John Deere 440E, 450E Round Baler Technical Service Manual TM148319 PDF

440E and 450E Round Balers

TECHNICAL MANUAL 440E and 450E Round Balers TM148319 01DEC18 (ENGLISH)

John Deere Ottumwa Works

Introduction Foreword

majority of routine failures quickly. Repair groups tell how to repair the components.

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.

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.

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

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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.

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Contents 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 27 - Gear Case Repair 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 - Cylinder Repair Group 30 - Hydraulic Bale Ramp (If Equipped)

Section 40 - Twine Application Group 05 - General Information Group 10 - Diagnosing Malfunctions Group 15 - Twine System Adjustments Group 20 - Twine System Repair

Section 50 - CoverEdge™ (If Equipped) Group 05 - General Information Group 10 - Diagnosing Malfunctions Group 15 - CoverEdge™ Repair

Section 60 - Electrical System Group 05 - General Information Group 10 - Common Electrical Tests and Checks Group 15 - Diagnosing Malfunctions Group 20 - Tests and Adjustments-BaleTrak™ System Group 30 - BaleTrak™ Pro Monitor-Controller Operations Group 35 - Repair-BaleTrak™ Pro System Group 40 - Connector Repair

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Section 70 - Feed System Group 05 - General Information Group 10 - Diagnosing Malfunctions Group 15 - Regular Pickup Repair Group 25 - MegaWide™ Pickup Common Repair Group 26 - MegaWide™ Plus Pickup Repair Group 30 - Gauge Wheels

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 Group 35 - Bale Ramp (If Equipped)

Section 99 - Dealer Fabricated Tools Group 05 - Dealer Fabricated Tools

Section 240 - Electrical Group 20 - Theory of Operation Group 30 - Schematics

Section 249 Information

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Electrical

Component

Group 40A - Electrical Assemblies Group 40B - Sensors Group 40E - Lights Group 40S - Switches Group 40X - Interconnects and Ground Points Group 40Y - Electronically Actuated Mechanical Devices

Section 270 - Hydraulics Group 20 - Theory of Operation Group 30 - Schematics

Section 279 Information

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Hydraulic

Component

Group 40C - Cylinder, Actuator, or Piston Group 40D - Check Valve Group 40G - Valve Block, Assembly, or Gearcase Group 40V - Valve Group 40X - Diagnostic Receptacle or Coupler

440E and 450E Round Balers

Section 10

General Contents Page

Page

Use Proper Tools.................................................. . 10-05-9

Group 05 - Safety Recognize Safety Information .............................. . 10-05-1 Understand Signal Words..................................... . 10-05-1 Follow Safety Instructions..................................... . 10-05-1 Handle Fluids Safely-Avoid Fires .......................... 10-05-2 Prevent Battery Explosions .................................. . 10-05-2

Construct Dealer-Made Tools Safely.................... . 10-05-9 Dispose of Waste Properly ................................... . 10-05-10 Precautions for Welding ....................................... . 10-05-10 Protect Against High Pressure Spray................... . 10-05-10 Live With Safety ................................................... . 10-05-11

Prepare for Emergencies...................................... . 10-05-2

Group 10 - Specifications

Park Machine Safely............................................. . 10-05-2

Machine Specifications-440E and 450E............... . 10-10-1

Operate Baler Safely ............................................ . 10-05-3

Metric Bolt and Screw Torque Values................... . 10-10-3

Protect Bystanders ............................................... . 10-05-3

Unified Inch Bolt and Screw Torque Values ......... . 10-10-4

Service Machine Safely ........................................ . 10-05-4 Support Machine Properly .................................... . 10-05-5

Service Recommendations For 37° Flare and 30° 10-10-5 Cone Seat Connectors.................................. .

Wear Protective Clothing ...................................... . 10-05-5

Group 15 - General Information

Work in Clean Area .............................................. . 10-05-6

Machine Decal Identification ................................ . 10-15-1

Service Machines Safely ...................................... . 10-05-6

Machine Description............................................. . 10-15-1

Work In Ventilated Area ........................................ . 10-05-6 Illuminate Work Area Safely ................................. . 10-05-6 Replace Safety Signs ........................................... . 10-05-7 Use Proper Lifting Equipment............................... . 10-05-7 Avoid High-Pressure Fluids .................................. . 10-05-7 Remove Paint Before Welding or Heating ............. 10-05-8 Avoid Heating Near Pressurized Fluid Lines ......... 10-05-8 Service Tires Safely.............................................. . 10-05-8

Group 20 - Lubricants Grease.................................................................. . 10-20-1 Gear Case Oil....................................................... . 10-20-1 Alternative and Synthetic Lubricants .................... . 10-20-2 Mixing of Lubricants ............................................. . 10-20-2 Lubricant Storage ................................................. . 10-20-2 Perform Lubrication and Maintenance ................. . 10-20-2

Practice Safe Maintenance................................... . 10-05-9

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Safety

Group 05 Safety Recognize Safety Information

T81389-UN: 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.

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DANGER; The signal word DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Understand Signal Words

WARNING; The signal word WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION; The signal word CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events which could lead to personal injury.

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.

TS187-19: Signal Words

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Follow Safety Instructions

TS201-UN: 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.

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.

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Safety

Handle Fluids Safely—Avoid Fires

TS227-UN: 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.

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Prevent Battery Explosions

TS204-UN: Battery Explosions

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

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Prepare for Emergencies

TS291-UN: 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.

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Park Machine Safely

TS230-UN: Remove the Key

Before working on the machine:

Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag in operator station.

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Safety

Operate Baler Safely

Stand clear of baler at all times when machine is operating.

Keep all shields in place when operating baler.

Do not exceed maximum bale diameter or weight limits. This can lead to accelerated wear or machine failures.

Become familiar with all controls affecting machine functions.

Do not attempt to pull hay or twine from pickup when baler is running.

Never hand-feed twine or hay into baler.

Before servicing, adjusting, or removing material from the baler, always disengage all power and stop tractor engine.

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All machinery should be operated by responsible persons who have been properly instructed and delegated to do so.

Protect Bystanders

E32162-UN: 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.

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Safety If machine is connected to a tractor, engage tractor parking brake and/or place transmission in "Park", shut off engine, and remove key.

Service Machine Safely

If machine is detached from tractor, block wheels to prevent movement.

Before servicing or adjusting baler:

Disengage all power.

Shut off tractor engine.

Wait until all moving parts have stopped.

Let all components cool.

CAUTION: While working inside or around baler with an open gate, gate lock lever and channel must be moved to locked position. Use this safety feature anytime gate is open.

Close gate anytime baler must be left unattended. If gate is not locked while performing this procedure, gate could close suddenly causing injury or death. If gate cannot be fully raised to engage gate lock channel (A) during service, use hoist or appropriate lifting device to support gate.

TS698-UN: Safety Art

Channel (A) locks the left-hand gate lift cylinder to prevent the gate from falling if the hydraulic lift system fails.

To lock gate in open position:

Raise gate fully.

Move lever (B) to locked position (D). Inside surface (E) of channel (A) must contact top of cylinder rod. If channel (A) does not contact top of cylinder rod (as shown), adjust gate lock channel (A) side-to-side to engage cylinder rod or loosen cap screw (G).

Lower gate cylinder slowly, approximately 20 mm (0.75 in.). Ensure gate lock channel (A) is against top of cylinder rod and end of cylinder barrel. If inside of channel (F) of gate lock channel (A) is not against top of cylinder rod and end of cylinder.

E79081-UN: Gate Lock Rod

To unlock gate:

Move lever (B) to unlocked position (C).

Lower the gate.

E56984-UN: Channel Against Cylinder Rod Shown

E57018-UN: Channel Not Against Cylinder Rod Shown

LEGEND: A-Channel B-Lever in Gate Unlocked Position C-Unlocked Position D-Locked Position E-Inside Surface F-Inside of Channel G-Cap Screw

E80035-UN: Service Baler - Output Shaft

Use an open-end wrench to turn hex gear case output shaft to aid in servicing.

To help prevent personal injury caused by unexpected movement, be sure to service machine on a level surface.

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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.

440E and 450E Round Balers

Safety

E47598-UN: Safety—Pinched Hand

TS268-UN: Safety—Sharp Knives

Be careful when working around knives in the following areas.

They are sharp.

Twine Cutter Knife (if equipped) Net Cut-Off Knife (if equipped) Starter Roll Scraper (if equipped)

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. MR67966,0002AEE-19-20171213

Support Machine Properly

TS229-UN: 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.

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Wear Protective Clothing

TS206-UN: 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.

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Safety

Work in Clean Area

T6642EJ-UN: 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.

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Service Machines Safely

TS228-UN: Moving Parts

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.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

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Work In Ventilated Area

TS220-UN: Engine exhaust fumes

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

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Illuminate Work Area Safely

TS223-UN: Work Area Safely

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.

DX,LIGHT-19-19900604

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