John Deere 540, 545, 550, 570, 580, 590 Forage Round Baler Technical Service Manual TM3265

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

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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

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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)

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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.

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Section 05 page 1

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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

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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.

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Section 05 page 1

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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

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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.

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Section 05 page 3

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