John Deere 460M, 460M Precutter, 560M, and 560M Precutter Round Balers Technical Manual TM148119 25MAY21

Introduction
Foreword
Contents
General
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 Round Baler Safely
Gate Lock Valve
Knife Lockout Valve
Positioning Machine for Service
Sharp Knives
Pinch Points
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
Specifications
Machine Specifications—460M and 560M
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Metric Face Seal Fitting Torque Chart—Standard Pressure Applications
Metric Face Seal Fitting Torque Chart—High Pressure Applications
SAE Face Seal Fitting Torque Chart—Standard Pressure Applications
SAE Face Seal Fitting Torque Chart—High Pressure Applications
Service Recommendations For 37° Flare and 30° Cone Seat Connectors
General Information
Machine Decal Identification
Machine Description—4×6 and 5×6
Lubricants
Grease
Gear Case Oil
Alternative and Synthetic Lubricants
Mixing of Lubricants
Lubricant Storage
Perform Lubrication and Maintenance
Drive Train
General Information
Drive Train Operation
Machine with Regular Pickup
Machines with MegaWide™ Plus
Machines with MegaWide™ HC2 Pickups
Diagnosing Malfunctions
PTO Driveline Difficulties
Slip Clutch Alert Feature (If Equipped)
Slip Clutch Difficulties (If Equipped)
Gear Case Difficulties
Drive Chain Difficulties
Drive Train Protection
Other Material
Specifications
Replace PTO Speed Sensor
Replace Baler Speed Sensor
Adjust PTO and Baler Speed Sensors (MegaWide™ and MegaWide™ HC2 Pickups)
Verify the Operation and Adjustment of Sensors
Check Pickup Cam Clutch Torque (MegaWide™ Pickup)
Check Pickup Cam Clutch Torque (MegaWide™ HC2 Feed System)
Remove and Install MegaWide™ Pickup Cam Clutch
Remove
Install
Remove and Install MegaWide™ HC2 Pickup Cam Clutch
Repair PTO Driveline Hub—Friction Clutch Type
Repair PTO Driveline Friction Clutch (If Equipped)
Adjust PTO Driveline Friction Clutch (If Equipped)
Slipping Seized PTO Friction Clutch (If Equipped)
PTO Driveline
Specifications
PTO Driveline Exploded View—Friction Clutch Type
PTO Driveline Exploded View—Cam Clutch
540 rpm PTO Driveline Precutter Option
1000 rpm PTO Driveline Precutter Option
Repair PTO Lock-Back Collar Disconnect
Repair PTO Constant Velocity Joint
Remove and Install PTO Driveline Pedestal Bearing (If Equipped)
Remove and Install Gear Case
Other Material
Specifications
Remove and Install Gear Case
Remove
Install
Disassemble Gear Case
Gear Case Exploded View
Essential or Recommended Tools
Convert Baler to 1000 RPM
Replace Gear Case Hex Shaft—Left-Hand Side
T-Gear Case Repair
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Specifications
Remove and Install T-Gear Case
Remove
Install
Disassemble T-Gear Case
T-Gear Case Exploded View
Assemble T-Gear Case
Repair T-Gear Case Hex Shaft—Left-Hand Side
Replace T-Gear Case Hex Shaft—Right-Hand Side
Remove
Install
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
Third Roll Drive
Specifications
Disassemble and Assemble Third Roll Drive
Repair Third Roll Drive Clutch
Rolls
Essential or Recommended Tools
Specifications
Diagram of Rolls and Belt Routing—Non-Silage
Diagram of Rolls and Belt Routing—Silage
Remove and Install Starter Roll
Starter Roll End Play Adjustment
Remove and Install Belt Staggering Roll
Remove and Install Cleaning Auger Roll—Silage
Checking and Adjusting Clearance Between Cleaning Auger and Staggered Belt Roll
Check Clearance
Adjust Clearance
Remove and Install Front Idler Roll
Remove and Install Upper Tension Arm Roll
Remove and Install Top Idler Roll
Remove and Install Top Idler Roll—Third Roll Drive
Remove and Install Top Idler Roll Bearing—Third Roll Drive
Remove and Install Auxiliary Take-Up Roll
Remove and Install Upper Rear Gate Roll
Remove and Install Lower Rear Gate Roll—Without CoverEdge™
Remove and Install Lower Rear Gate Roll—With CoverEdge™
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 Upper Drive Roll
Install Upper Drive Roll Bearings
Install Upper Drive Roll
High-Moisture Kit (Silage Baling) Difficulties
Miscellaneous
Specifications
Adjust Lower Front Gate Roll Scraper
Adjust Starter Roll Scraper (If Equipped)
Adjust Idler Roll Scraper (If Equipped)
Check Belt Tracking
Adjust Belt Tracking
Adjust Lower Belt Guides—Precutter
Hydraulics
General Information
Tensioning Valve
High-Pressure Adjustable Relief Valve
High-Pressure Relief Valve (Non-Adjustable)
Low-Pressure Relief Valve (Non-Adjustable)
Pilot-Operated Check Valves
Optional Variable Soft Core Solenoid Valve
Install Inline Orifice Correctly
Bale Density Gauge
Diagnosing Malfunctions
Diagnosing Hydraulic Malfunctions
Operation and Tests
Specifications
Hydraulic System Operation
Baler Hydraulics Without Third Roll Drive
Baler Hydraulics With Third Roll Drive
Baling Soft Core
Baling Soft Core OFF
Opening the Gate
Closing the Gate
Belts Tight
Tension Arm Down
Low-Pressure Relief Valve Test
High-Pressure Relief Valve Test—Field Test
High-Pressure Relief Valve Test—Shop Test
Test Relief Valve
Check Bale Density Valve for Oil Leaks
Check Adjustable Relief Valve
Test Tension or Gate Cylinder for Leakage
Test Pickup or Precutter Drop Floor Lift Cylinders for Leakage
Test Gate Lock Valve for Leakage
Valve Repair
Remove and Install Tensioning Valve
Disassemble and Inspect Tensioning Valve
Assemble Tensioning Valve
Check Condition of Valve Seat and Poppet
Install Check Valves Correctly
Remove and Install Precutter Valve (If Equipped)
Remove and Install Third Roll Drive Valve (If Equipped)
Repair Gate Lock Valve
Remove and Install Knife Lockout Valve (If Equipped)
Replace Knife Lockout Valve Seals (If Equipped)
Cylinder Repair
John Deere Hydraulic Cylinder Repair—Use CTM
Remove and Install Gate Cylinder
Remove and Install Tension Cylinder
Remove and Install Regular and MegaWide™ Pickup Lift Cylinder
Adjust Initial Length of Regular and MegaWide™ Pickup Lift Cylinder
Remove and Install MegaWide™ HC2 Pickup Lift Cylinders
Remove and Install Third Roll Drive Cylinder
Remove and Install Knife Engagement Cylinder (If Equipped)
Remove and Install Precutter Lift Cylinder (If Equipped)
CoverEdge™ (If Equipped)
General Information
Other Material
Specifications
System Description
Net Switch Description
Net Application
Setting Number of Net Layers
Correct Feeding Problems
Check for Looped Net Material
Check and Adjust Net Pan
Check and Straighten Net Pan Angle
Checking and Adjusting Net Pan Pressure without Leaf Spring
Check Front Sheet-to-Rubber Roll Clearance
Diagnosing Malfunctions
Net Material Difficulties
BaleTrak™ Difficulties
CoverEdge™ Repair
Specifications
Remove and Install CoverEdge™
Repair Cuts on Feed Roll
Remove and Install Upper (Rubber) Feed Roll
Replace Upper Feed Roll Bearings
Remove and Install Lower (Steel) Feed Roll
Remove and Install Lower Net Guide
Adjust Lower Net Guide
Check Net Pan Pressure
Replace Lower Front Gate Roll Belt Guide
Check and Adjust Lower Belt Guides (MegaWide™ Pickup)
Check and Adjust Lower Belt Guides (MegaWide™ HC2)
Replace Cover Hinge Seal
Check Cover Gas Springs
Check and Adjust Cover Latch
Remove and Install Net Actuator
Remove
Install
Remove and Install Net Drive V-Belt
Adjust V-Belt Idler Tension
Check and Adjust Feed Roll Brake
Replace Net Switch and Net Switch Actuator
Replace the Net Switch
Replace the Net Switch Actuator
Remove and Install Cut-Off Knife
Sharpen Cut-Off Knife
Adjust Counterknife
Check for Left-Hand Side Counterknife Contact
Install and Adjust Net Brush
Adjusting Net Feed Roll Pressure
Checking Rubber Roll Bearing Support Clearance
Adjust Net Material Stretch
Check For Bent Rubber Crop Deflectors
Check Hole Wear in CoverEdge™ Side Sheet
Electrical System
General Information
Electrical System Description—BaleTrak™ Pro and Plus
BaleTrak™ Monitor-Controller
Sensors
Switches
Optional Variable Core Feature
Slip Clutch Alert (If Equipped)
Lighting Enhancement Module Operation
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
Shorted Circuit
High Resistance or Open Circuit
Grounded Circuits
Electrical Circuit Malfunctions
High Resistance or Open Circuit
Grounded Circuit
Shorted Circuit
Probe Light Check—Voltage from Battery
Probe Light Check—Continuity to Ground
Seven-Step Electrical Test Procedure
Diagnosing Malfunctions-BaleTrak™ System
Tests and Adjustments-BaleTrak™ System
BaleTrak™ Monitor-Controller Operations
BaleTrak™ Monitor-Controller Keypad
BaleTrak™ Pro—for Non-Precutter Machines
BaleTrak™ Plus—for Precutter Machines
BaleTrak™ Monitor-Controller Displays and Indicators
BaleTrak™ Monitor-Controller Operation
BaleTrak™ Monitor-Controller Specifications
BaleTrak™ Monitor-Controller Setup Values and Initial Settings
Adjusting Audible Alarm Volume
Using Manual Actuator, Wrap, and Bypass Switches
Using Bypass Switch (Twine Only)
Repair-BaleTrak™ System
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)
Install Repair Wire Assembly (RWA)—Method 1
Install Repair Wire Assembly (RWA)—Method 2
Use Electrical Insulating Compound
Use Terminal Cleaner and Di-Electric Grease
Harness Repair—Splice Connector
Repair Procedure R-A
Remove Contact From Connector Body
Install New Contact
Repair Procedure R-B
Remove Contact From Connector Body
Install New Contact
Repair Procedure R-E
Remove Contact From Connector Body
Install New Contact
Repair Procedure R-J
Remove Contact From Connector Body
Install New Contact
Feed System
General Information
Specifications
Pickup Description
Inspect Pickup Components
Center Shaft
Pickup Teeth
Flares/Crop Dividers
Strippers
Drives
Pickup Gauge Wheels
Float
Cam Follower Bearing, Cam Follower Arm, Cam, and Spider
Auger/Rotor Assembly
Precutter
Check Pickup Tooth End Play
Diagnosing Malfunctions
Pickup Difficulties
High-Moisture Kit Difficulties—Silage Baling
Feeding Difficulties
Feeding Difficulties with Roller Baffle
General Baler Difficulties—BaleTrak™
Regular Pickup Repair
Other Material
Specifications
Replace Cam Follower Bearings
Remove and Install Pickup Cam
Remove and Install Pickup
Disassemble Regular Pickup Reel
Assemble Regular Pickup
Tooth Bar, Center Shaft, and Spider Assembly
Left-Hand Side
Right-Hand Side
Pickup Drive Belt and Chain Alignment
Adjust Initial Length of Drive Belt Idler Spring
Adjust Drive Belt Idler
Adjust Pickup Float Springs
Remove and Install Compressor Rack Assembly
Remove
Install
Adjusting Compressor Rack Assembly
MegaWide™ Pickup Common Repair
Specifications
Replace MegaWide™ Pickup Teeth
Outer Teeth
Center Teeth
Remove and Install MegaWide™ Crop Strippers
MegaWide™ Crop Divider, Gauge Wheels, and Cam Exploded Views
Right-Hand Side
Left-Hand Side
Disassemble and Assemble MegaWide™ 4 ft Pickup Reel
Disassemble and Assemble MegaWide™ 5 ft Pickup Reel
MegaWide™ 5 ft Pickup Reel Exploded View
Replace MegaWide™ Cam Follower Bearings
Remove and Install MegaWide™ Pickup Cam
MegaWide™ Plus Pickup Repair (Non-Precutter)
Specifications
Remove and Install MegaWide™ Pickup Roller Baffle (Non-Precutter)
Install Roller Baffle
Repair MegaWide™ Pickup Roller Baffle (Non-Precutter)
Adjust MegaWide™ Pickup Roller Baffle Height (Non-Precutter)
Adjust MegaWide™ Pickup Roller Baffle Float Tension (Non-Precutter)
Balancing MegaWide™ Pickup Roller Baffle (Non-Precutter)
Remove and Install MegaWide™ Pickup Compressor Rack Assembly (Non-Precutter)
Adjust MegaWide™ Pickup Compressor Rods (Non-Precutter)
Remove and Install MegaWide™ Pickup/Rotor Assembly (Non-Precutter)
MegaWide™ Pickup and Rotor Exploded View (Non-Precutter)
MegaWide™ Pickup/Rotor Frame-to-Baler Frame Shimming Procedure (Non-Precutter)
Remove and Install MegaWide™ Pickup Reel Assembly (Non-Precutter)
Left-Hand Side
Right-Hand Side
Both Sides
Remove and Install MegaWide™ Auger/Rotor Assembly (Non-Precutter)
Disassemble and Assemble MegaWide™ Auger/Rotor Assembly (Non-Precutter)
MegaWide™ Pickup Drive Chain Sprocket Alignment (Non-Precutter)
Adjust MegaWide™ Pickup Auger Scrapers (Non-Precutter)
Adjust MegaWide™ Pickup Drive Chains (Non-Precutter)
Adjust MegaWide™ Pickup Float Springs (Non-Precutter)
MegaWide™ Pickup Repair (Precutter)
Essential or Recommended Tools
Other Material
Specifications
Remove and Install MegaWide™ Compressor Rack (Precutter)
Remove and Install MegaWide™ Roller Baffle (Precutter)
Disassemble and Assemble MegaWide™ Roller Baffle (Precutter)
Balancing MegaWide™ Roller Baffle (Precutter)
Remove and Install MegaWide™ Roller Baffle Bearings (Precutter)
Remove and Install MegaWide™ Pickup (Precutter)
Remove
Install
Remove and Install MegaWide™ Primary Rotor (Precutter)
Remove
Install
Remove and Install MegaWide™ Primary Rotor Stripper Assembly (Precutter)
Remove
Install
Remove and Install MegaWide™ Secondary Rotor (Precutter)
Remove
Install
Adjust MegaWide™ Pickup Float Springs (Precutter)
Precutter Repair
Remove and Install Precutter Knives
Sharpen Knives
Diagnosing Precutter
Remove and Install Knife Locking Shaft
Remove and Install Knife Holder Pivot Shaft
Remove
Install
Precutter Exploded Views
Precutter Floor
Knife Shaft
Rotor Repair-MegaWide™ HC2 Pickup
Gauge Wheels
Specifications
Repair Gauge Wheel—Regular Pickup
Repair MegaWide™ Gauge Wheel
Remove and Install MegaWide™ Gauge Wheel Arm Assembly
Miscellaneous
Wheel Repair
Service Equipment and Tools
Specifications
Remove Baler Wheel
Tire Installation and Wheel Nut Torque
Machines with 14L x 16.1 tires:
Machines with 21.5L x 16.1 tires, MegaWide™ pickup only:
Install Wheel Spindles on Baler with Regular Pickup and 11L-14 Tires
Install Wheel Spindles on Baler with Regular Pickup and 14L X 16.1 Tires
Install Wheel Spindles on Balers with MegaWide™ Pickup and 14L X 16.1 Tires
Install Wheel Spindles on Balers with MegaWide™ Pickup and 21.5L X 16.1 Tires
Install Wheel Spindles on Balers with MegaWide™ HC2 Pickup and 21.5 X 16.1 Tires
Inspect and Replace Baler Wheel Bearings 14L x 16.1Tires
Inspect and Replace Baler Wheel Bearings 21.5L X 16.1 Tires
Repair Gathering Wheel (If Equipped)
Remove Excessive Play from Gathering Wheel Pivot
Gate Repair
Specifications
Straighten Gate
Remove and Install Gate
Tension Arm Repair
Specifications
Remove and Install Tension Arm
Adjust Upper Tension Arm Compression Spring
Adjust Bale Size Indicator
Inspect Tension Arm Wear Channel
Replace Tension Arm Wear Channel
Tongue Repair
Specifications
Remove and Install Tongue
Belt Repair
Essential or Recommended Tools
Service Equipment and Tools
Remove Belts
Install Belts
Prepare Belts for New Lacings
Install Belt Lacing
Belts Eligible for Warranty Replacement
Belts Not Eligible for Warranty Replacement
Main Frame Repair
Service Equipment and Tools
Straighten Main Frame
Dealer Fabricated Tools
Dealer Fabricated Tools
DFEX1874A Support Strap
DFEXT11—Rotor Tine Straightening Tool
Materials Required:
Tool Fabrication:
Part Assembly
Tool Use:
DFEXT14—Precutter Spring Tool
Electrical
Theory of Operation
Auxiliary Power Electrical Theory
Bale Shape Electrical Theory
Gate Latch Electrical Theory
Lighting Electrical Theory
Precutter (Optional) Electrical Theory
Twine, Net, and B-Wrap Electrical Theory
Schematics
Auxiliary Power Electrical Schematic
Bale Shape Electrical Schematic
Gate Latch Electrical Schematic
Lighting Electrical Schematic
Precutter Electrical Schematic
Twine, Net, and B-Wrap Electrical Schematic
Electrical Component Information
Electrical Assemblies
XA1 — Flasher Module Connector
XA6 — BaleTrak Monitor Connector
Sensors
XB1 — Speed Sensor Connector
Cam Clutch PTO Speed Sensor
Friction Clutch PTO Speed Sensor
XB3 — Pickup Slip Clutch Alert Sensor Connector
Balers with MegaWide™ HC2 Pickup—Rotor Shaft Speed
Balers with MegaWide™ Plus Pickups—Drive Roll Speed
XB5 — Left-Hand Bale Shape Position Sensor Connector
XB6 — B-Wrap Sensor Connector
XB7 — Right-Hand Bale Shape Position Sensor Connector
XB8 — Bale Size Position Sensor Connector
XB13 — Knife Sensor Connector
XB14 — Drop Floor Switch Sensor Connector
Lights
XE1 — Left-Hand Amber Light Connector
XE2 — Left-Hand Red Light Connector
XE3 — Right-Hand Red Light Connector
XE4 — Right-Hand Amber Light Connector
Switches
XS1-1 —Oversize Bale Switch 1 Connector
XS1-2 — Oversize Bale Switch 2 Connector
XS2 — Right-Hand Gate Latch Switch Connector
XS3 — Left-Hand Gate Latch Switch Connector
XS4-1 — Net Switch 1 Connector
XS4-2 — Net Switch 2 Connector
Interconnects and Ground Points
XX1 — Tractor Main Interconnect
XX2 — Tractor Lighting Interconnect
XX4 — Precutter Interconnect
XX6 — Auxiliary Power Interconnect
XX8 — Tractor Convenience Interconnect
Electronically Actuated Mechanical Devices
XY1 — Twine Actuator Solenoid Connector
XY2 — Variable Core Solenoid Connector
XY3 — Net Actuator Solenoid Connector
XY4 — Pickup Solenoid Connector
XY5 — Knives Engage Solenoid Connector
XY6 — Drop Floor Solenoid A Connector
XY7 — Drop Floor Solenoid B Connector
Hydraulics
Theory of Operation
Precutter Valve (Optional) Hydraulic Theory
Tension Block Non-Variable Core Hydraulic Theory
Tension Block Variable Core (Optional) Hydraulic Theory
Schematics
Precutter Valve Hydraulic Schematic
Tension Block Non-Variable Core Hydraulic Schematic
Tension Block Variable Core Hydraulic Schematic
Hydraulic Component Information
Sensor or Gauge
B1 — Bale Density Gauge
Cylinder, Actuator, or Piston
C1 — Left-Hand Gate Cylinder
C2 — Right-Hand Gate Cylinder
C3 — Left-Hand Tension Cylinder
C4 — Right-Hand Tension Cylinder
C5 — Left-Hand Precutter Knife Cylinder
C6 — Right-Hand Precutter Knife Cylinder
C7 — Left-Hand Drop Floor Cylinder
C8 — Right-Hand Drop Floor Cylinder
C9 — Left-Hand Pickup Cylinder
C10 — Right-Hand Pickup Cylinder
C11 — Third Roll Drive Cylinder
Check Valve
D1 — Right-Hand Tension Check Valve
D2 — Left-Hand Tension Check Valve
D3 — Tension Check Valve
D4 — Third Roll Drive Check Valve
Valve Block, Assembly, or Gearcase
G1 — Tensioning Valve Block
G2 — Knife Lockout Valve
G3 — Gate Lock Valve
G4 — Precutter Valve
G5 — Third Roll Drive Valve Block
Valve
V1 — High Pressure Adjustable Relief Valve
V2 — Low Pressure Relief Valve
Diagnostic Receptacle or Coupler
X1P — Tension and Gate Pressure Coupler
X1R — Tension and Gate Return Coupler
X2P — Precutter Valve Pressure Coupler
X2R — Precutter Valve Return Coupler
Solenoid Valve
Y2 — Variable Core Solenoid Valve
Y4 — Pickup Solenoid Valve
Y5 — Knives Engage Solenoid Valve
Y6 — Drop Floor Extend Solenoid Valve
Y7 — Drop Floor Retract Solenoid Valve
Page Number
Section 10
Group 05
Group 10
Group 15
Group 20
Section 20
Group 05
Group 10
Group 15
Group 20
Group 25
Group 27
Group 30
Group 31
Group 35
Group 40
Section 30
Group 05
Group 10
Group 15
Group 20
Group 30
Section 41
Section 50
Group 05
Group 10
Group 15
Section 60
Group 05
Group 10
Group 15
Group 20
Group 30
Group 35
Group 40
Section 70
Group 05
Group 10
Group 15
Group 25
Group 26
Group 27
Group 28
Group 29
Group 30
Section 80
Group 05
Group 10
Group 15
Group 20
Group 25
Group 30
Section 99
Group 05
Section 240
Group 20
Group 30
Section 249
Group 40A
Group 40B
Group 40E
Group 40S
Group 40X
Group 40Y
Section 270
Group 20
Group 30
Section 279
Group 40B
Group 40C
Group 40D
Group 40G
Group 40V
Group 40X
Group 40Y