This comprehensive technical manual provides detailed instructions and illustrations for the maintenance, troubleshooting, diagnosis, and repair of John Deere Hay and Forage Round Balers, models 540, 545, 550, 570, 580, and 590. It covers all aspects of these balers, from the electrical system to the hydraulics, and includes detailed sections on the pickup, precutter, bale chamber, net wrapping system, and twine wrapping system.

The manual begins with an in-depth exploration of the electrical system, providing detailed diagrams and explanations for components such as connectors, sensors, switches, actuators, the BaleMaster Control Monitor, manual twine control switch, bale monitor, and sound alarm. It then delves into the power train, covering the 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 (for models 540, 545, and 550), precutter gear case, chain tension, and sprocket alignment.

Next, the manual thoroughly explores the hydraulic system, including the bale density control valve (for models 540, 545, 570, and 580), bale density control valve (for models 550 and 590), hydraulic cylinders, gate locking valve (for models 550 and 590), hydraulic twine arm control, hydraulic twine operating instructions (for models 545 and 550), net wrapping hydraulic components (for models 545 and 550), and precutter hydraulic components.

The manual also provides detailed information on miscellaneous components such as wheel and hub repair, tongue repair, gate latch, bale size indicator, and bale shape sender. It covers the intricacies of the pickup repair, including the 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, and pickup drive components.

The manual dives into the precutter system and bale chamber, providing detailed information on identifying rolls, baler rolls, scraper of roll, belt repair, belt guide for the net wrapping device, tension arm repair, and the top idler roll declutchable drive. It also provides detailed sections on the net wrapping system and twine wrapping system, including electrical system diagrams for road lights and both manual and electronic wrapping controls, as well as detailed instructions on checking the functionality of various components.

Last but not least, the manual provides comprehensive operation and tests information for both the hydraulic system and the net and twine wrapping systems. This includes a detailed description, troubleshooting guide, and tests for the bale density/gate control, pickup lift system on balers without a precutter, and the precutter hydraulic system.

This manual is an invaluable resource for anyone needing to maintain, troubleshoot, diagnose, or repair these John Deere balers. Its detailed explanations and comprehensive illustrations make it easy to understand and use, ensuring you have the knowledge and tools needed for successful baler maintenance and repair.

The John Deere 540, 545, 550, 570, 580, and 590 Hay & Forage Round Balers are robust and efficient machines designed for efficient baling of hay, straw, and other forage crops. These balers offer a range of features that cater to diverse farming needs, including variable-chamber bale densities, high-capacity pickup systems, and user-friendly controls. The 540, 545, and 550 models are the entry-level balers, ideal for small- to mid-sized operations. They feature a fixed-chamber design, allowing for efficient baling of a consistent bale size. The 570, 580, and 590 models are the more advanced versions, boasting variable-chamber technology that enables operators to adjust the bale diameter for optimal density and weight, depending on crop type and end-use. These models also feature larger pickup widths and higher bale capacities, making them suitable for larger farms and high-volume baling operations.

Regardless of the model chosen, the John Deere 540, 545, 550, 570, 580, and 590 Hay & Forage Round Balers are engineered for reliability and durability. They incorporate robust construction, high-quality materials, and advanced features such as automatic net wrap systems, twine tie systems, and bale density sensors, ensuring consistent bale quality and maximizing operational efficiency. The user-friendly design and intuitive controls make operation a breeze, while the optional hydraulically driven bale ejectors and automatic bale handling systems simplify the baling process further. These features make the John Deere 540, 545, 550, 570, 580, and 590 Hay & Forage Round Balers an excellent choice for farmers seeking reliable, high-performance balers for optimized hay and forage harvesting.