New Holland Haybine 499 Operator'S Manual Download Page 112

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SECTION 5 - TROUBLESHOOTING

5-2

Raise cutting height with adjust-

able skid shoes.*

Align guards and knives and

adjust hold-down clips so knife

assembly runs freely.

Adjust flotation springs to float

header with 16 kg-23 kg force (35

lbs.-50 lbs.).

Reduce ground speed.

Decrease ground speed.

Increase reel speed.

Lower cutting height with the

adjustable skid shoes.*

Maintain tractor PTO RPM. Do

not overspeed.

Move reel down and forward.

Decrease ground speed.

Do not crowd the uncut material.

Increase reel speed.

Replace or straighten knife sec-

tion or guard.

Maintain standard RPM on the

tractor PTO. Do not overspeed.

Raise baffle until no bunching

occurs.

Cutting too low in stony condi-

tions.

Guards, knives, and hold-down

clips not properly aligned.

Header flotation too heavy for

stony fields.

Ground speed too high in stony

conditions.

Ground speed too fast.

Reel speed too slow.

Cutting height too high.

Tractor PTO speed too slow.

Down crop not picked up by reel.

Ground speed too fast.

Crowding of the uncut material.

Reel speed too slow.

Broken or bent knife section or

guard.

Tractor PTO speed too slow.

Incorrect windrow baffle adjust-

ment.

PROBLEM

POSSIBLE CAUSE

CORRECTION

Excessive breakage of guards

and knives.

Not cutting short enough in down

material.

Small strip of run down, uncut

material.

Forming poor or bunchy windrow.

*Adjust the flotation springs for proper flotation (32 kg) (70 lbs.) at push bar - 16 kg-23 kg (35 lbs.-50 lbs.)

in stony conditions.

Summary of Contents for Haybine 499

Page 1: ... 5HSODFHV OO 3UHYLRXV VVXHV ...

Page 2: ... 1 PHULFD ...

Page 3: ...arts are manufactured and carefully inspected in the same factories that built the mower conditioner to insure high quality and accurate fitting of any necessary replacement parts Be prepared to give your dealer the model and product identification number PIN of the pivot tongue mower conditioner when ordering parts Locate these numbers now and record them below Refer to the General Information se...

Page 4: ...0 2 CONTENTS SAFETY 0 2 GENERAL INFORMATION 1 1 OPERATION 2 1 LUBRICATION 3 1 MAINTENANCE 4 1 TROUBLESHOOTING 5 1 OPTIONAL EQUIPMENT 6 1 SPECIFICATIONS 7 1 INDEX 7 5 DELIVERY REPORT 7 7 ...

Page 5: ... in death or serious injury The color associated with Warning is ORANGE CAUTION This word CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It may also used to alert against unsafe practices The color associated with Caution is YELLOW FAILURE TO FOLLOW THE DANGER WARNING AND CAUTION INSTRUCTIONS MAY RESULT IN SERIOUS BODILY INJURY OR DEA...

Page 6: ... size hitch pin with safety cotter at all times 10 Use of the safety chain is required when towing the machine on public roadways 11 When you disconnect and later reattach the machine to a standard electrical socket on propelling vehicle the brake light must be reconnected to function 12 Replace any safety signs that are missing or cannot be read Replacement safety signs are available from your lo...

Page 7: ... wheels before working on or under the machine 21 Limit towing speeds to 32 km hr 20 mph maximum 22 Never stand behind the mower conditioner while it is running 23 Operate the machine only at the PTO speed for which it is designed attach a 540 rpm implement only to a 540 rpm PTO and a 1000 rpm implement to a 1000 rpm PTO ...

Page 8: ...for those working with you Please take this manual and walk around your machine to note the content and location of these warning signs Review these warning signs and the operating instructions detailed in this manual with your machine operators Keep the decals legible If they are not obtain replacements from your New Holland dealer 3 2 1 4 5 6 7 8 ...

Page 9: ...is a sharp edge Avoid contact when servicing Carelessness may cause injury to hands or fingers Part 86624774 DANGER To avoid injury do not work under a raised header without cylinder locks in place Part 86622073 WARNING Read the complete opera tor s manual and become familiar with starting operating and safety instructions in the manual and on the unit Part 7700533 WARNING Ensure that the tongue s...

Page 10: ...nit Failure to comply could result in death or serious injury Part 87041061 Warning Shielding must be in place when PTO is engaged Failure to comply could result in death or serous 9 Part 86547782 Reflective Tape Yellow 10 Part 86547781 Reflective Tape Red 11 Part 86547783 Reflective Tape Orange ...

Page 11: ...der genuine New Holland parts from your New Holland dealer 10004558 1 1 SMV EMBLEM Some states and provinces require Slow Moving Vehicle SMV emblems on machines traveling at speeds under 40 km hr 25 MPH Consult local regulations for specific information and mounting requirements An SMV mounting bracket is located on the left rear main frame The SMV emblem 1 and mounting bracket are furnished as st...

Page 12: ... for this manual 50004634 1 5 TRACTOR REQUIREMENTS 45 kw 60 HP minimum PTO horsepower Adequate tractor weight ballast wheel spacing and tire inflation to stabilize the tractor on hillsides Two remote hydraulic circuits with a minimum of 121 bar 1750 PSI not to exceed 173 bar 2500 PSI One of the circuits must be two way for the swing cylinder 540 RPM PTO or 1000 RPM PTO depending on the mower condi...

Page 13: ...ith drawbars that can be adjusted to a distance of 508 mm 609 mm 20 24 dimension A from the end of the tractor PTO shaft to the center of the drawbar hole In this case the 499 tongue may be connected directly to the tractor drawbar NOTE Using a tractor with an incorrect PTO to hitch dimension can damage the gearbox pump hoses and or the tractor PTO drive line Ideally the top of the tractor drawbar...

Page 14: ...drawbar as shown in Figure 9 Install drawbar extension 1 and clamp 2 on the drawbar Install drilled pin 3 in the front hole of the extension and rear hole of the drawbar Install hairpin cotter Tighten the 5 8 nuts evenly to 189 N m 140 ft lbs NOTE If the extension is on the bottom of a high drawbar shorten the clamp bolts to clear the windrow NOTE Lubricate and be sure the ball in the hitch extens...

Page 15: ...sion solidly to the tractor drawbar Pivoting the tongue will put heavy side loads on the tractor drawbar Install a 5 8 drilled bolt 1 and plated washer up though the tractor drawbar and extension Use plated washers as required at 2 and install slotted nut 3 Install a 1 drilled bolt 4 and plated washer up through the tractor drawbar and extension Use plated washers as required at 5 and installed sl...

Page 16: ... Pull the spring loaded handle 1 and raise the jack up in the mount Release the handle to latch the jack in the raised position 10004562 1 12 If equipped with a round tube style jack retract the jack by turning the handle counter clockwise Pull the pin and remove the jack Store the jack 1 on the left side of the tongue Secure the jack with the pin NOTE To prevent the jack from unwinding during use...

Page 17: ...bar to keep the pump from rotating Bend the torque arm back or use spacers and longer bolts at the pump plate 3 to allow the pump to go all the way onto the PTO shaft 1 Move the torque arm up on the pump plate to prevent dragging the windrows 10003625 3 1 2 14 2 Loop chain 1 around the drawbar and secure the chain in the keyhole slot in the pump plate 3 To prevent damage to the hydraulic hoses tur...

Page 18: ...s loop the chain around the drawbar and secure the chain in the keyhole slot in the pump plate 19984845 2 1 16 The 1000 RPM direct drive pump attaches to the tractor by pulling back on the ring at the end of the PTO pump coupler 1 The ring will snap into place remaining retracted 19983052 1 17 Push the pump onto the shaft When the pump is on the shaft the retaining ring will return to the forward ...

Page 19: ...nting holes provided Tighten the bolts to the appropriate torque at this time Secure the chain around the drawbar and hook it into the mounting bracket 2 To prevent damage to the hydraulic hoses turn the tractor and tongue to the extreme left and right positions At each extreme position check the hoses to be sure they are not pinched or binding Remove twists from the hoses then tighten hose connec...

Page 20: ...tings are used on the three hydraulic cylinder hoses Install hose couplings that will match the tractor couplings Use a thread sealant Connect the center and right swing cylinder hoses 1 to the remote couplers from a two way tractor control valve IMPORTANT If this valve is adjustable set it for slow hydraulic flow to the swing cylinder Attach the lift cylinder hose 2 to a remote coupler from the s...

Page 21: ...far enough to engage the right transport stop lower the header all the way to the ground A timing notch inside the cylinder will allow excess oil to drain from the slave cylinder Raise the header again to engage both transport locks Raise and lower the header several times until all air is purged from the system Repeat the previous steps if necessary WARNING Before pivoting the tongue be sure the ...

Page 22: ...oming traffic if the tongue lock is not engaged Failure to comply may cause death or serious injury 10004563 24 TRANSPORT STOPS DANGER Always engage the transport stops when working around a raised head or transporting the machine on the highway Failure to comply will cause death or serious injury IMPORTANT If the right master cylinder does not extend far enough to engage the right transport stop ...

Page 23: ...PH maximum SAFETY CHAIN The Safety chain is required when towing the machine on a public road The safety chain is intended to keep the machine under control in the event of loss or failure of the hitch pin or bolt WARNING Always hook the safety chain to the tractor when towing the machine Failure to do so will result in serious injury or death 10004562 26 SLOW MOVING VEHICLE EMBLEM Some states and...

Page 24: ...ght Red Inner Brake Lamp 3 Right Red Inner Tail Lamp 3 Right Amber Outer Lamp 4 Lights Off Off Off Off Off Off Off Lights On Off Off On Off On Off Brakes Only Off On Off On Off Off Hazards No Brakes Flashing Off Off Off Off Flashing Hazards with Brakes Flashing On Off On Off Flashing Left Turn No Brakes Flashing Flashing Off Off Off On Left Turn with Brakes Flashing Flashing Off On Off On Right Tu...

Page 25: ...cket Older model tractors and most competitive tractors do not provide this capability On these tractors the brake lights on trailing implements will not function however hazard turn and tail lamps will function NOTE On some competitive tractors the number 4 pin in the socket is utilized for other functions Therefore this circuitry may be on all the time or any time the key switch is on This will ...

Page 26: ... machine to swing into oncoming traffic if the lockpin is not engaged Failure to comply may cause death or serious injury 10004563 33 Leave the hydraulic hoses 1 and PTO pump 2 connected to the tractor or be sure they are positioned in the hanger and secured to prevent damage If the pump is secured in its hanger right turns must be limited to prevent damaging the pump Use a safety chain 3 when tra...

Page 27: ...ps Lower and lock the jack stand 1 or remove the jack from the storage position and install Remove the hydraulic pump 2 from the PTO shaft and store the pump on the tongue bracket DANGER Before disconnecting the lift cylinder hoses be sure the header is resting on the ground or on the transport stops Failure to comply will result in death or serious injury Disconnect the hydraulic hoses swing and ...

Page 28: ...SECTION 1 GENERAL INFORMATION 1 18 ...

Page 29: ... chain Use this manual as a guide to be sure that no grease fittings have been missed Be sure the tongue reservoir and gearboxes are filled to the correct level Run the machine at rated PTO speed 540 or 1000 RPM Overspeed causes excessive wear vibration and breakdowns Underspeed may cause plugging at the header or conditioner Your New Holland dealer can use a hand tachometer to check tractor PTO s...

Page 30: ...k swath in the opposite direction to pick up more of the crop that was run down by the tractor tires Cut the back swath at a slower speed to pick up most of the crop 1 To cut square corners Start turning the tractor after the rear wheels pass the edge of the standing crop At this time swing the header toward the tractor using the swing cylinder control lever and at a rate required to maintain stra...

Page 31: ...t crop gradually steer the header away from the tractor to keep it in the standing crop 4 To cut oversquare corners While approaching a sharply angled corner gradually swing the header towards the tractor to keep the unit positioned between the previously cut windrows As the header comes out of the standing crop raise the header and turn the tractor to the right continue to swing the unit towards ...

Page 32: ...k up about 30 cm 1 with the header down and running 2 If the reel does not clear the plugged cutter bar raise the header about 15 cm 6 with the header running 3 If the reel still does not clear the cutter bar Shut off the PTO Raise the header and engage the transport stops Shut off the engine and lock the tractor brakes or shift transmission to park Clean the cutter bar 4 If plugging continues use...

Page 33: ...hen working around a raised head or transporting the machine on the highway Failure to comply will result in death or serious injury 3 Clean off the cutter bar and the area under the reel 4 Pull as much material as possible from in front of and from behind the rolls 5 Rotate the machine in the opposite direction of operation reverse by using an adjustable wrench on the lower roll hub 1 6 Clear all...

Page 34: ...ing loaded lockpin 3 Lower the header to the ground Or let the header rest on the transport stops 4 Lower and lock the jack 5 Remove the hydraulic pump from the PTO shaft and store the pump on the tongue DANGER Before disconnecting the lift cylinder hoses be sure the header is resting on the ground or on the transport stops Failure to comply will result in death or serious injury 6 Disconnect the ...

Page 35: ...resulting in physical injury or death NOTE Readjust the header flotation springs after changing the skid shoes 10004569 1 6 HEADER FLOTATION WARNING Disengage the PTO turn off the tractor engine and remove the key Wait for all movement to stop before leaving the operator s position Never adjust lubricate clean or unplug machine with the engine running Failure to comply could result in death or ser...

Page 36: ...aterial use the 10 degree position to pick up more material in stone free level fields Use the 4 degree position in extremely rough or stony conditions where cutter bar damage is a problem To change the cutter bar angle loosen the bolts in the slots of the top header links 1 on each side of header Remove the bolts in the center holes of the links NOTE Do not remove the bolts in the slots Lengthen ...

Page 37: ... lift valve is operated the tilt cylinders retract tilting the header back the lift cylinders then raise the unit When the unit is lowered the tilt cylinders will extend after the lift cylinders fully retract The header tilt can be limited to 3 positions by repositioning pin 2 Tilt limiter pin can be repositioned with the header raised and the tilt cylinders fully retracted Be sure to reinstall th...

Page 38: ...ted to minimum tilt position without lifting the header Just move the tractor valve to the raise position long enough to retract the tilt cylinder After the obstacle is passed extend the cylinder by moving the tractor lever to the lowering position 10005377 1 2 10 WARNING Disengage the PTO turn off the tractor engine and remove the key Wait for all movement to stop before leaving the operator s po...

Page 39: ...e same position IMPORTANT The reel drive belt must be loosened before moving the reel 10004572 1 11 To move the reel up or down loosen four bolts 1 and adjust bolt 2 Then tighten the bolts Move the opposite end of the reel to the same position IMPORTANT Never lower the reel to the point where the tines dig into the ground or touch the guards For short crops move the reel rearward and raise it as r...

Page 40: ...for all movement to stop before leaving the operator s position Never adjust lubricate clean or unplug machine with the engine running Failure to comply could result in death or serious injury The reel speed chart shows the various reel speeds resulting from rotating the outer sheave half on the inner hub Another range of reel speeds results if the outer sheave half is turned so the belt rides on ...

Page 41: ...e key Wait for all movement to stop before leaving the operator s position Never adjust lubricate clean or unplug machine with the engine running Failure to comply could result in death or serious injury The reel drive belt 1 must be tensioned to slip if the reel hits a foreign object in the field or if the reel is overloaded Adjust the eyebolt for a spring length of 304 mm 12 between spring hooks...

Page 42: ...eath or serious injury 10004575 1 17 In shorter crops it may be necessary to lower the push bar Remove bolts 1 on both ends to adjust Reinstall and retighten bolts after adjustment is made Turn the push bar end for end and upside down if the crop is very short Adjust the push bar to push the material forward regardless of how high the crop is NOTE The push bar must be in the highest position to in...

Page 43: ... little or no resistance the gap should be reset closer see Section 2 Operation If you cannot pass the stem between the rolls at all the gap should be increased slightly To get peak machine performance and efficiency check the roll gap before each cutting during the season and also when cutting different forage crops because each crop will be different In high volume crops like Sudan grass and oth...

Page 44: ...perly conditioned crops will show a pattern of cracks at regular intervals along the plant stem Each crack will be about 25 50 mm 1 2 in in length The stem should look flat in these cracked areas Depending on crop height when cut there will be at least two or three cracks along the plant length The plant leaves should show only minimal bruising Leaf bruising is characterized by dark green streaks ...

Page 45: ...arts to bend to rear while torsion bar maintains conditioning pressure 50051185 22 Rolls Fully Open at 27 3 Degrees Rolls are now fully open due to crop slug or foreign object entering rolls The link between torsion bar and top roll arm is no longer applying direct pressure to roll arm Rolls are against stop link back with conditioning pressure now removed Rolls will return to former position with...

Page 46: ...n handle 1 in the desired location Lowering the handle produces a wider and generally fluffier swath If the gate is positioned too low in some crops an uneven swath may be formed In heavy crops raise the handle one or two positions to allow enough room for the crop to discharge behind the rolls To windrow the material raise the swath gate handle 1 to the highest position WARNING Disengage the PTO ...

Page 47: ...a minimum of 0 4 mm 1 64 clearance at the closest point of the rolls WARNING Disengage the PTO turn off the tractor engine and remove the key Wait for all movement to stop before leaving the operator s position Never adjust lubricate clean or unplug machine with the engine running Failure to comply could result in death or serious injury 10004581 0 4 mm 1 64 27 ...

Page 48: ...stemmed cane type crops add more shims at 1 on the right side and a similar location on the left side Shims can be obtained from your New Holland dealer Install pad 3 so the steel is on top and the rubber is on the bottom Shims to adjust roll gap are below the pad Extra shims can be turned to the rear and stored on the bolts at 4 After the rolls have worn from heavy or prolonged use it may be nece...

Page 49: ...o not set the push bar too low Long stems may become tangled in the reel before they are cut off and the push bar or reel could be damaged 2 Move the reel back at 2 and down at 3 so the reel is close to the rolls and header floor pan If the cutter bar plugs set the reel within 6 mm 1 4 of the top of the guards 3 If plugging at the cutter bar is not a problem reduce the reel speed Be sure the reel ...

Page 50: ...SECTION 2 OPERATION 2 22 ...

Page 51: ...ine with the engine running Failure to comply could result in death or serious injury 1 Disengage the header drive 2 Lower the header to the ground or raise the header and engage the lift locks 3 Stop the tractor engine and engage the parking brake before leaving the cab 4 Reinstall and close all shielding before operating the mower conditioner Wipe dirt from grease fittings before greasing Always...

Page 52: ...ots 2 fittings X Left upper roll drive shaft 3 fittings X Right sickle drive shaft 3 fittings X Sickle drive sheave hub 1 fitting X Grease the tractor PTO shaft and pump splines X Jack 1 fitting X Roll pressure trunnion 1 fitting X Tongue pivot 1 fitting X Oil the tongue latch pin X Hex shaft bearing 1 fitting X Check hydrostatic oil level 20 gal capacity X Check header drive gearbox oil level X L...

Page 53: ...ut of the bearings TYPE AND QUANTITY OF OIL USED Main drive gearbox Lubricant SAE 80W 90 Lube Class GL 5 Sickle drive gearboxes 2 Lubricant SAE 80W 90 Lube Class GL 5 Hydrostatic reservoir Lubricant Ambra Multi G 134 or Ambra 134D hydraulic oil Capacity 75 7 L 20 gal Lubrication fittings Lubricant Lithium based EP high temp grease STORING LUBRICANTS The pivot tongue mower conditioner can only oper...

Page 54: ...3 4 EVERY 10 HOURS 1 Reel shaft bearing 2 fittings Left side shown 10004582 1 1 1 Sickle drive connecting rod 4 fittings Left side shown 2 Oil the reel drive chain 10004583 2 1 2 1 Reel intermediate drive shaft 10004584 1 3 ...

Page 55: ...ttings 2 Left PTO telescoping section 10004585 2 1 1 4 1 Header lift arm pivots 2 fittings Right side shown 2 Wheel arm pivots 2 fittings Right side shown 10004586 1 2 5 1 Right sickle drive U joints 2 fittings 2 Right PTO telescoping section 10004587 1 2 1 6 ...

Page 56: ...rst 50 hours of use Any contamination remaining in the system should have been loosened and filtered out The remaining oil is clean and the system should operate without problems if the filter is changed at 400 hour intervals or once each season Replace oil which is lost when the filter is changed The filler cap dipstick is in the top of the tongue 10004589 1 8 ...

Page 57: ...BRICATION 3 7 EVERY 50 HOURS 1 U joint drive gearbox to lower roll 2 fittings 10004590 1 1 9 1 Roll pressure crank trunnion and threads 10004591 1 1 10 1 Jack assembly if equipped with this style jack 10004716 1 11 ...

Page 58: ...an cloth Reinstall the dipstick finger tight and remove it to check oil level The oil level should be in the crosshatched area on the dipstick If the oil level is low add Ambra Multi G 134 Hydraulic oil to the tongue reservoir until the oil level is between the marks on the dipstick Replace the dipstick and tighten with a wrench The reservoir holds approximately 75 7L 20 gal 10004717 1 13 LEFT SID...

Page 59: ...plug holes 1 in the sickle drive gearboxes 10004719 1 15 1 Hex shaft bearing This is located under the header just forward of the lower conditioner roll DANGER Always engage the transport stops when working around a raised head or transporting the machine on the highway Failure to comply will cause death or serious injury 10004720 1 16 ...

Page 60: ...SECTION 3 LUBRICATION 3 10 ...

Page 61: ...key Wait for all movement to stop before leaving the operator s position Never adjust lubricate clean or unplug machine with the engine running Failure to comply could result in death or serious injury DAILY MAINTENANCE Careful inspection and service of the unit prior to operation each day will prevent needless break downs and delays in the field Make the following checks and adjustments 1 Check a...

Page 62: ...death or serious injury 3 Have someone start the unit and engage the header Carefully walk around the unit while it is running at a slow speed Look for abnormal movements of components and listen for unusual noises 4 Check the controls for proper function Pivot points of linkages often become stiff from rust during the off season END OF SEASON MAINTENANCE Prior to storing the unit during the off s...

Page 63: ...to snap in half if a sudden heavy load is applied to the drive If a driven sheave stops due to a plugging problem the drive sheave may burn a section of the belt The drive may then vibrate because of a narrow burned spot Replace the belt immediately to prevent other problems Vibration can also be caused by a lumpy V belt Check belts for swells and lumps Use only factory recommended V belts of the ...

Page 64: ...in drives should be cleaned regularly Remove and clean the chains by soaking them in diesel fuel overnight Dry the chain then oil it thoroughly Before starting the unit clean the chains and lubricate them with a heavy oil or grease When removing the unit from storage reclean the chains and lubricate them with SAE 30W oil SPROCKET ALIGNMENT Be certain all sprockets composing a drive are properly al...

Page 65: ...ESCRIPTION AFTER FIRST 5 HOURS EVERY 10 HOURS OR DAILY EVERY 50 HOURS OR WEEKLY EVERY 400 HOURS OR YEARLY Inspect and tighten hardware X Check reel drive belt tension X X Check reel drive chain tension X X Check sickle drive belts tension X X Check wheel bolts 150 N m 115 ft lbs X X Check tire pressure 193 kPa 28 psi X Check cutter bar guards knife sections and repair as needed X Check conditioner...

Page 66: ... Install a flangette bearing flangette and the lock collar in the correct order Install the flangette bolts Leave the bolts slightly loose so the bearings can move into alignment When the shaft and bearing are located correctly tighten the flangette bolts Tighten the locking collar last in the direction the shaft rotates as shown Tighten the setscrew in the locking collar 1 ...

Page 67: ...he first five hours of operation and then after every 50 hours use REEL DRIVE BELT 1 Reel drive belt 2 Idler spring 3 Eyebolt two 3 8 hex nuts 4 Reel vari drive sheave 5 Flat idle 10004722 1 2 3 4 5 2 1 V idler 2 Stop 3 Flat idler arm 4 Reel pulley 10004723 1 3 2 4 3 IMPORTANT Reel belt tension must be readjusted after the reel speed or reel position is changed The reel drive belt must be tight en...

Page 68: ... not touch the reel chain 10004723 1 2 3 5 WARNING Disengage the PTO turn off the tractor engine and remove the key Wait for all movement to stop before leaving the operator s position Never adjust lubricate clean or unplug machine with the engine running Failure to comply could result in death or serious injury REEL DRIVE CHAIN Adjust eyebolt 1 so idler spring 2 measures 178 mm 7 between the hook...

Page 69: ...e drive belts 1 Loosen four bolts 1 IMPORTANT Shims 2 on these four bolts are used to line up the pulleys The shims are located between the frame and mount for the upper pulley If the shims are misplaced check pulley alignment with a straightedge Correct any misalignment with the shims The number of shims at the top and bottom may be different 2 Use nuts on adjusting bolt 3 to tighten the belts 3 ...

Page 70: ... position Pull the pulley mount away Remove the old belts and install the new ones 6 Replace bolts 1 and shims 2 Check pulley alignment Adjust the number of shims at the top or bottom to correct misalignment 10004725 1 1 2 10 7 Replace brace 1 8 Tighten the belts 8 lbs force deflects one belt 4 8 MM 3 16 3 6 kg deflects 5 mm 10004726 1 11 ...

Page 71: ...SECTION 4 MAINTENANCE 4 11 9 Tighten bolts 1 and nuts 2 10004725 1 1 2 12 ...

Page 72: ...re available for use in difficult cutting conditions The stub guards do not protect the front of the knife sections The stub guards require sharp knifes frequent alignment and adjustment of the hold down clips Refer to the Stub Guard portion of Section 6 Optional Equipment of this manual for additional information IMPORTANT Black overserrated fully bolted knife sections are original factory equipm...

Page 73: ...ned be sure to maintain the original bevel and angles as shown 1 New sections 2 Correctly sharpened proper angle and bevel 3 Incorrectly sharpened wrong angle narrow bevel 4 Incorrectly sharpened ends off center 4837 16 3 4 1 2 14 SPARE KNIFE STORAGE Two spare knives can be stored in the frame tube Install drilled pins 1 through the frame holes and knife heads Install hairpin cotters 2 in the dril...

Page 74: ... to the center of its stroke before tightening bolts 1 and 4 The knife will be in center stroke if a socket wrench installed through frame hole 3 lines up with the connecting rod bolt 4 IMPORTANT Straighten the knife assembly if it is bent Hold the knife head and sight along the knife back The knife must be straight Rotate the knife 1 4 turn and recheck for bends To remove a bend clamp the knife b...

Page 75: ...ight knife in the same way 10004739 3 2 1 17 KNIFE HEAD The knife head assembly attaches to the knife using the same rivets or bolts that attach the knife sections to the cutter bar Refer to the Replacing Knife Sections section KNIFE HEAD BUSHING The knife head bushing has rubber bonded between steel bushings Replace the bushing if the rubber is loose or charred from heat Use a vise or press to re...

Page 76: ...SECTION 4 MAINTENANCE 4 16 KNIFE ASSEMBLIES AA AA BB BB CC DD B B B B A A A A D D C C A B C RIGHT KNIFE LEFT KNIFE RIGHT KNIFE LEFT KNIFE LEFT KNIFE RIGHT KNIFE 2 1 4 3 2 1 3 4 6 5 7 8 19 ...

Page 77: ... be used to replace riveted a knifes by replacing the special center guard and the hold down clips When replacing knife sections refer to the drawing for the knife on your machine Riveted A or Bolted B Knives With a Single Overlap Section The riveted and bolted knives use the same knife sections The right knife assemblies require two bottom countersunk sections 1 A knife back extension 2 is also i...

Page 78: ...knife back extension require longer rivets than those used for the knife back Special flat head rivets are also required at the knife overlap area Be sure to use the correct type and length rivets when replacing a knife section bolt The LH riveted single section overlap knife uses thirty one 21 32 long rivets twelve 1 long rivets and six 9 16 long flat head rivets The RH riveted single section ove...

Page 79: ...emblies The knife sections are fastened to the knife back with two special bolts and lock nuts 1 A knife section can be replaced without removing the complete knife assembly from the mower conditioner On machines with standard guards it will be necessary to remove a hold down clip to replace certain sections On machines with stub guards remove the hold down clip to replace a section Remove the spe...

Page 80: ...ap knife uses thirty five 5 8 long bolts three 7 8 long bolts nine 1 long bolts five 1 2 long flat head bolts and fifty two locknuts The Right two section overlap knife uses twenty eight 5 8 long bolts five 3 4 long bolts three 7 8 long bolts nine 1 long bolts six 1 2 long flat head bolts and fifty one locknuts 4889 11 1 25 To remove a bolt support the knife back 1 and use a punch 2 and hammer to ...

Page 81: ...with the knife section acts as a shear to cut the crop They help guide the knife back and also help keep trash from building up on the knife back Replace worn or dull guards promptly A guard should be replaced when the corners of the ledger surface become rounded or dull 4837 16 2 1 29 SPECIAL GUARDS End Guards The Model 499 uses several special guards The guards at each end of the cutter bar have...

Page 82: ... overlap section have the ledger surface on the left guard point and the left part of the knife support rib machined lower The center stub style guard used on machines with two overlapping sections is a regular stub guard that is installed with a shim between the guard and cutter bar NOTE Do not use a regular guard in place of the special center guards The knives will not pass through the guard Se...

Page 83: ...ub guards to the left of the center guard DO NOT place a shim between the center guard and cutter bar DO NOT place shims between the cutter bar and the guards to the right of the center When the machine is equipped with standard guards install a 3 mm 0 120 shim 4 under the center hold down clip and all hold down clips to the right of the center clip When the machine is equipped with stub guards th...

Page 84: ...d be replaced The tips 2 of the standard guards should be relatively sharp If they are blunted from contact with foreign objects material can hairpin and plug the cutter bar A hand grinder can be used to restore the original point If the trash bars 3 on the guards are bent they should be straightened so they are parallel to the knife back tc28 1 3 2 33 ...

Page 85: ...f the knife section contacts the front of the ledger surface at 2 The lip 3 of the guard does not contact the knife section The back rib 4 on the guard holds the knife back level The hold down 5 is close to the knife section but does not cause it to bind The top of Figure 34 shows the guard and knife improperly adjusted The knife section contacts the rear of the ledger surface at 6 The lip 7 of th...

Page 86: ...high guards down as the knife is being installed Bend any low guards up after the knife is installed If a hammer is used to bend the guards be sure to hit the solid surface in front of the knife section to avoid breaking the lip 4889 14 4889 15 1 35 In case of severe damage to the cutter bar remove all guards Stretch a string 1 across the width of the cutter bar to use as a guide in straightening ...

Page 87: ...en the hold down and cutter bar adjust the clearance between the hold down and knife section Check the guard alignment by sighting along the ledger surfaces An estimate of the guard alignment can be obtained by sighting along the tips of the guards however the important surface to align is the ledger surface 0 to 0 38 mm 0 to 015 8 7 6 5 1 1 2 3 4 8 37 HOLD DOWN CLIPS The hold down clips 1 keep th...

Page 88: ...r the adjustable clip through the clip before installing the clip NOTE Be sure a 3 mm 0 120 shim 6 is installed between the center guard and cutter bar and also between all the guards to the left of center and the cutter bar IMPORTANT Check and adjust the guard alignment before checking the hold down clip adjustment LEFT OF CENTER CENTER RIGHT OF CENTER 1 5 4 2 3 6 1 5 4 2 3 6 1 5 4 2 3 39 One Pie...

Page 89: ...assist the hold down clips in keeping the knife close to the guard ledger surface NOTE Be sure a 3 mm 0 120 shim is installed between the center guard and cutter bar and also between all the guards to the left of center and the cutter bar IMPORTANT Check and adjust the guard alignment before checking the hold down clip adjustment tc29 1 1 41 The clip should hold the knife in position without bindi...

Page 90: ...at the top of the rocker arms 2 3 Move the rocker arms up or down until knife to guard clearance is correct 4 Tighten bolt 1 10004728 1 2 4 2 3 3 4 43 The knife back bar should be centered in the opening in the guard If the back bar rubs the guard the knife head bushing will be overloaded and may fail If the front or back edge of the knife back bar rubs the guards 1 Loosen the two guard bolts Hold...

Page 91: ...SECTION 4 MAINTENANCE 4 31 1 Loosen upper rocker arm bolt 1 10004728 1 44 2 Remove connecting rod bolt 1 knife head bolt 2 and hub cap 3 10004729 1 2 3 45 ...

Page 92: ...ber of washers should not change 7 Replace Dust shield 5 Washer 6 Cone and seal 7 The cone may be slightly loose on the pin 8 Install Connecting rod Be sure the seal lip and dust shield are not damaged Front bearing cone 8 Remaining washers 4 Slotted nut 3 9 Tighten slotted nut 3 to 47 N m 35 ft lbs Back off the nut until it is loose then retighten it until snug Rotate the nut to the closest of th...

Page 93: ...d nut special thread 4 1 1 64 ID x 1 9 16 OD x 0 060 thick hardened shim washers as required 5 Dust shield 6 Washer 1 1 32 ID x 1 5 16 OD x 1 8 thick 7 Bearing cone and seal 8 Bearing cone 9 Bearing cup 2 10 Washer bevel towards gearbox 11 Front spacer 12 Rear spacer 13 Seal 2 14 Bearing cone 2 15 Bearing cup 2 16 Cup spacer 17 Cone spacer Bearings 14 and 15 and spacers 16 and 17 are only availabl...

Page 94: ... connecting rod in a vise with front spacer 11 up Use a punch through the bolt hole to drive out the rear spacer 12 3 Remove seal 13 cone 14 and cone spacer 17 4 Remove front spacer 11 seal 13 and cone 14 5 Drive out bearing cups 15 6 Use a small punch in the grease fitting hole to collapse cup spacer 16 so it can be removed 8 3 2 1 7 4 10 5 9 4 6 11 13 12 13 17 14 15 15 14 16 49 ...

Page 95: ...h the gap in line with the grease fitting hole 3 Install two bearing cups 15 4 Press one bearing cone 14 on rear long spacer 12 Install these parts in the connecting rod 5 Install cone spacer 17 and second cone 14 on the long spacer Be sure the parts are seated Install front spacer 11 in rear spacer 12 6 Install grease seals 13 with seal lips out Dirt will be flushed out as the fitting is greased ...

Page 96: ...bble at the center of the swath or under the windrow If the knives are out of time severe vibration may damage the header or reel To time the knives 1 Rotate the conditioner rolls by hand until the right knife assembly is at the inner end of its stroke 2 Loosen three bolts 1 3 Without moving the right knife rotate the hex shaft and hub 2 in relation to hub 3 until the left knife is at the inner en...

Page 97: ... bent tine bars can cause premature failure of the tine bar bearings Place a wood block at the bend and use a heavy sledge to straighten the tine bar It is usually not necessary to remove the tine bars to straighten them To remove a tine bar Use a 3 8 allen wrench and 1 1 8 box end wrench to loosen nuts 1 at each end of the tine bar At the center of the header remove four bolts 2 in the spider arm...

Page 98: ...Be sure it is seated against the shoulder of the housing Install the snap ring 5 Fill the cavity on the outer side of the bearing slightly more than level full of wheel bearing grease or a good grade of heavy water pump grease When the dust cap is installed the grease should fill the area under the cap to provide a seal against dust or dirt However too much grease will force the dust cap out of po...

Page 99: ...imilar 5 8 flat washers are used at each side of each roller Slotted shims between the roller plate and spider are used to get 0 25 mm 3 175 mm 0 010 0 125 at the closest point between the roller and cam tracks when the reel is turned one complete revolution NOTE Be sure to use the same number of shims at both leading and trailing edges of the four roller plates 8 locations for each cam Shims are ...

Page 100: ...OLLAR REEL SHAFT FRONT SPIDER LEG LEFT REEL SUPPORT BUSHING CAST BEARING HOUSING 5 8 FLAT WASHERS GREASE FITTING DIRECTION OF ROTATION C 1 4 2 3 5 57 To move the cam track in 1 Loosen the set screw in the lock collar inside the reel support 2 Loosen the lock collar with a punch and hammer The lock collar must be turned opposite the direction the reel rotates 3 Move the support and cam track in on ...

Page 101: ...esult in death or serious injury Removing a U joint 1 Remove the snap ring at bearing 2 2 Loosen bolts 1 2 3 and 4 THREE TURNS 3 Using a hammer and large punch hit bolts 1 and 2 until the bolt heads are against the bearings The bearings at 1 and 2 will be partway out of the tube 4 Turn the reel so the slot in the tube is on top Bearing 4 or 3 will be up Place a wood block between the spider and re...

Page 102: ...d start the cap screw into the universal Seat bearing 2 in the housing and install the snap ring Tighten the cap screws and hit bolts 1 and 2 to seat the bearings 5 Be sure all hardware is tight and turn the reel through one revolution to check for binding Tighten bolts 1 2 3 and 4 to 203 N m 150 ft lbs REEL SUPPORT BEARINGS AND CAMS When servicing the left reel support bearings remove the reel be...

Page 103: ...r serious injury Rubber lugs on the lower conditioner roll must be timed to mesh correctly with lugs on the upper roll The lug of lower roll must be centered between lugs of the upper roll Spaces at each side of the lug must be equal If the roll timing is not correct the machine will vibrate and require more power The machine may be damaged and the crop may be overconditioned 10004581 60 To adjust...

Page 104: ...oll timing at each end of the rolls If the rolls are timed correctly at one side but not at the other rotate the rolls and recheck the roll timing If one end is still not timed correctly move the top roll endways at the roll bearings and readjust roll timing 1 2 3 10004733 63 64 To adjust roll gap add or remove shims at the roll ends as shown Adjust to a minimum of 0 38mm 0 015 NOTE The rolls must...

Page 105: ... once Serious infection or reaction can develop if medical treatment is not adminis tered immediately WARNING Disengage the PTO turn off the tractor engine and remove the key Wait for all movement to stop before leaving the operator s position Never adjust lubricate clean or unplug machine with the engine running Failure to comply could result in death or serious injury HYDRAULIC SYSTEM The tracto...

Page 106: ...rvice department if you have problems with the hydraulic or hydrostatic systems The hydrostatic system is completely separated from the hydraulic system The hydrostatic system drives the cutter bar reel auger and conditioner rolls The square section of the mower conditioner tongue is used for a reservoir The hydrostatic system must be kept free of dirt dust water rust etc or the hydrostatic pump o...

Page 107: ...rings jack up the wheel and remove the hub cap and cotter pin Tighten the adjusting nut until the wheel drags Loosen the nut one castellation or until the wheel turns freely Install a new cotter pin and replace the hub cap 5 Coat the exposed portion of the swing cylinder rod with grease 6 Inspect for worn or broken parts Replace with genuine New Holland service parts 7 Clean the mower conditioner ...

Page 108: ...303 531 392 648 478 839 619 897 662 1160 855 572 422 NOTE Torque values shown with are inch pounds IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5 6 AND UP MANUFACTURER S IDENTIFICATION PROPERTY CLASS HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER S IDENTIFICATION MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON METERS FOOT POUNDS FOR NORMAL ASSEMBLY APPLICATIONS METRIC NON FLANGED HA...

Page 109: ...5 17 149 20 178 26 229 28 250 37 324 17 5 155 25 220 5 16 1 4 6 2 55 8 1 72 9 7 86 13 112 14 121 18 157 8 5 75 12 2 109 1 4 MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON METERS FOOT POUNDS FOR NORMAL ASSEMBLY APPLICATIONS INCH NON FLANGED HARDWARE AND LOCKNUTS NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR B GR C NOMINAL SIZE or W ZnCr or W ZnCr or W ZnCr w GR5 w GR8 SIZE PLATED PLATED...

Page 110: ...SECTION 4 MAINTENANCE 4 50 ...

Page 111: ...d speed Header flotation too light Sickle drive belts too loose Reel belt slipping excessively Raise swath gate one latch hole Run reel 10 faster than ground speed See Reel Speed Chart Section 2 Adjust reel position Reduce pressure until leaves are not damaged Decrease the reel speed Op tional 16 tooth reel driver sprocket available See Reel Speed Chart Section 2 Match ground to reel speeds Sharpe...

Page 112: ...e until no bunching occurs Cutting too low in stony condi tions Guards knives and hold down clips not properly aligned Header flotation too heavy for stony fields Ground speed too high in stony conditions Ground speed too fast Reel speed too slow Cutting height too high Tractor PTO speed too slow Down crop not picked up by reel Ground speed too fast Crowding of the uncut material Reel speed too sl...

Page 113: ...mely thick or wet undergrowth Excessive roll pressure Ground speed too slow Reel speed too fast Reel in wrong location Reel speed too fast Replace the rubber bushing Adjust or replace bearings Adjust ledger and back clearance at knife head end Align knives at center overlap Adjust belt as detailed in Reel Drive Belt Section 4 Remove paint or rust Cut when undergrowth is dry Raise cutting height to...

Page 114: ...SECTION 5 TROUBLESHOOTING 5 4 ...

Page 115: ...p screws lock washers flat washers and nuts at 2 NOTE The deflector must bend down in front of arrow 3 Attach deflector 3 to the bracket with a 5 16 x 1 3 4 Grade 5 cap screw lock washer flat washer and nut at 4 Attach the brace to the deflector with a 5 16 x 1 1 4 cap screw lock washer and nut at 5 Remove paint from the deflector so the brace sleeve can be positioned at the rear hole in the defle...

Page 116: ...ment to stop before leaving the operator s position Never adjust lubricate clean or unplug machine with the engine running Failure to comply could result in death or serious injury 20005377 3 REEL SPEED REDUCTION SPROCKET A sixteen tooth sprocket 1 is available for cane or stemmy crops between 457 mm and 610 mm 18 and 24 tall where a slower reel speed is necessary to deliver the material to the ro...

Page 117: ...may build up on the points of the standard guards In these conditions stub guards may be used to reduce the plugging IMPORTANT Stub guards do not have points to protect the front of the knife sections so the cutter bar will require more maintenance Stub guards may leave longer or more uneven stubble and are not recommended for fields with rocks Regular guards should be reinstalled when cutting con...

Page 118: ...ards and guards on right half of cutter bar 634780 5 4 Knife clip Use at OUTER REGULAR stub guards 767636 2 5 Knife clip Use at all guards except two outer guards on each side 767636 21 6 Right stub guard No knife clip used 858774 1 7 Regular stub guard 858764 22 8 Center stub guard 858765 1 9 Left stub guard No knife clip used 858775 1 10 2 guard bolt 280804 4 11 1 3 4 guard bolt 88807 39 Quantit...

Page 119: ...RPM PTO 2 01 cu in w step up gearbox on tractor PTO Motor 82 6 cc 5 04 cu in Relief valve 24 133 kPa 3500 PSI Filter Full flow Flow rate 88 9 L M 23 5 GPM Min Reservoir capacity 75 7 L 20 gal Tractor Requirement 45 kw 60 HP or greater with standard ASAE hitch and PTO locations Two remote hydraulic systems required capable of pumping fluid at 120 65 bar 1750 PSI Material Discharge Swath width 2540 ...

Page 120: ...10 degrees optional hydraulic guard angle adjustment kit Guards Twin forged steel heat treated PN 219191 Cutting height Adjustable 32 mm 159 mm 1 1 4 6 1 4 Knives Two opposing knife assemblies with underserrated sections 3 mm 0 120 thick Sickle Drive Type Bevel gearbox driven crankshaft drive rocker arm through a connecting rod Knife head pivots on rubber bushing Gearboxes are driven by 3 HB V bel...

Page 121: ... roller Rims 355 6 mm 14 drop center Tire size 11L x 14 four ply tubeless agricultural implement with heavy undertread Tire pressure 193 kPa or 1 83 bar 28 PSI Tread width 3404 mm 134 Hydraulic Cylinders Swing cylinder 76 2 mm 3 bore x 406 mm 16 stroke Lift cylinder Master slave system Master cylinder 64 mm 2 1 2 bore x 203 mm 8 stroke Slave cylinder 51 mm 2 bore x 203 mm 8 stroke ...

Page 122: ...SECTION 7 SPECIFICATIONS 7 4 ...

Page 123: ...ation Schedule 3 2 Lubrication After the First 50 Hours 3 6 Lubrication Every 10 hours 3 4 Lubrication Every 50 hours 3 7 Maintenance 4 1 Maintenance Schedule 4 5 Manual Holder 1 2 Minimum Hardware Tightening Torques 4 48 Mounting Pump on the PTO Shaft 1 7 Operation 2 1 Optional Equipment 6 1 Order Form 7 11 Parking the Machine 2 6 Parking the Mower Conditioner 1 17 Precautionary Statements 0 3 Pr...

Page 124: ...7 6 Trailing Lights 1 14 Transport Locks 1 12 Transporting the Mower Conditioner 1 13 Troubleshooting 5 1 Type and Quantity of Oil Used 3 3 V Belt Care and Maintenance 4 3 V Belt Cleaning 4 3 ...

Page 125: ...ty precautions and safety practices __ Attaching to the tractor __ Lubrication points and schedule __ Maintenance schedule __ Operation of control and instruments __ Field operation and adjustments for various crop conditions __ Troubleshooting __ Preseason service __ End of season service Dealer representative signature Date I have been instructed in the operation maintenance and safety features ...

Page 126: ...7 8 ...

Page 127: ...ty precautions and safety practices __ Attaching to the tractor __ Lubrication points and schedule __ Maintenance schedule __ Operation of control and instruments __ Field operation and adjustments for various crop conditions __ Troubleshooting __ Preseason service __ End of season service Dealer representative signature Date I have been instructed in the operation maintenance and safety features ...

Page 128: ...7 10 ...

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