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