Complete Diagnosis Test Service Repair manual with electrical wiring diagrams for John Deere 540, 545, 550, 570, 580, 590 Hay & Forage Round Balers, with workshop information to maintain, diagnose, repair, and service like professional mechanics.

John Deere Hay and Forage Round Balers Models 540, 545, 550, 570, 580 and 590 workshop Diagnostic and Repair manual includes:
* 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.

TM3265 - John Deere Hay and Forage Round Balers Models 540, 545, 550, 570, 580, 590 All Inclusive Technical Manual (Diagnosis Operation Test Service Repair).PDF
TM3265 - John Deere Hay and Forage Round Balers Models 540, 545, 550, 570, 580, 590 All Inclusive Technical Manual (Diagnosis Operation Test Service Repair).EPUB

Total Pages: 1,372 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
   Electrical System
      Connectors
      Sensors and Switches
      Actuators
      BaleMaster Control Monitor
      Manual Twine Control Switch
      Bale Monitor
      Sound Alarm
   Power Train
      Bondioli Powerline
      Walterscheid Powerline
      Walterscheid CV Joint
      Baler Main Drive Shaft
      John Deere Slip Clutch
      Shear Bolt Clutch
      Walterscheid Slip Clutch
      Cam-Type Cut Out Clutch
      Comer Gear Case
      Superior Gear Case (540, 545 and 550)
      Precutter Gear Case
      Chain Tension
      Sprocket Alignment
   Hydraulic System
      Bale Density Control Valve (540, 545, 570 and 580)
      Bale Density Control Valve (550 and 590)
      Hydraulic Cylinders
      Gate Locking Valve (550 and 590)
      Hydraulic Twine Arm Control (545 and 550)
      Hydraulic Twine Operating Instructions (545 and 550)
      Net Wrapping Hydraulic Components (545 and 550)
      Precutter Hydraulic Components
   Miscellaneous
      Wheel and Hub Repair
      Tongue Repair
      Gate Latch
      Bale Size Indicator
      Bale Shape Sender
   Pickup Repair
      1.41 m (4 ft 7 in.) Pickup
      1.81 m (5 ft 11 in.) Pickup
      2.20 m (7 ft 3 in.) Pickup
      Pickup Adjustments
      Pickup Drive Components
   Precutter System
   Bale Chamber
      Identification of Rolls
      Baler Rolls
      Scraper of Roll
      Belt Repair
      Belt Guide for Net Wrapping Device
      Tension Arm Repair
      Top Idler Roll Declutchable Drive
   Net Wrapping System
   Twine Wrapping System
   Electrical System
      Electrical System Diagrams for Road Light
      Electrical System / Manual Twine Control
      Electrical Diagram / Manual Twine Control Switch
      Checking Twine Wrapping Function
      Checking Soft Core Function
      Electrical System / Electronic Wrapping Control
      Electrical Diagram / Electronic Wrapping Control
      Checking Twine Wrapping Function
      Checking Soft Core Function
      Checking the Bale Oversize and Gate Function
      Electrical System / BaleMaster Control
      Electrical Diagrams / BaleMaster Control
      BaleMaster Diagnostic Mode
      Checking BaleMaster Monitor
      Checking Controller Power Supply and Data Link
      Checking Twine Wrapping Function
      Checking Net Wrapping Function
      Checking Twine and Net Wrapping Control Function
      Checking Bale Oversize and Tension Control Function
      Checking Gate Function
      Checking Precutter Function
      Checking Soft Core Function
   Hydraulic System - Operation and Tests
      Bale Density / Gate Control - Description
      Bale Density / Gate Control - Troubleshooting
      Bale Density / Gate Control - Tests
      Pickup Lift System (Baler without Precutter)
      Precutter Hydraulic System - Description
      Precutter Hydraulic System - Tests
   Net Wrapping - Operation and Tests
   Twine Wrapping - Operation and Tests

tm3265 - 540, 545, 550, 570, 580 and 590 round balers

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

Dispose of Waste Properly

Live With Safety

Section 10: General

Group 10: Serial Numbers

Serial Number Plates

Baler Serial Number Plate

Baler Identification Number

Component Serial Number Plate

Net Wrapping Serial Number Record

Precutter Device Serial Number Record

Group 15: Torques for Hardware

Unified Inch Bolt and Cap Screw Torque Values

Metric Bolt and Cap Screw Torque Values

Group 20: Lubrication

Gear Oil

Grease

Group 25: General Information

Locking Collars for Shaft Bearings

Section 40: Electrical System

Group 05: Connectors

Special or Essential Tools

Electrical Repair Tool Kit

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-SEALSURE-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

Replacing DEUTSCHDEUTSCH is a trademark of Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

WEATHER PACKWEATHER PACK is a trademark of Packard Electric. Male and Female Connectors

Replacing METRI PACK METRI PACK is a trademark of Delphi Packard Electric Systems. ConnectorsFor METRI PACK connectors, 150 series

Replacing SCHLEMMERSCHLEMMER is a trademark of Josef Schlemmer GmbH. Connectors

Harness Repair (Splice Broken or Cut Wire)

Harness Repair-Splice Connector

Group 10: Sensors and Switches

Specifications

Gate Latch Switches A13 and A14 (550 Up to SN 295307)

Gate Latch Switches A13, A14 (550 From SN 295308) - S1, S2 (590 With BaleMaster Control Monitor) - S8, S10 (590 Without BaleMaster Control Monitor)

Gate Latch Switch A13 (540 and 545) - S1 (570 and 580 With BaleMaster Control Monitor) - S8 (570 and 580 Without BaleMaster Control Monitor)

Bale Size Switch A7 (545 and 550)

Bale Size Switch S1 (570 and 580 With Manual Twine Control Switch)

Bale Size Switch S1 (570, 580 and 590 With Electronic Wrapping Control Monitor)

Oversize Bale Switch S1 (570 and 580 With Manual Twine Control Switch)

Oversize Bale Switch A12 (540 and 545) - S9 (570 With Electronic Wrapping Control Monitor) - S3 (570 With BaleMaster Control Monitor)

Oversize Bale Switch A12 (550 Up to SN 295307)

Oversize Bale Switch A12 (550 From SN 295308) - S9 (580 and 590 With Electronic Wrapping Control Monitor) - S3 (580 and 590 With BaleMaster Control Monitor)

Twine Arm Switch A8 (545 and 550)

Twine Pump Switch A21 (545 and 550)

Net Cut Switch A22 (545 and 550) - S4 (570, 580 and 590 Up to SN 313557)

Adjusting Net Cut Switch S4 (570, 580 and 590 From SN 313558 Up to SN 320630)

Adjusting Net Cut Switch S4 (570, 580 and 590 From SN 320631 Up to SN 322399)

Adjusting Net Cut Switch S4 (570, 580 and 590 From SN 322400)

Soft Core Switch A26 (545 and 550) - S7 (570, 580 and 590 Without BaleMaster Control Monitor)

Bale Shape Senders A17 - A18 (545 and 550)

Bale Shape Senders R3 - R4 (570, 580 and 590 With BaleMaster Control Monitor)

Twine Pulley Sensors S7 - S8 (570, 580 and 590 With BaleMaster Control Monitor)

Bale Size Potentiometer R2 (570, 580 and 590 With BaleMaster Control Monitor)

Adjusting Lower Drive Roll Sensor S6 (570, 580 and 590 With BaleMaster Control Monitor)

Adjusting Precutter Knife Sensor S10 (580 and 590 With BaleMaster Control Monitor)

Adjusting Precutter Reverse Sensor S9 (580 and 590 With BaleMaster Control Monitor)

Group 15: Actuators

Other Material

Specifications

Disassembling/Assembling Twine Arm Actuator A4 (540 Only) - M1 (570, 580 and 590 without BaleMaster Control Monitor)

Disassembling Twine Arm Actuator M1 (570, 580 and 590 With BaleMaster Control Monitor)

Assembling Twine Arm Actuator M1 (570, 580 and 590 With BaleMaster Control Monitor)

Adjusting Twine Arm Actuator Rod (Baler With BaleMaster Control Monitor Only)

Adjusting Twine Arm Re-extension Point (Baler with Electronic Wrapping Control Monitor)

Adjusting Bale End Wrap Position (Baler With BaleMaster Control Monitor Only)

Disassembling/Assembling Net Wrapping Actuator M2 (570, 580 and 590 With BaleMaster)

Group 20: BaleMaster Control Monitor (570, 580 and 590)

Replacing LCD Screen Bulbs H1- H2

Replacing Monitor Sound Alarm H3

Replacing Monitor Main Switch S11

Group 25: BaleMaster Controller (570, 580 and 590)

Replacing BaleMaster Controller Fuse F3

Replacing Controller EPROM

Replacing Circuit Board

Group 30: Manual Twine Control Switch (540, 570 and 580)

Manual Twine Control Switch A3 (540 Only)

Manual Twine Control Switch A1 (570 and 580)

Group 35: Bale Monitor (545 and 550)

Bale Monitor (545 Up to SN 306327 and 550 Up to SN 295307)

Bale Monitor (545 From SN 306328 and 550 From SN 295308)

Group 40: Sound Alarm (540 and 545)

Sound Alarm A4 (540 and 545)

Section 50: Power Train

Group 05: Bondioli Powerline

Powerline Shield Disassembly

Powerline Shield Reassembly

Disassembling Hook-Up

Bondioli Powerline Exploded View

Reassembling Hook-Up

Group 10: Walterscheid Powerline

Special or Essential Tools

Bearing Extractor

Powerline Guard Removal 540, 545 and 550 shown

Remove Powerline With Shear Bolt

Remove Powerline With Slip Clutch

Remove Powerline with Cam-Type Cut Out Clutch

Removing Half Guard

Installing Half Guard

Disassembling Hook-Up

Walterscheid Powerline Exploded View

Assembling Hook-Up

Disassembling Coupler

Assembling Coupler

Group 15: Walterscheid CV Joint

Special or Essential Tools

Bearing Extractor

Disassembling CV Joint Shield

Assembling CV Joint Shield

Disassembling CV Joint

Assembling CV Joint

Group 20: Baler Main Drive Shaft

Other Material

Specifications

Drive Shaft (w/o Precutter Device)-Cross-Sectional View

Drive Shaft (with Precutter Device)-Cross-Sectional View

Removing Bearing

Installing Bearing

Group 25: John Deere Slip Clutch

Specifications

Removing Slip Clutch

Disassembling and Assembling Slip Clutch

Installing Slip Clutch

Adjusting Slip Clutch

Group 30: Shear Bolt Clutch

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

Disassembling Cam-Type Cut Out Clutch

Adjusting Cam-Type Cut Out Clutch

Exploded View of Cam-Type Cut Out Clutch

Assembling Cam-Type Cut Out Clutch

Group 45: Comer Gear Case

Other Material

Special or Essential Tools

Specifications

Removing Gear Case

Disassembling Gear Case

Inspect Gear Case

Exploded View of Comer Gear Case

Assembling Gear Case

Installing Gear Case (540, 545 and 550)

Installing Gear Case (570, 580 and 590)

Group 50: Superior Gear Case (540, 545 and 550)

Other Material

Specifications

Removing Gear Case

Disassembling Gear Case

Inspect Gear Case Parts

Exploded View of Superior Gear Case

Assembling Gear Case

Installing Gear Case

Group 55: Precutter Gear Case

Other Material

Specifications

Removing Gear Case

Disassembling Gear Case

Exploded View of Precutter Gear Case

Assembling Gear Case

Installing Gear Case

Group 60: Chain Tension

Adjusting Main Drive Chain

Checking Starter Roll Drive Chain (Baler without Precutter Device Only)

Adjusting Starter Roll Drive Chain (Baler with Precutter Device Only)

Adjusting Upper Drive Roll Chain (590 Only)

Adjusting Upper Drive Roll Chain (580 Only)

Adjusting Upper Drive Roll Chain (570 Only)

Adjusting Top Idler Roll Drive Chain

Adjusting Precutter Drive Chain

Adjusting 2.00 m (6 ft 6.7 in.) Pickup Drive Chain (baler with precutter)

Adjusting 2.00 m (6 ft 6.7 in.) Precutter Pickup Left-Hand Auger Drive Chain

Adjusting Pickup Main Drive Chain (Baler without Precutter Device)

Adjusting 1.41 m (4 ft 7 in.) Pickup Drive Chain

Adjusting 1.81 m (5 ft 11 in.) Pickup Drive Chains

Adjusting 2.20 m (7 ft 3 in.) Pickup Drive Chains

Group 65: Sprocket Alignment

Specifications

Checking and Adjusting Sprockets Alignment

Section 70: Hydraulic System

Group 05: Bale Density Control Valve (540, 545, 570 and 580)

Avoid High-Pressure Fluids

General Repair Information

Removing and Installing Bale Density Control Valve

Disassembling Bale Density Control Valve

Assembling Bale Density Control Valve

Checking Condition of Valve Seats and Poppets

Group 10: Bale Density Control Valve (550 and 590)

Avoid High-Pressure Fluids

General Repair Information

Removing and Installing Bale Density Control Valve

Disassembling Bale Density Control Valve

Assembling Bale Density Control Valve

Checking Condition of Valve Seats and Poppets

Installing Check Valves Correctly

Group 15: Hydraulic Cylinders

Other Material

Specifications

Removing and Installing Tension Cylinder (540, 545 and 570)

Removing and Installing Tension Cylinder (580)

Removing/Installing Tension Cylinder (550 Up to SN 295307 Only)

Removing and Installing Tension Cylinder (550 From SN 295308 and 590)

Removing/Installing Gate Cylinder (550 Up to SN 295307 Only)

Removing and Installing Gate Cylinder (550 From SN 295308 and 590)

Removing Twine Wrap Cylinder (545 and 550)

Disassembling and Assembling Tension Cylinder (550 up to SN 295307, 540, 545 and 570) and Gate Cylinder (550 up to SN 295307)

Disassembling and Assembling Tension Cylinder (550 from SN 295308 and 590 only)

Disassembling and Assembling Gate Cylinder (550 from SN 295308 and 590 only) and Tension Cylinder (580 only)

Disassembling and Assembling 1.41 m (4 ft 7.5 in.)/1.81 m (5 ft 11 in.) Pickup Lift (up to SN 328675), Belt Slack Control and Twine Wrapping (545 and 550) Cylinder

Disassembling and Assembling 1.41 m (4 ft 7.5 in.)/1.81 m (5 ft 11 in.) Pickup Lift Cylinder (from SN 328676)

Disassembling and Assembling Precutter Pickup Lift Cylinder (2.20 m (7 ft 3 in.)

Disassembling and Assembling Precutter Knives Cylinder

Disassembling and Assembling Gear Case Reverse Cylinder and Declutchable Top Idler Roll Drive

Group 20: Gate Locking Valve (550 and 590)

Repairing Gate Locking Valve (550 and 590)

Group 25: Hydraulic Twine Arm Control (545 and 550)

Removing Hydraulic Pump

Removing and Installing Pump Pulley

Installing Hydraulic Pump

Removing Pump Relief Valve

Repairing Pump Relief Valve

Installing Relief Valve

Removing Twine Flow Control Valve

Installing Twine Flow Control Valve

Removing Single-Spool Valve

Repairing/Installing Single-Spool Valve

Group 30: Hydraulic Twine Operating Instructions (545 and 550)

Operating Twine Arm With Empty Baler (545 Only)

Operating Twine Arm With Empty Baler (550 Only)

Operating Net Wrapping System with Empty Baler (545 Only)

Operating Net Wrapping System With Empty Baler (550 Only)

Priming the Twine Hydraulic Pump

Releasing Knife Arm Manually

Group 35: Net Wrapping Hydraulic Components (545 and 550)

Removing Net Flow Control Valve

Installing Net Flow Control Valve

Disassembling Hydraulic Components

Assembling Hydraulic Components

Group 40: Precutter Hydraulic Components

Specifications

Avoid High-Pressure Fluids

Removing and Installing Precutter Valve

Bleeding Precutter Circuit

Identification View of Precutter Valve

Disassembling and Assembling Precutter Valve (Baler Up To S.N. 325423)

Disassembling and Assembling Precutter Valve (Baler From S.N. 325424)

Section 80: Miscellaneous

Group 05: Wheel and Hub Repair

Specifications

Exploded View of Wheel Hub (540 up to SN 300788)

Disassembling Wheel Hub (540 up to SN 300788)

Assembling Wheel Hub (540 up to SN 300788)

Exploded View of Wheel Hub (540 from SN 300789, 545, 550, 570, 580 and 590)

Disassembling Wheel Hub (540 from SN 300789, 545, 550, 570, 580 and 590)

Assembling Wheel Hub (540 from SN 300789, 545, 550, 570, 580 and 590)

Exploded View of Pickup Gauge Wheel

Repairing Pickup Gauge Wheel

Exploded View of Converging Wheel

Repairing Converging Wheel

Remove Excessive Play From Converging Wheel Pivot

Group 15: Tongue Repair (540, 545 and 550)

Specifications

Removing Tongue

Installing Tongue

Group 20: Tongue Repair (570, 580 and 590)

Specifications

Removing Tongue

Installing Tongue

Removing/Installing Ball Joint Hitch

Group 25: Gate Latch

Specifications

Adjusting Gate Latch (590 Only)

Adjusting Gate Locking Hooks (570 with Soft Core Only)

Group 30: Bale Size Indicator

Adjusting Bale Size Indicator

Group 35: Bale Shape Sender

Adjusting Bale Shape Senders (Baler without BaleMaster Control Monitor)

Section 100A: Pickup Repair

Group 05: 1.41 m (4 ft 7 in.) Pickup

Other Material

Specifications

1.41 m (4 ft 7 in.) Pickup Inspection Checklist

Replacing Teeth with 1.41 m (4 ft 7 in.) Pickup Installed

Replacing Cam Follower Bearings

Replacing Stiffener Plastic Bearings on Heavy-Duty 1.41 m (4 ft 7 in.) Pickup

Removing 1.41 m (4 ft 7 in.) Pickup

Disassembling 1.41 m (4 ft 7 in.) Pickup Cylinder

Inspecting 1.41 m (4 ft 7 in.) Pickup Cylinder

Assembling 1.41 m (4 ft 7 in.) Pickup Cylinder

Installing 1.41 m (4 ft 7 in.) Pickup

Group 10: 1.81 m (5 ft 11 in.) Pickup

Other Material

Specifications

1.81 m (5 ft 11 in.) Pickup Inspection Checklist

Replacing Teeth with 1.81 m (5 ft 11 in.) Pickup Installed

Replacing Cam Follower Bearings

Removing 1.81 m (5 ft 11 in.) Pickup Augers

Installing 1.81 m (5 ft 11 in.) Pickup Augers

Removing 1.81 m (5 ft 11 in.) Pickup

Removing Staggered Packer (570, 580 and 590), (545 From SN 306897), (550 From SN 295308)

Disassembling and Assembling Staggered Packer

Installing Staggered Packer (570, 580 and 590), (545 from SN 306897) (550 from SN 295308)

Removing Straight Packer (550 Up to SN 295307 Only)

Disassembling and Assembling Straight Packer (550 Up to SN 295307 Only)

Removing Straight Packer Drive Sprockets (550 Up to SN 295307 Only)

Aligning Straight Packer Shaft Bearings (550 Up to SN 295307 Only)

Installing Straight Packer (550 Up to SN 295307 Only)

Disassembling 1.81 m (5 ft 11 in.) Pickup Cylinder

Inspecting 1.81 m (5 ft 11 in.) Pickup Cylinder

Assembling 1.81 m (5 ft 11 in.) Pickup Cylinder

Installing 1.81 m (5 ft 11 in.) Pickup

Group 15: 2.20 m (7 ft 3 in.) Pickup

Other Material

Specifications

Removing the Pickup

Installing the Pickup

Repairing the Pickup Cylinder

Repairing the Pickup Feeder Fork and Crankshaft

Group 20: Pickup Adjustments

Specifications

Adjusting Pickup Auger Scrapers

Adjusting Left-Hand 1.41 m (4 ft 7 in.) Pickup Float Spring (570, 580 and 590) (540 From SN 301476) (545 From SN 306327) (550 From SN 295308)

Adjusting Right-Hand 1.41 m (4 ft 7 in.) Pickup Float Spring (570, 580 and 590) (540 From SN 301476) (545 From SN 306327) (550 From SN 295308)

Adjusting Left-Hand 1.81 m (5 ft 11 in.) Pickup Float Spring (570, 580 and 590) (540 From SN 301476) (545 From SN 306327) (550 From SN 295308)

Adjusting Right-Hand 1.81 m (5 ft 11 in.) Pickup Float Spring (570, 580 and 590) (540 From SN 301476) (545 From SN 306327) (550 From SN 295308)

Adjusting Pickup Float Springs (540 Up to SN 301475) (545 Up to SN 306326) (550 Up to SN 295307)

Adjusting 2.20 m (7 ft 3 in.) Pickup Float Spring (from S.N. 327824)

Adjusting Pickup Float Spring (Baler With Precutter Device)

Adjusting Pickup Belt Idler (540 Up to SN 301475) (545 Up to SN 306326) (550 Up to SN 295307)3

Group 25: Pickup Drive Components

Replacing Pickup Drive Shear Bolt (Baler without Precutter Device)(570, 580 and 590) (540 From SN 301476) (545 From SN 306327)

Replacing Pickup Drive Shear Bolt (Baler with Precutter Device)

Replacing Pickup Drive Cam Clutch Components (545 From SN 306897) (550 Up to SN 295308)

Section 100B: Precutter System

Group 05: Adjustment

Specifications

Precutter Rotor and Bearing-Cross-Sectional View (From S.N. 322878)

Adjusting Scrapers

Section 120: Bale Chamber

Group 05: Identification of Rolls

Identification of Rolls (540, 545 and 570)

Identification of Rolls (550, 580 and 590 without Precutter Device)

Identification of Rolls (580 and 590 with Precutter Device)

Group 10: Baler Rolls

Other Material

Specifications

Removing Starter Roll - No. 1 (Baler without Precutter)

Removing Starter Roll - No. 1 (Baler with Precutter)

Installing Starter Roll - No. 1 (Baler with Precutter)

Removing Lower Belt Drive Roll - No. 2 (Baler without Precutter)

Removing Lower Belt Drive Roll - No. 2 (Baler with Precutter)

Installing Lower Belt Drive Roll - No. 2

Removing Cleaning Auger

Installing Cleaning Auger

Removing and Installing Front Idler Roll - No. 3 (550, 580 and 590)

Removing Upper Belt Drive Roll - No. 4 (550 From SN 295308 and 590)

Removing Upper Belt Drive Roll - No. 4 (550 Up to SN 295307) (540, 570 and 580)

Installing Upper Belt Drive Roll - No. 4

Removing and Installing Front Tension Arm Idler Roll - No. 5

Removing and Installing Top Arm Roll - No. 6

Removing and Installing Upper Rear Gate Roll - No. 7

Removing and Installing Lower Rear Gate Roll - No. 8

Removing and Installing Lower Front Gate Roll - No. 9

Removing and Installing Rear Tension Arm Roll - No. 10 (540, 545 and 570)

Removing and Installing Rear Tension Arm Roll - No. 10 (580 Only)

Removing and Installing Center and Rear Tension Arm Rolls - No. 10 and No. 12 (550 and 590)

Removing Top Idler Roll - No. 11 (540, 545 and 570)

Removing Top Idler Roll - No. 11 (580 and 590)

Installing Top Idler Roll - No. 11

Remove and Install Center Tension Arm Roll - No. 12 (540, 545, 570 and 580)

Removing Belt Staggering Roll - No. 13

Installing Belt Staggering Roll - No. 13

Replace Tension Arm Roll Shaft

Replace Stationary Shaft Roll Bearings

Replacing Bearings With Cast Housings

Replacing Bearings With Steel Flange

Group 15: Scraper of Roll

Specifications

Adjusting Scraper of Starter Roll - No. 1 (Baler without Precutter Device)

Adjusting Scraper of Starter Roll - No. 1 (Baler with Precutter Device)

Adjusting Scraper of Lower Rear Gate Roll - No. 8

Adjusting Scraper of Lower Front Gate Roll - No. 9 (540) (545 Up to SN 306326) (550 Up to SN 295307)

Adjusting Scraper of Lower Front Gate Roll - No. 9 (570, 580 and 590 with Net Wrapping)

Adjusting Scraper of Net Feed Roll - No. 14 (Baler with Net Wrapping)

Group 20: Belt Repair

Essential Tools

Specifications

Removing Belts

Preparing Damaged Belts

Installing Standard Belt Hooks

Installing Goro Belt Hooks With Vice-Type Lacing Tool (Old Design)

Installing Goro Belt Hooks With Vice-Type Lacing Tool (New Design)

Installing Goro Belt Hooks With Bench-Type Lacing Tool

Installing Mato Belt Hooks

Installing Belts

Length and Routing Belts Through the Baler (540, 545 and 570 with Cleaning Auger Roll)

Length and Routing Belts Through the Baler (540, 545 and 570 without Cleaning Auger Roll)

Length and Routing Belts Through the Baler (550, 580 and 590 With Cleaning Auger Roll)

Length and Routing Belts Through the Baler (550, 580 and 590 Without Cleaning Auger Roll)

Adjusting Belt Tracking (Baler without Net Wrapping)

Group 25: Belt Guide for Net Wrapping Device

Other Material

Assembling Roll No. 10 Belt Guide

Adjusting Belt Tracking (Baler with Net Wrapping)

Group 30: Tension Arm Repair

Specifications

Removing Tension Arm (550 From SN 295308, 580 and 590)

Installing Tension Arm (550 From SN 295308, 580 and 590)

Removing Tension Arm (550 Up to SN 295307)

Installing Tension Arm (550 Up to SN 295307)

Removing Tension Arm (540, 545 and 570)

Installing Tension Arm (540, 545 and 570)

Adjusting Upper Arm Spring (540 and 545 baler)

Adjusting Upper Arm Spring (550 Up to SN 295307)

Adjusting Upper Arm Spring (550 From SN 295308, 580 and 590 Baler without Precutter Device)

Adjusting Upper Arm Spring (590 Baler with Precutter Device Only)

Adjusting Upper Arm Cylinder (570 and 580 Baler)

Group 35: Top Idler Roll Declutchable Drive

Adjusting Top Idler Roll Declutchable Drive (590)

Section 130A: Net Wrapping System

Group 05: Repair (Baler Up To SN 322399)

Specifications

Removing Drive Belt (545 Only)

Installing Drive Belt (545 Only)

Removing Net Feed Roll Drive Belt (550, 570, 580 and 590 Up to SN 323332)

Installing Net Feed Roll Drive Belt (550, 570, 580 and 590 Up to SN 322399)

Checking Drive Belt

Removing Lower Net Guide

Disassembling/Assembling Lower Guide

Installing Lower Net Guide

Checking Lower Net Guide Panel

Checking Lower Net Guide Crossbar

Checking Lower Net Guide Channels

Removing Net Knife (Baler Up to SN 322399)

Sharpening Net Knife

Installing Net Knife (Baler Up to SN 322399)

Adjusting Net Knife Arm Stop (545 and 550)

Adjusting Net Knife Arm Stop (570, 580 and 590)

Adjusting Net Feed Roll Pressure (Baler Up to SN 322399)

Adjusting Net Feed Roll Brake (545 and 550)

Adjusting Net Feed Roll Brake (570, 580 and 590)

Removing Rear Net Guide

Installing Rear Net Guide

Removing Front Net Guide (545 and 550) (570, 580 and 590 Up to SN 313557)

Removing Front Net Guide (570, 580 and 590 From SN 313558)

Checking Front Net Guide Rubber Band

Installing Front Net Guide (545 and 550) (570, 580 and 590 Up to SN 313557)

Installing Front Net Guide (570, 580 and 590 From SN 313558)

Net Box - Exploded View

Adjusting Net Box Latch

Removing Lower Feed Roll - No. 14

Removing Upper Feed Roll - No. 15

Checking and Adjusting Galvanized Net Feed Roll No.14 Radial Play

Checking and Adjusting Galvanized Net Feed Roll No. 14 Bearing

Group 10: Repair (Baler From SN 322400)

Specifications

Exploded View of Net Wrapping System

Removing Lower Net Guide

Installing Lower Net Guide

Adjusting Lower Net Guide Crosstube

Adjusting Lower Net Guide Channels

Checking Lower Net Guide Panel

Removing Galvanized Net Feed Roll - No. 14 (570, 580 and 590 From SN 322400)

Installing Galvanized Net Feed Roll - No. 14 (570, 580 and 590 From SN 322400)

Removing Rubber Net Feed Roll - No. 15 (570, 580 and 590 From SN 322400)

Installing Rubber Net Feed Roll - No. 15 (570, 580 and 590 From SN 322400)

Removing and Installing Net Feed Roll Drive Belt (570, 580 and 590 From SN 322400)

Replacing Bearings in Roll

Removing and Installing Net Knife (Baler From SN 322400)

Sharpening Net Knife

Manually Releasing Net Feed Roll Brake

Adjusting Net Feed Roll Pressure (Baler From SN 322400)

Net Wrapping Device Check Procedure

Checking Swinging Bar Position (Test 1)

Checking Net Actuator Retraction (Test 2)

Checking Net Feed Roll Brake (Test 3)

Checking Steel Roll/Rubber Feed Roll Parallelism (Test 4)

Checking Net Drive Pulley Alignment (Test 5)

Checking Net Actuator Extension (Test 6)

Checking Net Feed Roll Drive Belt (Test 7)

Checking Net Wrapping Cover Hook (Test 8)

Removing Net Wrapped Around Feed Rolls

Adjusting Net Roll Support Brackets

Increasing Brake Bar Tension

Decreasing Brake Bar Tension

Section 130B: Twine Wrapping System

Group 05: Electrical Wrapping System (540, 570, 580 and 590)

Specifications

Adjusting Twine Guide (Baler with Precutter Device)

Adjusting Twine Guide (Baler without Precutter Device)

Adjusting Twine Cutter Anvil

Adjusting Twine Arm Travel (Baler Without BaleMaster)

Adjusting Twine Arm Timing (Baler With BaleMaster)

Group 10: Hydraulic Wrapping System (545 and 550)

Specifications

Adjusting Pump Drive Idler

Removing Twine Arm

Installing Twine Arm

Adjusting Twine Arm Return

Adjusting Twine Arm Travel

Adjusting Twine Valve Trip Rod

Adjusting Twine Cutter Tension

Adjusting Twine Cutter Anvil

Adjusting Twine Trip Rod and Valve Latch Clearance (545 Only)

Adjusting Twine Trip Rod and Valve Latch Clearance (550 Only)

Adjusting Pump Drive Latch for Bale Size

Adjusting Twine Trip Rope (545 From SN 306327) (550 From SN 295308)

Adjusting Twine Wrap Delayer

Section 240: Electrical System (570, 580 and 590)

Group 05: General Information

Read Me First!

Electrical Circuit Malfunctions

Open Circuit

Grounded Circuit

Shorted Circuit

How to Read A Functional Schematic

How to Read a Wiring and Harness Diagram

Symbols in System Diagrams

Component Identification Table

Group 06: Test Equipment

Special or Essential Tools

Group 10: Electrical System Diagrams for Road Light

Wiring Harness List

Component Identification

Components Location

Wiring Diagram

Group 15: Electrical System / Manual Twine Control

Specifications

Manual Twine Control

Operational Information

Group 15A: Electrical Diagram / Manual Twine Control Switch

Wiring Harness List

Component Identification

Components Location

Wiring Diagram

Wiring Diagram of Battery Wiring Harness W1 (if equipped)

Group 15B: Checking Twine Wrapping Function

Theory of Operation

Identification

Functional Schematic of Twine Wrapping Function

Group 15C: Checking Soft Core Function

Theory of Operation

Identification

Functional Schematic of Soft Core Function

Group 20: Electrical System / Electronic Wrapping Control

Specifications

Electronic Wrapping Control Monitor

Operational Information

Group 20A: Electrical Diagram / Electronic Wrapping Control

Wiring Harness List

Component Identification

Components Location

Wiring Diagram

Wiring Diagram of Battery Wiring Harness W1 (if equipped)

Group 20B: Checking Twine Wrapping Function

Theory of Operation

Identification

Functional Schematic of Twine Function

Group 20C: Checking Soft Core Function

Theory of Operation

Identification

Functional Schematic of Soft Core Function

Group 20D: Checking the Bale Oversize and Gate Function

Theory of Operation

Identification

Functional Schematic of Bale Oversize and Gate Function

Group 30: Electrical System / BaleMaster Control

Specifications

Read Me First!

Troubleshooting

BaleMaster Control Monitor

Keyboard Description

LCD Screen Description

BaleMaster Control Monitor Setup Values and Initial Settings

Operational Information

Displaying Software Versions

Group 30A: Electrical Diagrams / BaleMaster Control

Wiring Harness List

Component Identification

Component Location of Main Wiring Harness W2 (Part 1)

Wiring Diagram of Main Wiring Harness W2 (Part 1)

Component Location of Main Wiring Harness W2 (Part 2 - 570 and 580)

Wiring Diagram of Main Wiring Harness W2 (Part 2 - 570 and 580)

Component Location of Main Wiring Harness W2 (Part 2 - 590 Only)

Wiring Diagram of Main Wiring Harness W2 (Part 2 - 590 Only)

Component Location of Precutter Wiring Harness W3

Wiring Diagram of Precutter Wiring Harness W3

Wiring Diagram of Battery Wiring Harness W1

Group 30B: BaleMaster Diagnostic Mode

General Information

Keyboard Functions

Accessing BaleMaster Diagnostic Mode (Baler Without Precutter Device)

Accessing BaleMaster Diagnostic Mode (Baler with Precutter Device)

Malfunction Check-Up at Start Up

Diagnosing Right Gate Latch Switch S1

Diagnosing Left Gate Latch Switch S2 (590 Baler Only)

Diagnosing Oversize Bale Switch S3

Diagnosing Right Bale Formation Potentiometer R4

Diagnosing Left Bale Formation Potentiometer R3

Diagnosing Twine Pulley 1 Sensor S8

Diagnosing Twine Pulley 2 Sensor S7

Diagnosing Lower Drive Roll Sensor S6

Diagnosing Precutter Knife Sensor S10

Diagnosing Precutter Reverse Sensor S9

Diagnosing Bale Size Potentiometer R2

Diagnosing Twine Arm Potentiometer R1

Diagnosing Net Cut Switch S4

Diagnosing Net Cut Switch S4

Group 30C: Checking BaleMaster Monitor

Operational Information

Theory of Operation

Identification

Functional Schematic of Monitor

Group 30D: Checking Controller Power Supply and Data Link

Theory of Operation

Identification

Functional Schematic of Controller and Data Link

Group 30E: Checking Twine Wrapping Function

Operational Information

Theory of Operation

Identification

Functional Schematic of Twine Wrapping Function

Group 30F: Checking Net Wrapping Function

Operational Information

Theory of Operation

Identification

Functional Schematic of Net Wrapping Function

Group 30G: Checking Twine and Net Wrapping Control Function

Theory of Operation

Identification

Functional Schematic of Twine and Net Wrapping Control Function

Group 30H: Checking Bale Oversize and Tension Control Function

Theory of Operation

Identification

Functional Schematic of Bale Oversize and Tension Control Function

Group 30J: Checking Gate Function

Theory of Operation

Identification

Functional Schematic of Gate Function

Group 30K: Checking Precutter Function

Theory of Operation

Identification

Functional Schematic of Precutter Function

Group 30L: Checking Soft Core Function

Theory of Operation

Identification

Functional Schematic of Soft Core Function

Section 241: Electrical System (540, 545 and 550)

Group 05: General Information

How to Read a Circuit Plan

How to Read a Wiring Diagram

Group 06: Test Equipment

Special or Essential Tools

Multimeter

Group 10: Manual Twine Control Switch (540 only)

Manual Twine Control Switch - Function

Manual Twine Control Switch - Circuit Plan and Wiring Diagram

Group 15: Sound Alarm (540 and 545)

Sound Alarm - Function

Sound Alarm - Circuit Plan

Sound Alarm - Wiring Diagram

Group 20A: Basic Monitor (545 and 550)

Basic Monitor - Function (545 From SN 306327) (550 From SN 295308)

Basic Monitor - Circuit Plan (545 From SN 306327) (550 From SN 295308)

Basic Monitor - Wiring Diagram (545 From SN 306327) (550 From SN 295308)

Basic Monitor - Function (545 Up to SN 306326) (550 Up to SN 295307)

Basic Monitor - Circuit Plan (545 Up to SN 306326) (550 Up to SN 295307)

Basic Monitor - Wiring Diagram (545 Up to SN 306326) (550 Up to SN 295307)

Group 20B: Monitor For Net Wrapping (545 and 550)

Monitor for Net Wrapping - Function (545 From SN 306327) (550 From SN 295308)

Monitor for Net Wrapping - Circuit Plan (545 From SN 306327) (550 From SN 295308)

Monitor for Net Wrapping - Wiring Diagram (545 From SN 306327)(550 From SN 295308)

Monitor for Net Wrapping - Function (545 Up to SN 306326) (550 Up to SN 295307)

Monitor for Net Wrapping - Circuit Plan (545 Up to SN 306326) (550 Up to SN 295307)

Monitor for Net Wrapping - Wiring Diagram (545 Up to SN 306326) (550 Up to SN 295307)

Group 20C: Monitor for Soft Core (545 and 550)

Monitor for Soft Core - Function

Monitor for Soft Core - Circuit Plan

Monitor for Soft Core - Wiring Diagram

Group 25: Electrical Diagnostics

General Procedure

Check Potentiometer (545 With Monitor, 550)

Check Bale Shape Gauge (545 With Monitor, 550)

Check Buzzer (540 with Sound Alarm, 545 with Monitor or Sound Alarm, 550)

Check Wire for Continuity (545 with Monitor, 550)

Check Microswitches

Section 270: Hydraulic System - Operation and Tests

Group 05: Safety

Recommendations

Group 10: General Information

Hydraulic Symbols (As Defined by ISO 1219)

Group 20: Bale Density / Gate Control - Description

Bale Density/Gate Control - Working Principle

Soft Core Option - Working Principle

Description and Diagram - Bale Density/Gate Control (540, 545 and 570)

Description and Diagram - Bale Density/Gate Control (580)

Description and Diagram - Bale Density/Gate Control with and without 55 bar Soft Core Device (550 and 590)

Description and Diagram - Bale Density/Gate Control With 0 bar Soft Core (550 and 590)

Components Description

Starting a Bale (540, 545, 570 and 580 Without Soft Core Option)

During Baling (540, 545, 570 and 580 With Soft Core Option)

During Baling (540, 545, 570 and 580)

Opening the Gate (540, 545, 570 and 580)

Closing the Gate (540, 545, 570 and 580)

Starting a Bale (550 and 590 Without Soft Core Option)

During Baling (550 and 590 With 55 bar Soft Core Option)

Starting a Bale (550 and 590 With 0 bar Soft Core Option)

During Baling (550 and 590)

Opening the Gate (550 and 590)

Closing the Gate

Group 21: Bale Density / Gate Control - Troubleshooting

Diagnosing Hydraulic Functions

Group 22: Bale Density / Gate Control - Tests

Essential Tools

Specifications

Check Bale Density Hydraulic System

Check Gate Operation Hydraulic System

Check Bale Density Gauge (550, 580 and 590)

Check Bale Density Adjustable Relief Valve and Check Valve

Check 12 to 1 Check Valves (550 and 590)

Check Valve Pilot Piston Check

Check Safety Relief Valve

Checking Soft Core Electrovalve Function

Check Tension Cylinder for Leakage

Check Gate Cylinder for Leakage (590)

Check Gate Locking Valve for Leakage

Group 30: Pickup Lift System (Baler without Precutter)

1.41 m (4 ft. 7.5 in.) / 1.81 m (5 ft. 11 in.) Pickup Single Acting Cylinder- Identification and Diagram

1.41 m (4 ft. 7.5 in.) / 1.81 m (5 ft. 11 in.) Pickup Double Acting - Identification and Diagram

2.20 m (7 ft. 3 in.) Pickup - Identification and Diagram

Group 40: Precutter Hydraulic System - Description

Pickup Attachment and Precutter System

Hydraulic System - Description and Diagram

Group 41: Precutter Hydraulic System - Tests

Essential Tools

Specifications

Checking Pickup Lift Function (Baler with Precutter Device)

Checking Gear Case Reverser Function (Baler with Precutter Device)

Checking Knife Function (Baler with Precutter Device)

Checking Electrovalve Function (Baler with Precutter Device)

Section 330A: Net Wrapping - Operation and Tests

Group 05: Troubleshooting

Troubleshooting

Group 10: General Information

Hydraulic Net Wrapping - Description (545 and 550)

Hydraulic System Circuit Diagram - Hydraulic Net Wrapping (545 and 550)

Group 20A: Net Wrapping System - Operation (545 and 550)

How the Net Wrapping Mechanism Works (545 and 550)

Releasing Knife Arm Manually (545 and 550)

Group 20B: Net Wrapping System - Operation (570, 580 and 590)

How the Net Wrapping Works (Baler up to SN 322399)

How the Net Wrapping Works (Baler from SN 322400)

Section 330B: Twine Wrapping - Operation and Tests

Group 05: Troubleshooting

Twine Wrapping

Group 10: General Information

Hydraulic Twine Wrapping - Description (545 and 550)

Hydraulic System Circuit Diagram - Hydraulic Twine Wrapping (545 and 550)

Group 15: Twine Wrapping System - Operation (545 and 550)

Activating Hydraulic Pump

Twine Cylinder Control (Forward Travel)

Twine Cylinder Control (Return Travel)

Group 30: Twine Wrapping System - Tests (545 and 550)

Specifications

Special or Essential Tools

Hydraulic Test Kit and Adapting Parts

Check Twine Hydraulic Pump

John Deere Hay and Forage Round Balers Models 540, 545, 550, 570, 580, 590 All Inclusive Service Technical Manual (TM3265)