Group 20 - Tensioning Valve Repair
Group 25 - Gate Lock Valve Repair
Group 30 - Cylinder Repair
Group 35 - Optional Hydraulic Bale Ramp Repair
Section 40 - TWINE MECHANISM—ELECTRIC
Group 05 - General Information
Group 10 - Diagnosing Malfunctions
Group 15 - Twine Wrap System Adjustments
Group 20 - Twine Wrap System Repair
Section 50 - COVEREDGE NET WRAP SYSTEM (IF EQUIPPED)
Group 05 - General Information
Group 10 - Diagnosing Malfunctions
Group 15 - Net Wrap Repair
Section 60 - ELECTRICAL SYSTEM
Group 05 - General Information
Group 10 - Common Electrical Tests and Checks
Group 15 - Diagnosing Malfunctions BALETRAK Pro System
Group 20 - Tests and Adjustments BALETRAK Pro System
Group 25 - Electrical Diagrams BALETRAK Pro System
Group 30 - BALETRAK Pro Monitor-Controller Operations
Group 35 - Repair BALETRAK Pro System
Group 40 - Connector Repair
Section 70 - PICKUP
Group 05 - General Information
Group 10 - Diagnosing Malfunctions
Group 15 - Regular Pickup Repair
Group 25 - MEGAWIDE PLUS Pickup Repair
Group 30 - Miscellaneous
Section 80 - MISCELLANEOUS
Group 05 - Wheel Repair
Group 10 - Gate Repair
Group 15 - Tension Arm Repair
Group 20 - Tongue Repair
Group 25 - Belt Repair
Group 30 - Main Frame Repair
Section 99 - DEALER FABRICATED TOOLS
Group 05 - Dealer Fabricated Tools
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Foreword
This manual is written for an experienced technician Essential tools required in performing certain service work are identified in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual
CAUTION:
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
The technical manual contains two types of information: diagnostics and repair Diagnostic groups help you identify the majority of routine failures quickly Repair groups tell how to repair the components
Information is organized in groups for the various components requiring service instruction At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes
Group 05 - Safety
Recognize Safety Information
Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.
Understand Signal Words
Signal Words
A signal word DANGER, WARNING, or CAUTION is used with the safety-alert symbol DANGER identifies the most serious hazards
DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety messages in this manual
Follow Safety Instructions
Safety Messages
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.
There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator′s manual.
Learn how to operate the machine and how to use controls properly Do not let anyone operate without instruction
Keep your machine in proper working condition Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.
If you do not understand any part of this manual and need assistance, contact your John Deere dealer
Operate Baler Safely
Keep all shields in place when operating baler.
Do not attempt to pull hay or twine from pickup when baler is running Never hand-feed twine or hay into baler.
All machinery should be operated by responsible persons who have been properly instructed and delegated to do so Stand clear of baler at all times when machine is operating.
Become familiar with all controls affecting machine functions
Do not exceed maximum bale diameter or weight limits. This can lead to accelerated wear or machine failures.
Before servicing, adjusting, or removing material from the baler, always disengage all power and stop tractor engine
Protect Bystanders
Crush
To prevent crushing injury be sure bystanders stand clear before operating gate and unloading bale Stay clear of gate and/or push bar while opening or closing gate
Handle Fluids Safely—Avoid Fires
Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards
Store flammable fluids away from fire hazards Do not incinerate or puncture pressurized containers
Make sure machine is clean of trash, grease, and debris
Do not store oily rags; they can ignite and burn spontaneously
Prepare for Emergencies
First Aid Kit
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Fire Prevention
Fire Prevention
To reduce the risk of fire, follow these guidelines, especially in dry crop conditions:
Equip the baler with a water-type fire extinguisher. Large capacity water fire extinguishers are recommended because application of water can cool hot parts to prevent a fire. (See Attachments section in the Operator′s Manual.)
Keep foreign material (crop, chaff, twine, net wrap material, etc ) from building up on the machine near potentially hot areas, such as bearings on ends of baler rolls and slip clutch Remove this buildup as part of the regular service operations
Avoid high pressure power-washing adjacent to the bearings on ends of baler rolls to prevent damaging seals. Check bearings on ends of baler rolls regularly for early signs of failure replace as necessary. (See Lubrication and Maintenance section in the Operator′s manual.)
If noticeable changes in machine performance occur which might indicate a part is beginning to fail, stop baling immediately and investigate the cause of any sounds, smells, or sights which are unusual Promptly eject bales after they have been tied or wrapped Do not use the baler to transport bales from the field Do not bring a baler, with a bale inside it, into a building. Never leave a baler unattended with a bale inside the chamber. Use extreme care if it is necessary to park a baler in a field of dry crop or stubble. Whenever possible, park baler on bare ground or in an area surrounded by bare ground Before leaving a baler which has been operating, verify there are no areas which are hot enough to start a fire Do not leave the baler unattended near bales which have been baled wet, because spontaneous combustion can occur
If service operations require using a welder, cutting torch or grinder on the baler, refer to FIRE PREVENTION WELDING in this group for guidelines which may prove useful in preventing a fire. Use extreme care when smoking around the baler.
Fire Prevention—Welding
If service operations require using a welder, cutting torch or grinder on the baler, these guidelines may prove useful in preventing a fire:
[1] - Park baler on pavement or bare ground
[2] - Remove chaff to minimize exposure of flammable material to sparks; if chaff cannot be removed, soak it thoroughly with water before starting Protect hoses and belts from exposure to sparks, arcs or flames
[3] - Be sure a fully charged water-type fire extinguisher or other source of water is ready for immediate use
[4] - Use an assistant to watch for fire while welding, cutting or grinding.
[5] - After welding, cutting or grinding is finished, wait long enough to allow parts to cool down before starting to bale. Verify that no sparks or slag have started a fire before leaving service area.
Avoid High-Pressure Fluids
High Pressure
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure
Search for leaks with a piece of cardboard Protect hands and body from high-pressure fluids
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U S A , by calling 1-800-822-8262 or +1 309-748-5636
Support Machine Properly
Support Properly
Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them If left in a raised position, hydraulically supported devices can settle or leak down
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual
Wear
Clothing
Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job
Prolonged exposure to loud noise can cause impairment or loss of hearing
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine
Work in Clean Area
Clean Work Area
Before starting a job:
Clean work area and machine
Make sure you have all necessary tools to do your job
Have the right parts on hand
Read all instructions thoroughly; do not attempt shortcuts
Service Machine Safely
Safety Art
To help prevent personal injury caused by unexpected movement, be sure to service the machine on a level surface. If machine is connected to a tractor, engage tractor parking brake and/or place transmission in "Park", shut off engine and remove key.
If machine is detached from tractor, block wheels to prevent movement
While working inside or around the baler with an open gate, the gate lock lever (A) must be moved to locked position. Use this safety feature anytime the gate is open. Close the gate anytime the baler must be left unattended.
Before servicing or adjusting baler:
1 Disengage all power
2 Shut off tractor engine
3.Wait until all moving parts have stopped.
4.Let all components cool.
LEGEND:
AGate Lock Lever
BInterlock Lever
458, 458S and 558
When positioning the gate to provide access for service, always be sure tension arm is fully raised, and against its stops. This is to prevent the gate from rotating downward unexpectedly while service work is being performed. ALWAYS raise the gate fully and lower it to the desired opening height before engaging the gate lock. Crop material can hold the tension arm at a lower position, and if this material is disturbed during service, the tension arm can swing up, and the gate can swing suddenly downward, even if the gate lock is engaged Verifying that tension arm is positioned against its stops will avoid this situation Failure to do this may result in serious injury or death.
When locking the gate in any position:
1.Raise gate fully.
2 Lower gate to desired height
3 Rotate interlock lever (B) and move gate lock lever (A) to locked position (shown)
4 Verify that tension arm is fully raised and against its stops
If gate lock lever can be moved to locked position with gate fully closed, interlock lever is not adjusted properly. (See Checking Gate Lock Valve Interlock Lever Adjustment in Operating the Baler section of machine Operator′s manual.)
IMPORTANT:
Before operating baler, make sure gate lock lever is in the UNLOCKED position. Operating baler with gate lock engaged will damage baler.
Disconnect power supply to electronic controls when servicing electrical systems or when welding on baler. Over-voltage can damage the electronic controls.
Tie long hair behind your head Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts If these items were to get caught, severe injury could result
Moving Parts
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
Service Baler
Use an open-end wrench to turn hex gear case output shaft to aid in servicing
Never use any type of tool or wrench on shaft while tractor engine is running. Always remove tool from shaft whenever you are finished using it.
Check PTO hookup tubular shield to ensure it is free to turn Make necessary repairs if shield will not turn
Safety Sharp Knives
Be careful when working around knives in the following areas They are sharp CoverEdge ™ Net Wrap (if equipped) Starter Roll Scraper (if equipped)
Safety Pinched Hand
Twine arm(s) can move unexpectedly when twine arm power is on Stay out of the path of twine arm(s) at all times when twine arm power is on. During service or adjustment procedures for twine arm(s) or twine cutter mechanism, turn off power to twine arm(s) BEFORE placing your hands in the path of twine arm travel.
If there is crop material which is holding twine arm(s) from moving freely during twine arm cycle, it is recommended that twine arm(s) be manually positioned to release any “hold” they may have on the crop material Turn off power to twine arm(s) This will help to make the unplugging operation easier and prevent twine arm(s) from moving unexpectedly while your hands may be in the path of the twine arm(s). Stay out of the path of twine arm(s) at all times when power to twine arm(s) is ON.
Illuminate Work Area
Illuminate your work area adequately but safely Use a portable safety light for working inside or under the machine Make sure the bulb is enclosed by a wire cage The hot filament of an accidentally broken bulb can ignite spilled fuel or oil
Replace Safety Signs
Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
Use Proper Lifting Equipment
Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual
Remove Paint Before Welding or Heating
Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust Wear an approved respirator
If you use solvent or paint stripper, remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly
Avoid Heating Near Pressurized Fluid Lines
Flammable Spray
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.
Service Tires Safely
Explosive Tire and Rim Parts
Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts
Keep Area Clean
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving Keep hands, feet , and clothing from power-driven parts
Disengage all power and operate controls to relieve pressure Lower equipment to the ground Stop the engine Remove the key. Allow machine to cool.
Securely support any machine elements that must be raised for service work
Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine
On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine
Use Proper Tools
Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners
For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
Construct Dealer-Made Tools Safely
Construct Dealer-Made Tools Safely
Faulty or broken tools can result in serious injury When constructing tools, use proper, quality materials, and good workmanship
Do not weld tools unless you have the proper equipment and experience to perform the job
Dispose of Waste Properly
Recycle Waste
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants
Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.
Live With Safety
Safety Systems
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems Install all guards and shields
Group 10 - Specifications
Machine Specifications—458, 458 Silage Special and 558
[ (Specifications and design subject to change without notice ) ]
Machine Specifications 458, 458 Silage Special, and 558
BALER DIMENSIONS
Length: Gate Closed; w/o COVEREDGE Net
Wrap
Length: Gate Closed; w/COVEREDGE Net Wrap
Length: Gate Open
Height: Gate Closed
Height: Gate Open
Width: Regular Pickup
Width: MEGAWIDE PLUS ™ Pickup
BALER WEIGHT
[ Depending on crop conditions ]
Maximum Weight
REGULAR PICKUP
Width: Inside
Width: On Flare
Width: Between Outer Teeth Drive
Tooth Bars
Number of Teeth
Tooth Spacing
Stripper Diameter
MEGAWIDE PLUS PICKUP
Width: Inside
Width: On Flare
Width: Between Outer Teeth Drive
Tooth Bars
Number of Center Teeth
Number of Outside (MegaTeeth)
Tooth Spacing
Stripper Diameter
FORMING BELTS
Numbe
r
BALE WRAP (BaleTrak™Pro)
458458 Silage Special
178 mm (7 in )
458 Silage Special
Diamond Tough™, diamond tread, friction surface, with plate type splices (2) 11679 mm (460 in.) (4) 11819 mm (468 in ) 558
in ) 2565 mm (101 in ) 1901 kg (4190 lb )
3612 mm (142 2 in )
3980 mm (156.7 in.)
4542 mm (178 8 in )
2597 mm (102 2 in )
3251 mm (128 in.)
2847 mm (112 1 in )
2819 mm (111 in )
1975 kg (4310 lb )
889 1524 mm (35 60 in )
1565 mm (61.6 in.)
658 kg (1450 lb )
794 kg (1750 lb.)
1560 mm (61 4 in )
1803 mm (71 1 in )
1519 mm (59 8 in )
Roller chain with V-belt
48 (96 tines)
66 mm (2 6 in ) 254 mm (10 in )
1864 mm (73 4 in )
2210 mm (87 in )
1519 mm (59 8 in )
Roller chains with slip clutch
4 Left-Hand and 4 Right-Hand
56 (112 tines)
8 (8 tines)
66 mm (2 6 in )
254 mm (10 in )
558 8 178 mm (7 in )
Diamond Tough™, diamond tread, friction surface, with plate type splices (4) 11679 mm (460 in.) (4) 11819 mm (468 in )
Section 10 - GENERAL
TypeTwine wrap (standard)
COVEREDGE Net wrap (optional)
ControlSelf-activating; automatic at desired bale size
