John Deere 468, 468 Silage Special and 568 Balers Repair Technical Manual TM1035

468, 468 Silage Special and 568 Round Balers Repair

REPAIR TECHNICAL MANUAL Round Balers models 468, 568 TM1035 29 DEC 13 (ENGLISH)

John Deere Agriculture Pinted by Belgreen

TM1035-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

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 Section 41 - 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 20 - MEGATOOTH Pickup Repair (568 Only) Group 25 - MEGAWIDE PLUS Pickup Repair Group 30 - Miscellaneous Section 80 - MISCELLANEOUS Group 05 - Wheel Repair Group 10 - Gate Repair <- Go to Global Table of contents

TM1035-REPAIR TECHNICAL MANUAL

TM1035-REPAIR TECHNICAL MANUAL

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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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TM1035-REPAIR TECHNICAL MANUAL

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TM1035-REPAIR TECHNICAL MANUAL

GENERAL

(g) by Belgreen v2.0

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.

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Section 10 page 1

TM1035-REPAIR TECHNICAL MANUAL

TM1035-REPAIR TECHNICAL MANUAL

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Section 10 - GENERAL Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Operate Baler Safely ............................................................................................................................ 2 Protect Bystanders ............................................................................................................................... 2 Handle Fluids Safely—Avoid Fires ......................................................................................................... 3 Prepare for Emergencies ...................................................................................................................... 3 Fire Prevention ..................................................................................................................................... 3 Fire Prevention—Welding ..................................................................................................................... 4 Avoid High-Pressure Fluids ................................................................................................................... 4 Support Machine Properly .................................................................................................................... 5 Wear Protective Clothing ...................................................................................................................... 6 Work in Clean Area ............................................................................................................................... 6 Service Machine Safely ......................................................................................................................... 8 Illuminate Work Area Safely ............................................................................................................... 10 Replace Safety Signs .......................................................................................................................... 10 Use Proper Lifting Equipment ............................................................................................................. 11 Remove Paint Before Welding or Heating ........................................................................................... 11 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 12 Service Tires Safely ............................................................................................................................ 12 Practice Safe Maintenance ................................................................................................................. 14 Use Proper Tools ................................................................................................................................. 14 Construct Dealer-Made Tools Safely ................................................................................................... 15 Dispose of Waste Properly .................................................................................................................. 15 Live With Safety ................................................................................................................................. 16 Group 10 - Specifications ..................................................................................................................... 17 468, 468 Silage Special and 568 Round Baler Specifications (Specifications and design subject to change without notice.) ............................................................................................................... 17 Metric Bolt and Screw Torque Values ................................................................................................. 19 Unified Inch Bolt and Screw Torque Values ........................................................................................ 20 Face Seal Fittings Assembly and Installation—All Pressure Applications ............................................ 20 Metric Face Seal Fitting Torque Chart—Standard Pressure Applications ............................................ 22 Metric Face Seal Fitting Torque Chart—High Pressure Applications ................................................... 23 SAE Face Seal Fitting Torque Chart—Standard Pressure Applications ................................................ 24 SAE Face Seal Fitting Torque Chart—High Pressure Applications ....................................................... 25 Service Recommendations For 37° Flare and 30° Cone Seat Connectors .......................................... 26 Group 15 - General Information ........................................................................................................... 27 Machine Description—468, 468 Silage Special, and 568 .................................................................... 27 Group 20 - Lubricants ............................................................................................................................ 29 Grease ................................................................................................................................................ 29 Gear Case Oil ...................................................................................................................................... 30 Alternative and Synthetic Lubricants .................................................................................................. 30 Mixing of Lubricants ........................................................................................................................... 30 Lubricant Storage ............................................................................................................................... 30 Perform Lubrication and Maintenance ................................................................................................ 31

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TM1035-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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

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Section 10 page 1

TM1035-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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. <- Go to Section TOC

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TM1035-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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

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Section 10 page 3

TM1035-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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

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TM1035-REPAIR TECHNICAL MANUAL