John Deere 540 545 550 570 580 590 Round Baler Workshop Repair Service Manual TM3265 PDF - MJODTM3265.zip
A comprehensive diagnostic, testing, and repair manual featuring electrical wiring schematics for the John Deere 540, 545, 550, 570, 580, and 590 Hay & Forage Round Balers — packed with workshop-level guidance so you can maintain, troubleshoot, fix, and service your machine just like a professional technician.
Inside this John Deere Hay and Forage Round Balers 540, 545, 550, 570, 580 and 590 Diagnostic and Repair workshop manual, you'll find:
* 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)