John Deere 842 852 854 862 864 Hay and Forage Round Balers Repair Service Manual PDF Download TM300119 - MJODTM300119.zip
A complete diagnostic and repair manual featuring electrical wiring diagrams for the John Deere Hay and Forage Round Balers — Models 842, 852, 854, 862, and 864 (Worldwide Edition) — packed with the shop-level details needed to maintain, troubleshoot, and service these machines just like a professional technician would.
The John Deere 842, 852, 854, 862, 864 Hay & Forage Round Balers workshop Diagnostics Repair Technical Service Manual contains:
* 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.
TM300119 - John Deere Hay and Forage Round Balers Models 842, 852, 854, 862, 864 All Inclusive Technical Manual (Diagnosis Operation Test Repair Service).PDF
Total Pages: 2,002 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
Electrical System - Repair
Connectors
Sensors and Switches
Actuators
BaleTrak and BaleTrak Plus Monitor
Power Train
Walterscheid Powerline
Baler Main Drive Shaft
Shear Bolt Clutch
Walterscheid Slip Clutch
Cam-Type Cut Out Clutch
Gear Case
Chains
Sprocket Alignment
Braking System - Repair
Air Brakes
Hydraulic Brakes
Brake Shoe and Drum
Hydraulic System
Bale Density Control Valve
Hydraulic Cylinders
Hydraulic Hoses
Gate Lock Valve
Rotary Feeder Hydraulic Components
Miscellaneous
Axle
Gate Latch
Lubrication System - Repair
Drive Chain Lubrication
Pickup Repair
Rotary Feeding Device
Bale Chamber
Net Tying System
Twine Tying System
Diagnostic Trouble Codes
Diagnostic Trouble Codes for ISOBUS Baler
Diagnostic Trouble Codes for BaleTrak Control
Description
Battery Voltage
Bale Size Potentiometer R2 or RB311
Right Bale Shape Potentiometer R4 or RB322
Left Bale Shape Potentiometer R3 or RB321
Twine Actuator M1
Net Actuator M2
Soft Core Valves Y1, Y5 and Y6
Pickup Solenoid Valve Y4
Knife Solenoid Valve Y3
Drop Floor Solenoid Valve Y2
Cleaning Auger S12
Lower Drive Roll RPM Sensor S6
Twine Pulley Sensors S7/S8
Net Cut Switch S4 or Sensor SB414
Right Gate Switch S1 or Sensor SB337
Left Gate Switch S2 or Sensor SB336
Oversize Bale Switch S3 or sensor SB317
Positive Analog Reference
EPROM
Observable Symptoms
Electrical System
General Information
Test Equipment
Electrical Diagram/Battery Wiring Harness
Electrical System/ELC Plus Monitor (Electronic Tying Control)
Electrical Diagram/ELC Plus Monitor (Electronic Tying Control)
Electrical System/BaleTrak Control
Electrical Diagram/BaleTrak Monitor
Diagnostic Modes/BaleTrak Monitor
Electrical Diagram/ISOBUS Baler
Diagnostic Tests - ISOBUS Baler
Diagnostic Modes/ISOBUS Baler
Advanced Machine Settings Mode/ISOBUS Baler
Connector and Component Information
Lubrication System - Operation and Tests
Air Brake System - Operation and Tests
Hydraulic Brake System - Operation and Tests
Hydraulic System - Operation and Tests
Safety
General Information
Bale Density/Gate Control - Description
Bale Density/Gate Control - Tests
Pickup Lift System (Baler without Precutter Device)
Rotary Feeder Hydraulic System without Precutter Device - Description
Rotary Feeder Hydraulic System without Precutter Device - Tests
Rotary Feeder Hydraulic System with Precutter Device - Description
Rotary Feeder Hydraulic System with Precutter Device - Tests
Net Tying - Operation and Tests
Special Tools
tm300119 - 842, 852, 854, 862, and 864 Round Balers -: (Worldwide Edition)
Table of Contents
Foreword
Section 05: Safety
Group 05: Safety Information
Prevent Battery Explosions
Prepare for Emergencies
Prevent Acid Burns
Avoid High-Pressure Fluids
Support Machine Properly
Wear Protective Clothing
Service Machines Safely
Work in Clean Area
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Service Tires Safely
Practice Safe Maintenance
Use Proper Tools
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Live With Safety
Relieve Hydraulic Pressure Safely
Safety Information - Air Brake System
Section 10: General
Group 10: Serial Numbers
Baler Serial Number Record
Serial Number Plate Description
Group 15: Torques for Hardware
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Group 20: Lubrication
High Viscosity Gear Case Oil
Grease
Multiluber Chain Oil
Group 25: General Information
Locking Collars for Shaft Bearings
Section 40: Electrical System — Repair
Group 05: Connectors
Special or Essential Tools
Electrical Connector Handling
Disconnecting Electrical Circuit
Insulated and Non-Insulated Connectors
Replacing Small MATE-N-LOK MATE-N-LOK is a trademark of AMP, Inc. Contacts in Connector Housings
Replacing SURE-SEAL SURE-SEAL is a trademark of ITT Cannon Electric. Connector Bodies
Replace CPC, Large MATE-N-LOK and METRIMATE CPC, MATE-N-LOK, and METRIMATE are trademarks of AMP Inc. Pin Type Connectors
DEUTSCH Connectors
WEATHER PACK Connectors
METRI PACK Connectors For Metri Pack connectors, 150 series
Replacing SCHLEMMER SCHLEMMER is a trademark of Josef Schlemmer GmbH. Connectors
CINCH Connectors
Harness Repair (Splice Broken or Cut Wire)
Harness Repair—Splice Connector
Group 10: Sensors and Switches
Specifications
Replace Sensors SB337, SB336, SB317 and SB414
Gate Latch Switch S1 (842, 852, 854)(S.N. —134999)
Gate Latch Sensor SB337 (842, 852, 854 with BaleTrak Monitor)(S.N. 135000—)
Gate Latch Switches S1, S2 (862 with ELC Monitor and 862, 864 with BaleTrak Monitor) or SB333, SB334 (ISOBUS Baler)(S.N. —134999)
Gate Latch Sensors SB336, SB337 (862, 864 with BaleTrak Monitor or ISOBUS)(S.N. 135000—)
Oversize Bale Switch S3 (Baler with ELC or BaleTrak Monitor) or SB312 (ISOBUS Baler)(S.N. —134999)
Oversize Bale Sensor SB317 (842 with BaleTrak Monitor)(S.N. 135000—)
Oversize Bale Sensor SB317 (852, 854 with BaleTrak Monitor)(S.N. 135000—)
Oversize Bale Sensor SB317 (862, 864 with BaleTrak Monitor or ISOBUS)(S.N. 135000—)
Net Cut Switch S4 (Baler with ELC or BaleTrak Monitor) or SB412 (ISOBUS Baler)(S.N. —134999)
Net Cut Sensor SB414 (Baler with BaleTrak Monitor or ISOBUS)(S.N. 135000—)
Bale Size Switch S5 (Baler with ELC Plus Monitor)
Soft Core Switch S6 (Baler with ELC Plus Monitor)
Baler Rotation Speed Sensor S6 (Baler with BaleTrak Monitor) or SB362 (ISOBUS Baler)
Twine Pulley Sensors S7, S8 (Baler with BaleTrak Monitor)
Precutter Knife Sensor S10 (Baler with BaleTrak Monitor) or SB553 (ISOBUS Baler)
Cleaning Auger Sensor S12 (Baler with BaleTrak Monitor) or SB363 (ISOBUS Baler)
Drop Floor Sensor S13 (854 and 864) or SB532 (ISOBUS Baler)
Bale Size Potentiometer R2 (Baler with BaleTrak Monitor)
Bale Size Potentiometer RB311 (ISOBUS Baler)
Bale Shape Potentiometers R3, R4 or RB321, RB322 (Baler with BaleTrak Monitor)
Bale Shape Potentiometers RB321, RB322 (ISOBUS Baler)
Gate Position Potentiometer RB331 (ISOBUS Baler)
Bale Discharging Ramp Sensor SB341 (ISOBUS Baler)
B-Wrap Sensor SB416
Group 15: Actuators
Other Material
Specifications
Removing and Installing Twine Tying Actuator M1
Remove Net Tying Actuator M2
Install Net Tying Actuator M2
Disassembling/Assembling Twine Tying Actuator M1 and Net Tying Actuator M2
Group 50: BaleTrak and BaleTrak Plus Monitor
Specifications
Replace BaleTrak EPROM
Disassembling BaleTrak Monitor
Assembling BaleTrak Monitor
Reprogramming BaleTrak Software
Section 50: Power Train
Group 10: Walterscheid Powerline
Special or Essential Tools
Bearing Extractor
Remove Powerline With Shear Bolt
Remove Powerline With Slip Clutch
Remove Powerline with Cam-Type Cut Out Clutch
Installing Powerline with Cam-Type Cut Out Clutch
Remove Powerline Joint Shield
Install Powerline Joint Shield
Disassemble CV Joint
Assemble CV Joint
Removing Half Guard
Installing Half Guard
Disassemble Hook-Up
Assemble Hook-Up
Disassembling Coupler
Assembling Coupler
Exploded View of Powerline for Baler with 540 rpm Gear Case (Clutch DC212746)
Exploded View of Powerline for Baler with 1000 rpm Gear Case (Clutch DC212747)
Exploded View of Powerline (Clutch DC44090 and DC44092)
Group 20: Baler Main Drive Shaft (Baler without Rotary Feeder Device)
Other Material
Specifications
Drive Shaft (Baler without Rotary Feeder Device)
Remove Drive Shaft (Baler without Rotary Feeder Device)
Install Drive Shaft (Baler without Rotary Feeder Device)
Group 25: Baler Main Drive Shaft (Baler With Rotary Feeder Device)
Other Material
Specifications
Drive Shaft (Baler with Rotary Feeder Device)
Remove Drive Shaft (Baler with Rotary Feeder Device)
Install Drive Shaft (Baler with Rotary Feeder Device)
Group 30: Shear Bolt Clutch
Specifications
Disassembling Shear Bolt Clutch
Assembling Shear Bolt Clutch
Group 35: Walterscheid Slip Clutch
Specifications
Disassembling Slip Clutch
Exploded View of Walterscheid Slip Clutch
Assembling Slip Clutch
Install Setting Ring
Group 40: Cam-Type Cut Out Clutch
Other Material
Specifications
Disassemble Cam-Type Cut Out Clutch
Adjust Cam-Type Cut Out Clutch
Exploded View of Cam-Type Cut Out Clutch
Assemble Cam-Type Cut Out Clutch
Group 50: Gear Case (Baler without Rotary Feeder Device)
Recommended Tools
Service Equipment and Tools
Other Material
Specifications
Remove Gear Case (Baler without Rotary Feeder Device)
Disassemble Gear Case (Baler without Rotary Feeder Device)
Exploded View of Gear Case (Baler without Rotary Feeder Device)
Inspect Gear Case
Assemble Gear Case (Baler without Rotary Feeder Device)
Install Gear Case (Baler without Rotary Feeder Device)
Group 55: Gear Case (Baler with Rotary Feeder Device)
Recommended Tools
Service Equipment and Tools
Other Material
Specifications
Remove Gear Case (Baler with Rotary Feeder Device)
Disassemble Gear Case (Baler with Rotary Feeder Device)
Exploded View of Gear Case (Baler with Rotary Feeder Device)
Inspect Gear Case
Assemble Gear Case (Baler with Rotary Feeder Device)
Install Gear Case (Baler with Rotary Feeder Device)
Group 60: Chain
Check the Chain Wearing
Adjusting 1.81 m (5 ft 11 in.) Pickup Drive Chains
Adjusting 2.00 m (6 ft 7 in.) HiFlow Pickup Drive Chains
Adjusting 2.20 m (7 ft 3 in.) HiFlow Pickup Drive Chains
Adjust Pickup Drive Chains (Baler with Rotary Feeder Pickup)
Adjust Bottom Roll Drive Chain (Baler with Rotary Feeder Pickup)
Adjust Main Drive Chain
Adjust Upper Drive Roll Chain (842 Only)
Adjust Upper Drive Roll Chain (Except 842)
Adjust Rotary Feeder Drive Chain
Adjust Top Idler Roll Drive Chain
Group 70: Sprocket Alignment
Specifications
Check and Adjust Upper Drive Sprocket Alignment
Check and Adjust Double Drive Sprocket Alignment for 1.81 m (5 ft 11 in.) Pickup (Baler without Rotary Feeder Device)
Check and Adjust Crankshaft Sprocket Alignment for 2.20 m (7 ft 3 in.) Pickup (Baler without Rotary Feeder Device)
Check and Adjust Feeding Device Chains Sprocket Alignment (Baler with Rotary Feeder Device)
Section 60: Braking System — Repair
Group 05: Air Brakes
Specifications
Preliminary Check
General Information
Drain Air Brake Reservoir
Clean Air Filters
Install Plug-in Connections
Remove Reservoir
Install Reservoir
Remove Relay Emergency Valve
Install Relay Emergency Valve
Remove Brake Cylinder
Adjust Brake Cylinder Clevis