John Deere 540, 545, 550, 570, 580, 590 Baler Manual TM3265 - PDF DOWNLOAD

540, 545, 550, 570, 580 and 590 Round Balers TM All Inclusive

TECHNICAL MANUAL Round Balers models 540, 545, 550, 570, 580, 590 TM3265 07 AUG 02 (ENGLISH)

John Deere Agriculture Pinted by Belgreen

tm3265-TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD Section 05 - SAFETY Group 05 - Safety Information Section 10 - GENERAL Group 10 - Serial Numbers Group 15 - Torques for Hardware Group 20 - Lubrication Group 25 - General Information Section 40 - ELECTRICAL SYSTEM Group 05 - Connectors Group 10 - Sensors and Switches Group 15 - Actuators Group 20 - BaleMaster Control Monitor (570, 580 and 590) Group 25 - BaleMaster Controller (570, 580 and 590) Group 30 - Manual Twine Control Switch (540, 570 and 580) Group 35 - Bale Monitor (545 and 550) Group 40 - Sound Alarm (540 and 545) Section 50 - POWER TRAIN Group 05 - Bondioli Powerline Group 10 - Walterscheid Powerline Group 15 - Walterscheid CV Joint Group 20 - Baler Main Drive Shaft Group 25 - John Deere Slip Clutch Group 30 - Shear Bolt Clutch Group 35 - Walterscheid Slip Clutch Group 40 - Cam-Type Cut Out Clutch Group 45 - Comer Gear Case Group 50 - Superior Gear Case (540, 545 and 550) Group 55 - Precutter Gear Case Group 60 - Chain Tension Group 65 - Sprocket Alignment Section 70 - HYDRAULIC SYSTEM Group 05 - Bale Density Control Valve (540, 545, 570 and 580) Group 10 - Bale Density Control Valve (550 and 590) Group 15 - Hydraulic Cylinders Group 20 - Gate Locking Valve (550 and 590) Group 25 - Hydraulic Twine Arm Control (545 and 550) Group 30 - Hydraulic Twine Operating Instructions (545 and 550) Group 35 - Net Wrapping Hydraulic Components (545 and 550) Group 40 - Precutter Hydraulic Components Section 80 - MISCELLANEOUS Group 05 - Wheel and Hub Repair Group 15 - Tongue Repair (540, 545 and 550) Group 20 - Tongue Repair (570, 580 and 590) Group 25 - Gate Latch Group 30 - Bale Size Indicator Group 35 - Bale Shape Sender Section 100A - PICKUP REPAIR Group 05 - 1.41 m (4 ft 7 in.) Pickup Group 10 - 1.81 m (5 ft 11 in.) Pickup Group 15 - 2.20 m (7 ft 3 in.) Pickup Group 20 - Pickup Adjustments <- Go to Global Table of contents

tm3265-TECHNICAL MANUAL

tm3265-TECHNICAL MANUAL

(g) by Belgreen v2.5

Group 25 - Pickup Drive Components Section 100B - PRECUTTER SYSTEM Group 05 - Adjustment Section 120 - BALE CHAMBER Group 05 - Identification of Rolls Group 10 - Baler Rolls Group 15 - Scraper of Roll Group 20 - Belt Repair Group 25 - Belt Guide for Net Wrapping Device Group 30 - Tension Arm Repair Group 35 - Top Idler Roll Declutchable Drive Section 130A - NET WRAPPING SYSTEM Group 05 - Repair (Baler Up To SN 322399) Group 10 - Repair (Baler From SN 322400) Section 130B - TWINE WRAPPING SYSTEM Group 05 - Electrical Wrapping System (540, 570, 580 and 590) Group 10 - Hydraulic Wrapping System (545 and 550) Section 240 - ELECTRICAL SYSTEM (570, 580 AND 590) Group 05 - General Information Group 06 - Test Equipment Group 10 - Electrical System Diagrams for Road Light Group 15 - Electrical System / Manual Twine Control Group 15A - Electrical Diagram / Manual Twine Control Switch Group 15B - Checking Twine Wrapping Function Group 15C - Checking Soft Core Function Group 20 - Electrical System / Electronic Wrapping Control Group 20A - Electrical Diagram / Electronic Wrapping Control Group 20B - Checking Twine Wrapping Function Group 20C - Checking Soft Core Function Group 20D - Checking the Bale Oversize and Gate Function Group 30 - Electrical System / BaleMaster Control Group 30A - Electrical Diagrams / BaleMaster Control Group 30B - BaleMaster Diagnostic Mode Group 30C - Checking BaleMaster Monitor Group 30D - Checking Controller Power Supply and Data Link Group 30E - Checking Twine Wrapping Function Group 30F - Checking Net Wrapping Function Group 30G - Checking Twine and Net Wrapping Control Function Group 30H - Checking Bale Oversize and Tension Control Function Group 30J - Checking Gate Function Group 30K - Checking Precutter Function Group 30L - Checking Soft Core Function Section 241 - ELECTRICAL SYSTEM (540, 545 AND 550) Group 05 - General Information Group 06 - Test Equipment Group 10 - Manual Twine Control Switch (540 only) Group 15 - Sound Alarm (540 and 545) Group 20A - Basic Monitor (545 and 550) Group 20B - Monitor For Net Wrapping (545 and 550) Group 20C - Monitor for Soft Core (545 and 550) Group 25 - Electrical Diagnostics Section 270 - HYDRAULIC SYSTEM - OPERATION AND TESTS Group 05 - Safety

<- Go to Global Table of contents

tm3265-TECHNICAL MANUAL

tm3265-TECHNICAL MANUAL

(g) by Belgreen v2.5

Group 10 - General Information Group 20 - Bale Density / Gate Control - Description Group 21 - Bale Density / Gate Control - Troubleshooting Group 22 - Bale Density / Gate Control - Tests Group 30 - Pickup Lift System (Baler without Precutter) Group 40 - Precutter Hydraulic System - Description Group 41 - Precutter Hydraulic System - Tests Section 330A - NET WRAPPING - OPERATION AND TESTS Group 05 - Troubleshooting Group 10 - General Information Group 20A - Net Wrapping System - Operation (545 and 550) Group 20B - Net Wrapping System - Operation (570, 580 and 590) Section 330B - TWINE WRAPPING - OPERATION AND TESTS Group 05 - Troubleshooting Group 10 - General Information Group 15 - Twine Wrapping System - Operation (545 and 550) Group 30 - Twine Wrapping System - Tests (545 and 550)

<- Go to Global Table of contents

tm3265-TECHNICAL MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.

<- Go to Global Table of contents

tm3265-TECHNICAL MANUAL

SAFETY

(g) by Belgreen v2.0

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections (up to Section 200) tell how to repair the components. Operation and tests sections (from Section 200) help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

<- Go to Section TOC

Section 05 page 1

tm3265-TECHNICAL MANUAL

tm3265-TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 05 - SAFETY Table of contents Group 05 - Safety Information ............................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 1 Prepare for Emergencies ...................................................................................................................... 1 Prevent Acid Burns ............................................................................................................................... 2 Avoid High-Pressure Fluids ................................................................................................................... 2 Support Machine Properly .................................................................................................................... 3 Wear Protective Clothing ...................................................................................................................... 4 Service Machines Safely ....................................................................................................................... 4 Work in Clean Area ............................................................................................................................... 4 Remove Paint Before Welding or Heating ............................................................................................. 5 Avoid Heating Near Pressurized Fluid Lines .......................................................................................... 6 Illuminate Work Area Safely ................................................................................................................. 6 Replace Safety Signs ............................................................................................................................ 6 Use Proper Lifting Equipment ............................................................................................................... 7 Service Tires Safely .............................................................................................................................. 8 Practice Safe Maintenance ................................................................................................................... 9 Use Proper Tools ................................................................................................................................... 9 Dispose of Waste Properly .................................................................................................................. 10 Live With Safety ................................................................................................................................. 10

<- Go to Global Table of contents

tm3265-TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Group 05 - Safety Information Prevent Battery Explosions

Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Prepare for Emergencies

First Aid Kit Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

<- Go to Section TOC

Section 05 page 1

tm3265-TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Prevent Acid Burns

Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1.Filling batteries in a well-ventilated area.

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added.

4.Avoiding spilling or dripping electrolyte.

5.Use proper jump start procedure.

If you spill acid on yourself: 1.Flush your skin with water.

2.Apply baking soda or lime to help neutralize the acid.

3.Flush your eyes with water for 15-30 minutes. Get medical attention immediately.

If acid is swallowed: 1.Do not induce vomiting.

2.Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3.Get medical attention immediately.

Avoid High-Pressure Fluids

<- Go to Section TOC

Section 05 page 2

tm3265-TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

High-Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

Support Machine Properly

Support Properly Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual.

<- Go to Section TOC

Section 05 page 3

tm3265-TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Wear Protective Clothing

Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

Service Machines Safely

Moving Parts Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

<- Go to Section TOC

Section 05 page 4

tm3265-TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Work in Clean Area

Clean Work Area Before starting a job: Clean work area and machine.

Make sure you have all necessary tools to do your job.

Have the right parts on hand.

Read all instructions thoroughly; do not attempt shortcuts.

Remove Paint Before Welding or Heating

Toxic Fumes Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating: Remove paint a minimum of 76 mm (3 in.) from area to be affected by heating.

If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

<- Go to Section TOC

Section 05 page 5

tm3265-TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Avoid Heating Near Pressurized Fluid Lines

Flammable Spray Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

Illuminate Work Area Safely

Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

Replace Safety Signs

<- Go to Section TOC

Section 05 page 6

tm3265-TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Safety Signs Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Use Proper Lifting Equipment

Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

<- Go to Section TOC

Section 05 page 7

tm3265-TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Service Tires Safely

Explosive Tire and Rim Parts Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

<- Go to Section TOC

Section 05 page 8

tm3265-TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Practice Safe Maintenance

Keep Area Clean Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts.

Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Use Proper Tools

<- Go to Section TOC

Section 05 page 9

tm3265-TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners.

Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

Dispose of Waste Properly

Recycle Waste Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Live With Safety

<- Go to Section TOC

Section 05 page 10

tm3265-TECHNICAL MANUAL

GENERAL

(g) by Belgreen v2.0

Safety Systems Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

<- Go to Section TOC

Section 10 page 11

tm3265-TECHNICAL MANUAL

tm3265-TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 10 - GENERAL Table of contents Group 10 - Serial Numbers ..................................................................................................................... 1 Serial Number Plates ............................................................................................................................ 1 Baler Serial Number Plate ..................................................................................................................... 1 Baler Identification Number .................................................................................................................. 1 Component Serial Number Plate .......................................................................................................... 2 Net Wrapping Serial Number Record .................................................................................................... 2 Precutter Device Serial Number Record ............................................................................................... 2 Group 15 - Torques for Hardware ......................................................................................................... 4 Unified Inch Bolt and Cap Screw Torque Values ................................................................................... 4 Metric Bolt and Cap Screw Torque Values ............................................................................................ 5 Group 20 - Lubrication ............................................................................................................................ 6 Gear Oil ................................................................................................................................................ 6 Grease .................................................................................................................................................. 7 Group 25 - General Information ............................................................................................................. 8 Locking Collars for Shaft Bearings ........................................................................................................ 8

<- Go to Global Table of contents

tm3265-TECHNICAL MANUAL

Section 10 - GENERAL

Group 10: Serial Numbers

Group 10 - Serial Numbers Serial Number Plates Serial numbers identifying the baler and the attachments are stamped on factory serial number plates.

These numbers and letters are required when ordering baler or attachment replacement parts.

To ensure that you have these numbers at hand, enter the appropriate serial numbers in the spaces provided in each illustration.

Baler Serial Number Plate LEGEND: AModel designation BSerial number CYear of production DNominal load E Weight FMaximum load at hitch GMaximum load on axle HMaximum permissible total weight

Baler Serial Number Plate up to S.N.318917

Baler Serial Number Plate from S.N.318918

Baler Identification Number

Previous Version

<- Go to Section TOC

Section 10 page 1

tm3265-TECHNICAL MANUAL

Section 10 - GENERAL

Group 10: Serial Numbers

Latest Version The baler identification number plate is located on the right-hand or left-hand side of the front frame.

Component Serial Number Plate LEGEND: AModel designation BSerial number CYear of production DNominal load E Weight FMaximum load at hitch GMaximum load on axle

Component Serial Number

Net Wrapping Serial Number Record

Net Wrapping Serial Number The serial number plate is located on the l.h. side of the net frame.

Precutter Device Serial Number Record

<- Go to Section TOC

Section 10 page 2

tm3265-TECHNICAL MANUAL

Section 10 - GENERAL

Group 15: Torques for Hardware

Precutter Device Serial Number The serial number plate is located on the l.h. side of the precutter device frame.

<- Go to Section TOC

Section 10 page 3

tm3265-TECHNICAL MANUAL

Section 10 - GENERAL

Group 15: Torques for Hardware

Group 15 - Torques for Hardware Unified Inch Bolt and Cap Screw Torque Values

Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings Unified Inch Bolt and Cap Screw Torque Values, 1 of 2 Grade 1 (No Mark)Grade 2 a (No Mark)Grade 5, 5.1 or 5.2Grade 8 or 8.2 bbbb

SizeLubricated c c c c

N·m(lb-ft)Dry N·m(lb-ft)LubricatedN·m(lb-ft)Dry N·m(lb-ft)LubricatedN·m(lb-ft)Dry N·m(lb-ft)LubricatedN·m(lb-ft)Dry N·m(lb-ft)

1/43.8 (2.8)4.7 (3.5)6 (4.4)7.5 (5.5)9.5 (7)12 (9)13.5 (10)17 (12.5) 5/167.7 (5.7)9.8 (7.2)12 (9)15.5 (11.5)19.5 (14.5)25 (18.5)28 (20.5)35 (26) 3/813.5 (10)17.5 (13)22 (16)27.5 (20)35 (26)44 (32.5)49 (36)63 (46) 7/1622 (16)28 (20.5)35 (26)44 (32.5)56 (41)70 (52)80 (59)100 (74) 1/234 (25)42 (31)53 (39)67 (49)85 (63)110 (80)120 (88)155 (115) 9/1648 (35.5)60 (45)76 (56)95 (70)125 (92)155 (115)175 (130)220 (165) 5/867 (49)85 (63)105 (77)135 (100)170 (125)215 (160)240 (175)305 (225) 3/4120 (88)150 (110)190 (140)240 (175)300 (220)380 (280)425 (315)540 (400) 7/8190 (140)240 (175)190 (140)240 (175)490 (360)615 (455)690 (510)870 (640) 1285 (210)360 (265)285 (210)360 (265)730 (540)920 (680)1030 (760)1300 (960) 1-1/8400 (300)510 (375)400 (300)510 (375)910 (670)1150 (850)1450 (1075)1850 (1350) 1-1/4570 (420)725 (535)570 (420)725 (535)1280 (945)1630 (1200)2050 (1500)2600 (1920) 1-3/8750 (550)950 (700)750 (550)950 (700)1700 (1250)2140 (1580)2700 (2000)3400 (2500) 1-1/2990 (730)1250 (930)990 (730)1250 (930)2250 (1650)2850 (2100)3600 (2650)4550 (3350) a

Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length. b

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

c

"Dry" means plain or zinc plated without any lubrication.

Unified Inch Bolt and Cap Screw Torque Values, 2 of 2 DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 Shear bolts are designed to fail under predetermined loads. Always replace shear bolts withpercent of the dry torque shown in the chart, applied to the nut, not to the identical grade.bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.

<- Go to Section TOC

Section 10 page 4

tm3265-TECHNICAL MANUAL

Section 10 - GENERAL

Group 20: Lubrication

Metric Bolt and Cap Screw Torque Values

Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings Metric Bolt and Cap Screw Torque Values, 1 of 2 Class 12.9

Class 4.8Class 8.8 or 9.8Class 10.9 aaa

Lubricated a N·m(lb-ft)Dry N·m(lb-ft)Lubricated-ft)Dry N·m(lb-ft)LubricatedN·m(lbN·m(lb-ft)Dry N·m(lb-ft) N·m(lb-ft) 15.5 (11.5) M64.7 (3.5)6 (4.4)9 (6.6)11.5 (8.5)13 (9.5)16.5 (12.2) SizeLubricated b b b

Dry b N·m(lb-ft) 19.5 (14.5)

M811.5 (8.5)14.5 (10.7)22 (16)28 (20.5)32 (23.5)40 (29.5)

37 (27.5)

47 (35)

M1023 (17)29 (21)43 (32)55 (40)63 (46)80 (59)

75 (55)

95 (70)

M1240 (29.5)50 (37)75 (55)95 (70)110 (80)140 (105)

130 (95)

165 (120)

M1463 (46)80 (59)120 (88)150 (110)175 (130)220 (165)

205 (150)

260 (190)

M16100 (74)125 (92)190 (140)240 (175)275 (200)350 (255)

320 (235)

400 (300)

M18135 (100)170 (125)265 (195)330 (245)375 (275)475 (350)

440 (325)

560 (410)

M20190 (140)245 (180)375 (275)475 (350)530 (390)675 (500)

625 (460)

790 (580)

M22265 (195)330 (245)510 (375)650 (480)725 (535)920 (680)

850 (625)

1080 (800)

M24330 (245)425 (315)650 (480)820 (600)920 (680)1150 (850)

1080 (800)

1350 (1000)

M27490 (360)625 (460)950 (700)1200 (885)1350 (1000)1700 (1250)

1580 (1160)

2000 (1475)

M30660 (490)850 (625)1290 (950)1630 (1200)1850 (1350)2300 (1700)

2140 (1580)

2700 (2000)

M33900 (665)1150 (850)1750 (1300)2200 (1625)2500 (1850)3150 (2325)

2900 (2150)

3700 (2730)

M361150 (850)1450 (1075)2250 (1650)2850 (2100)3200 (2350)4050 (3000)

3750 (2770)

4750 (3500)

a

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

b

"Dry" means plain or zinc plated without any lubrication.

Metric Bolt and Cap Screw Torque Values, 2 of 2 DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.

<- Go to Section TOC

Section 10 page 5

tm3265-TECHNICAL MANUAL

Section 10 - GENERAL

Group 20: Lubrication

Group 20 - Lubrication Gear Oil

Gear Oil Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following oils are preferred: John Deere GL-5 GEAR LUBRICANT John Deere EXTREME-GARD ™ Other oils may be used if they meet API Service Classification GL-5.

<- Go to Section TOC

Section 10 page 6

tm3265-TECHNICAL MANUAL

Section 10 - GENERAL

Group 25: General Information

Grease

Grease Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.

The following greases are preferred: John Deere SD POLYUREA GREASE The following greases are also recommended: John Deere HD MOLY GREASE John Deere HD LITHIUM COMPLEX GREASE John Deere HD WATER RESISTANT GREASE John Deere GREASE-GARD Other greases may be used if they meet the following: NLGI Performance Classification GC-LB IMPORTANT: Some types of grease thickener are not compatible with others. Consult your grease supplier before mixing different types of grease.

<- Go to Section TOC

Section 10 page 7

tm3265-TECHNICAL MANUAL

ELECTRICAL SYSTEM

(g) by Belgreen v2.0

Group 25 - General Information Locking Collars for Shaft Bearings LEGEND: A B C

Locking collar Bearing Rotating shaft

Locking Collars for Shaft Bearings Locking collars (A) on bearings (B) must be kept tight at all times.

On rotating shafts (C), locking collars (A) must be secured in the direction of shaft rotation.

<- Go to Section TOC

Section 40 page 8

tm3265-TECHNICAL MANUAL

tm3265-TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 40 - ELECTRICAL SYSTEM Table of contents Group 05 - Connectors ............................................................................................................................ 1 Special or Essential Tools ..................................................................................................................... 1 Electrical Repair Tool Kit ....................................................................................................................... 2 Electrical Connector Handling .............................................................................................................. 4 Disconnecting Electrical Circuit ............................................................................................................ 4 Insulated and Non-Insulated Connectors .............................................................................................. 6 Replacing Small MATE-N-LOK MATE-N-LOK is a trademark of AMP, Inc. Contacts in Connector Housings ....................................................................................................................................................... 6 Replacing SURE-SEALSURE-SEAL is a trademark of ITT Cannon Electric. Connector Bodies ................ 7 Replace CPC, Large MATE-N-LOK and METRIMATE CPC, MATE-N-LOK, and METRIMATE are trademarks of AMP Inc. Pin Type Connectors ................................................................................................... 7 Replacing DEUTSCHDEUTSCH is a trademark of Deutsch Co. Connectors ........................................... 8 Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact ................................................ 9 Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric.Connector ................... 11 WEATHER PACKWEATHER PACK is a trademark of Packard Electric. Male and Female Connectors ..................................................................................................................................................... 12 Replacing METRI PACK METRI PACK is a trademark of Delphi Packard Electric Systems.ConnectorsFor METRI PACK connectors, 150 series ............................................................................................ 14 Replacing SCHLEMMERSCHLEMMER is a trademark of Josef Schlemmer GmbH. Connectors ............. 15 Harness Repair (Splice Broken or Cut Wire) ....................................................................................... 18 Harness Repair-Splice Connector ....................................................................................................... 18 Group 10 - Sensors and Switches ........................................................................................................ 20 Specifications ..................................................................................................................................... 20 Gate Latch Switches A13 and A14 (550 Up to SN 295307) ................................................................ 20 Gate Latch Switches A13, A14 (550 From SN 295308) - S1, S2 (590 With BaleMaster Control Monitor) S8, S10 (590 Without BaleMaster Control Monitor) ..................................................................... 21 Gate Latch Switch A13 (540 and 545) - S1 (570 and 580 With BaleMaster Control Monitor) - S8 (570 and 580 Without BaleMaster Control Monitor) ............................................................................. 22 Bale Size Switch A7 (545 and 550) ..................................................................................................... 22 Bale Size Switch S1 (570 and 580 With Manual Twine Control Switch) .............................................. 23 Bale Size Switch S1 (570, 580 and 590 With Electronic Wrapping Control Monitor) ........................... 24 Oversize Bale Switch S1 (570 and 580 With Manual Twine Control Switch) ....................................... 24 Oversize Bale Switch A12 (540 and 545) - S9 (570 With Electronic Wrapping Control Monitor) - S3 (570 With BaleMaster Control Monitor) ................................................................................................ 25 Oversize Bale Switch A12 (550 Up to SN 295307) .............................................................................. 26 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) .................................................... 27 Twine Arm Switch A8 (545 and 550) .................................................................................................. 28 Twine Pump Switch A21 (545 and 550) .............................................................................................. 29 Net Cut Switch A22 (545 and 550) - S4 (570, 580 and 590 Up to SN 313557) ................................... 30 Adjusting Net Cut Switch S4 (570, 580 and 590 From SN 313558 Up to SN 320630) ........................ 31 Adjusting Net Cut Switch S4 (570, 580 and 590 From SN 320631 Up to SN 322399) ........................ 32 Adjusting Net Cut Switch S4 (570, 580 and 590 From SN 322400) .................................................... 33 Soft Core Switch A26 (545 and 550) - S7 (570, 580 and 590 Without BaleMaster Control Monitor) ..................................................................................................................................................... 33 Bale Shape Senders A17 - A18 (545 and 550) .................................................................................... 34 Bale Shape Senders R3 - R4 (570, 580 and 590 With BaleMaster Control Monitor) ........................... 35 Twine Pulley Sensors S7 - S8 (570, 580 and 590 With BaleMaster Control Monitor) .......................... 37 Bale Size Potentiometer R2 (570, 580 and 590 With BaleMaster Control Monitor) ............................ 37 Adjusting Lower Drive Roll Sensor S6 (570, 580 and 590 With BaleMaster Control Monitor) ............. 40

<- Go to Global Table of contents

tm3265-TECHNICAL MANUAL

tm3265-TECHNICAL MANUAL

(g) by Belgreen v2.5

Adjusting Precutter Knife Sensor S10 (580 and 590 With BaleMaster Control Monitor) ..................... 40 Adjusting Precutter Reverse Sensor S9 (580 and 590 With BaleMaster Control Monitor) ................... 42 Group 15 - Actuators ............................................................................................................................. 43 Other Material .................................................................................................................................... 43 Specifications ..................................................................................................................................... 43 Disassembling/Assembling Twine Arm Actuator A4 (540 Only) - M1 (570, 580 and 590 without BaleMaster Control Monitor) ........................................................................................................ 43 Disassembling Twine Arm Actuator M1 (570, 580 and 590 With BaleMaster Control Monitor) ........... 45 Assembling Twine Arm Actuator M1 (570, 580 and 590 With BaleMaster Control Monitor) ............... 47 Adjusting Twine Arm Actuator Rod (Baler With BaleMaster Control Monitor Only) ............................. 49 Adjusting Twine Arm Re-extension Point (Baler with Electronic Wrapping Control Monitor) ............... 51 Adjusting Bale End Wrap Position (Baler With BaleMaster Control Monitor Only) ............................... 52 Disassembling/Assembling Net Wrapping Actuator M2 (570, 580 and 590 With BaleMaster) ............ 55 Group 20 - BaleMaster Control Monitor (570, 580 and 590) ........................................................... 57 Replacing LCD Screen Bulbs H1- H2 ................................................................................................... 57 Replacing Monitor Sound Alarm H3 .................................................................................................... 57 Replacing Monitor Main Switch S11 .................................................................................................... 58 Group 25 - BaleMaster Controller (570, 580 and 590) ..................................................................... 60 Replacing BaleMaster Controller Fuse F3 ........................................................................................... 60 Replacing Controller EPROM ............................................................................................................... 61 Replacing Circuit Board ...................................................................................................................... 64 Group 30 - Manual Twine Control Switch (540, 570 and 580) ........................................................ 66 Manual Twine Control Switch A3 (540 Only) ....................................................................................... 66 Manual Twine Control Switch A1 (570 and 580) ................................................................................. 66 Group 35 - Bale Monitor (545 and 550) .............................................................................................. 68 Bale Monitor (545 Up to SN 306327 and 550 Up to SN 295307) ........................................................ 68 Bale Monitor (545 From SN 306328 and 550 From SN 295308) ......................................................... 70 Group 40 - Sound Alarm (540 and 545) .............................................................................................. 72 Sound Alarm A4 (540 and 545) .......................................................................................................... 72

<- Go to Global Table of contents

tm3265-TECHNICAL MANUAL

Section 40 - ELECTRICAL SYSTEM

Group 05: Connectors

Group 05 - Connectors Special or Essential Tools →NOTE: Order tools according to information given in the U.S. SERVICEGARD ™ Catalog or in the European Microfiche Tool Catalog (MTC).

Repair Kit AZ50578

AZ50578 Connector repair

<- Go to Section TOC

Section 40 page 1

tm3265-TECHNICAL MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.