New Holland 499 Operator's Manual
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New Holland 499 Operator's Manual

New Holland 499 Operator's Manual

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  • Page 1 5HSODFHV $OO 3UHYLRXV ,VVXHV  ...
  • Page 2 ¤     &1+ $PHULFD //&...
  • Page 3 Your New Holland dealer will instruct you in the general operation of your mower-conditioner. (Refer to the “Deliv- ery Report” at the back of this manual.) Your dealer’s staff of factory-trained service technicians will be glad to answer any questions that may arise regarding the operation of your mower-conditioner.

  • Page 4: Table Of Contents

    CONTENTS SAFETY ............GENERAL INFORMATION .
  • Page 5 PRECAUTIONARY STATEMENTS PERSONAL SAFETY Throughout this manual and on machine decals, you will find precautionary statements (“DANGER”, “WARNING”, and “CAUTION”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them. DANGER This word “DANGER”...

  • Page 6: Safety

    SAFETY PRECAUTIONARY STATEMENTS A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. To help prevent accidents, read the following precautions before operating this machine. This machine should be operated by only by those who are responsible and instructed to do so. Carefully review the procedures given in this manual.
  • Page 7 19. Never work under a raised header unless it is 22. Never stand behind the mower-conditioner securely locked with the header transport while it is running. stops. 23. Operate the machine only at the PTO speed 20. Always block the wheels before working on for which it is designed.
  • Page 8 Keep the decals legible. If they are not, obtain working with you. Please take this manual and walk replacements from your New Holland dealer. around your machine to note the content and location of these warning signs. Review these warning signs...
  • Page 9 Part #86622073 Part #7700533 WARNING: Read the complete opera- WARNING: Ensure that the tongue safety tor’s manual and become familiar with lock is engaged to prevent accidental starting, operating and safety instructions movement. in the manual and on the unit Part#86624774 DANGER: To avoid injury, do not work under a raised header without cylinder locks in...
  • Page 10 Part #87041061 Warning: Shielding must be in place when PTO is engaged. Failure to comply could result in death or serous Part #87041060 WARNING: Properly prepare machine for transport. Use caution when towing unit. Failure to comply could result in death or serious injury.

  • Page 11: General Information

    Date Purchased Give your dealer the model and PIN of your 10004558 mower-conditioner when ordering parts. Always order genuine New Holland parts from your New Holland dealer. SMV EMBLEM Some states and provinces require Slow-Moving Vehicle (SMV) emblems on machines traveling at speeds under 40 km/hr (25 MPH).
  • Page 12 SECTION 1 - GENERAL INFORMATION 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 drilled pins. NOTE: Spare knives do not come with the machine. 10004727 MANUAL HOLDER A manual holder, 1, is mounted on the left side of the...
  • Page 13 - 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.
  • Page 14 SECTION 1 - GENERAL INFORMATION HITCHING TO TRACTOR (S/N 520722 AND ABOVE) IMPORTANT: On tractors that can not adjust the drawbar to 20″ or 24″, the hitch extension must be installed on the tractor drawbar, so the mower-condi- tioner tongue clears the tractor tire when cutting around corners, and to prevent damage to the hydrostatic pump, hoses or tongue.
  • Page 15 SECTION 1 - GENERAL INFORMATION HITCHING TO TRACTOR (S/N 520721 AND BELOW) Tractor requirements are the same as shown in “Tractor Drawbar Dimensions” on page 1-2, except for an additional 21/32″ hole, 1, that is required in the drawbar for bolt, 1, Figure 7. NOTE: With the tractor on a level hard surface, measure from the ground to the top of the drawbar.
  • Page 16 SECTION 1 - GENERAL INFORMATION JACK NOTE: The 499 mower conditioner may be equipped with either a stationary square tube style jack or a removable round tube style jack. If equipped with a square tube style jack, retract the jack by turning the handle counter-clockwise. Pull the spring-loaded handle, 1, and raise the jack up in the mount.
  • Page 17 SECTION 1 - GENERAL INFORMATION MOUNTING PUMP ON THE PTO SHAFT IMPORTANT: Failure to use the drawbar extension or tractor with ASAE standard PTO to hitch dimensions can cause damage to the pump unit and hoses. The pump must not be fastened to the PTO. It must be free to slip off if a drawbar breaks or a hitch pin fails.
  • Page 18 SECTION 1 - GENERAL INFORMATION 1000 RPM PTO UNITS IMPORTANT: Coat the tractor PTO splines and splines in the pump, 1, all the way onto the PTO shaft, until the slide collar is fully engaged. IMPORTANT: The torque arm, 2, must be against the right side of the drawbar to keep the pump from rotating.
  • Page 19 SECTION 1 - GENERAL INFORMATION With the pump in place, the torque arm, 1, should extend below the drawbar, 3, preventing the pump from turning with the PTO shaft. Adjust the torque arm as needed by moving it up and down along the mounting holes provided.
  • Page 20 SECTION 1 - GENERAL INFORMATION HYDRAULIC CYLINDERS (Swing and Lift) WARNING Fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Always protect the skin and eyes from escaping fluid under pressure. Before disconnecting lines or fittings, be sure to relieve all pressure.
  • Page 21 SECTION 1 - GENERAL INFORMATION TO BLEED AIR FROM THE LIFT CYLINDERS: Loosen the hose swivel fitting, 1, at the upper end of the slave cylinder. NOTE: Use a shop rag or other shielding means for protection from seeping oil at loosened fittings. Actuate the tractor hydraulic lever and extend the master lift cylinder until oil flow from the loosened fitting is free of air.
  • Page 22 SECTION 1 - GENERAL INFORMATION TONGUE LOCK To disengage the tongue transport lock, rotate transport lock bracket, 1, up and over (one half turn) so that the transport lockpin is spring loaded upwards. Shift the machine slightly so that the transport lockpin disengages from the trailframe.
  • Page 23 A SMV mounting bracket is located on the left rear frame. The SMV emblem and mounting bracket are furnished as standard equipment on the 499 Mower-Conditioner. Attach the emblem in the frame socket at 1, as shown. 20006020...
  • Page 24 NOTE: The lighting control box is used to control the amber lamps and brake light circuits. The tail lamps are on only when the tractor park or road lights are on. The 499 trailing light harness uses a 7-pin trailer J560. If your tractor does not have a 7-pin conductor...
  • Page 25 SECTION 1 - GENERAL INFORMATION INSTALLING THE SOCKET Use the tractor wiring diagram or, if necessary, use a test light to identify the tractor wires. Connect the wires to the socket as follows: Connector ID Attached To White (WHT) Ground wire, all lights Black (BLK) Not used/worklights Yellow (YEL)
  • Page 26 SECTION 1 - GENERAL INFORMATION PULLING WITH A TRACTOR Ensure the unit is securely attached to an appropriately sized tractor. Refer to the “Hitching to Tractor” portion of this manual. Raise the header. Engage the transport stops, 1, to hold up the header. 10004565 Swing the tongue to the center position and engage the spring-loaded lockpin.
  • Page 27 SECTION 1 - GENERAL INFORMATION When towing the mower-conditioner on a road or highway, ensure that the flashing lights harness is attached to the tractor, and the lights, 1, are functioning to adequately warn operators of other vehicles. Consult local governmental regulations for specific lighting requirements.
  • Page 28 SECTION 1 - GENERAL INFORMATION 1-18...

  • Page 29: Operation

    Your New Holland dealer can use a hand tachometer to check tractor Before starting to use your new Model 499 PTO speed. The tractor throttle should be set mower-conditioner, be sure to do the following items: correctly to maintain correct RPM at the PTO shaft.
  • Page 30 SECTION 2 - OPERATION CUTTING IMPORTANT: Do not engage the PTO with the engine running at high speed or the pump drive can be damaged. Slowly engage the PTO before the unit is moved up to the standing material. Be sure the tractor PTO is running at the standard RPM (540 to 1000) before starting to cut.
  • Page 31 SECTION 2 - OPERATION 3. To maneuver around obstacles in the field: As the unit approaches the obstacle, swing the header towards the tractor, away from the obstacle. Be sure to allow enough time for the machine to pivot and track away from the obstacle.
  • Page 32 SECTION 2 - OPERATION CLEARING A PLUGGED CUTTER BAR OR CONDITIONER 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.
  • Page 33 SECTION 2 - OPERATION CONDITIONER ROLLS PLUG 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.
  • Page 34 SECTION 2 - OPERATION If plugging continues, use this manual as a guide to check: 1. Tractor PTO speed. 2. Reel position. 3. Condition of cutter bar, guards, knife sections, and knife clips. 4. Conditioner roll pressure. 5. Skid shoe and header tilt positions. 6.
  • Page 35 SECTION 2 - OPERATION FIELD ADJUSTMENTS CUTTING HEIGHT The cutting height is controlled by the skid shoe and cutter bar tilt settings. Five skid shoe positions, 1, are available to vary the stubble height from 25 mm-152 mm (1″- 6″). DANGER Always engage the transport stops when working around a raised head or transporting the...
  • Page 36 SECTION 2 - OPERATION CUTTER BAR ANGLE, FIXED LINKS 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.
  • Page 37 SECTION 2 - OPERATION CUTTER BAR ANGLE, HYDRAULIC (OPTIONAL) Optional hydraulic guard angle adjustment allows “on-the-go” cutter bar angle selections between 4 degrees and 10 degrees below horizontal. Also, the angle adjustment range can be locked at 4 degrees or limited to 7 degrees. The unit is equipped with two hydraulic tilt cylinders, 1.
  • Page 38 SECTION 2 - OPERATION 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.
  • Page 39 SECTION 2 - OPERATION REEL POSITION 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.
  • Page 40 The would be approximately 9.7 km/hr (6 MPH). These optional reel speed reduction sprocket is available are only guidelines. Different crop conditions may from the parts department at your local New Holland require other adjustments. dealer. WARNING Disengage the PTO, turn off the tractor engine and remove the key.
  • Page 41 SECTION 2 - OPERATION To increase the reel speed, remove the cap screw and clip at 1, and rotate the outer sheave half, 2, in a clockwise direction. For a lower range of speeds, remove the outer sheave half and turn the low side in toward the belt. NOTE: Do not turn the sheave half out past flush with the hub.
  • Page 42 SECTION 2 - OPERATION PUSH BAR The push bar,1, should normally be set in the highest position as shown. 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.
  • Page 43 SECTION 2 - OPERATION THEORY OF OPERATION ROLL CONDITIONING Roll conditioning passes the cut crop through a set of closely spaced intermeshing rolls with matching lands and valleys. The rolls crush and crack the plant stem at several points along its length, which wears away the waxy coating and allows moisture to escape.
  • Page 44 SECTION 2 - OPERATION Torsion Bar Tensioning System crack will be about 25--50 mm (1--2 in.) in length. The stem should look flat in these cracked areas. The torsion bar tensioning system maintains uniform Depending on crop height when cut, there will be at pressure throughout the range of roll movement as least two or three cracks along the plant length.
  • Page 45 SECTION 2 - OPERATION Rolls in Home Position Rolls are at zero degrees (home position). Link is straight. This allows full pressure of torsion bar to be applied to top roll arm. 50051184 Rolls Open at 15 Degrees Rolls begin to open as crop enters conditioning system.
  • Page 46 SECTION 2 - OPERATION CONDITIONING For legume-type crops, such as alfalfa and clover, about 90% of the stems and 5% of the leaves should show some conditioning action. The stems should only be cracked with minimum leaf damage. Overconditioning will cause the leaves to dry faster and break off where they are damaged.
  • Page 47 SECTION 2 - OPERATION ROLL GAP IMPORTANT: The rolls must not contact each other at any point or damage to the rolls and header frame 0.4 mm may result. Adjust roll to a minimum of 0.4 mm (1/64″) (1/64″) clearance at the closest point of the rolls.. WARNING Disengage the PTO, turn off the tractor engine and remove the key.
  • Page 48 Shims can be use, it may be necessary to remove shims to obtained from your New Holland dealer. maintain 0.4 mm -- 3 mm (1/64″ -- 1/8″) clearance Install pad, 3, so the steel is on top and the rubber is between the rolls.
  • Page 49 SECTION 2 - OPERATION CUTTING GRAIN FOR SILAGE OR HAY Rye, oats, barley, or wheat are often cut for silage or hay. These crops should feed through the header and conditioner, without problems, if the crop is taller than 1 m (36″). If these crops are shorter or not fully headed, the crop may stop or bunch up between the reel and conditioner rolls.
  • Page 50 SECTION 2 - OPERATION 2-22...

  • Page 51: Lubrication

    SECTION 3 LUBRICATION Complete all checks and services in this section at 2. Lower the header to the ground or raise the the hour interval shown. header and engage the lift locks. 3. Stop the tractor engine and engage the parking IMPORTANT: Failure to complete the required brake before leaving the cab.
  • Page 52 SECTION 3 - LUBRICATION LUBRICATION SCHEDULE AFTER EVERY EVERY EVERY EVERY FIRST HOURS HOURS HOURS HOURS HOURS Oil reel drive chain Reel shaft bearing rods (2 fittings) Sickle drive connecting rods (2 fittings each side) Reel intermediate drive shaft Lower header arm pivots (2 fittings) Wheel arm pivots (2 fittings) Left upper roll drive shaft (3 fittings) Right sickle drive shaft (3 fittings)
  • Page 53 SECTION 3 - LUBRICATION FLUIDS AND LUBRICANTS STORING LUBRICANTS The pivot tongue mower-conditioner can only Lubricants operate at proper efficiency if clean lubricants are Effective use of lubricating oils and greases is used. Use clean containers to handle all lubricants. perhaps the most important step toward low upkeep Store them in an area protected from dust, moisture, cost, long mower-conditioner life, and satisfactory...
  • Page 54 SECTION 3 - LUBRICATION EVERY 10 HOURS 1 Reel shaft bearing - 2 fittings (Left side shown) 10004582 1 Sickle drive connecting rod - 4 fittings (Left side shown) Oil the reel drive chain 10004583 1 Reel intermediate drive shaft 10004584...
  • Page 55 SECTION 3 - LUBRICATION Left upper roll U-joints - 2 fittings Left PTO telescoping section 10004585 1 Header lift arm pivots - 2 fittings (Right side shown) 2 Wheel arm pivots - 2 fittings (Right side shown) 10004586 1 Right sickle drive U-joints - 2 fittings 2 Right PTO telescoping section 10004587...
  • Page 56 SECTION 3 - LUBRICATION Header drive sheave hub 10004588 AFTER THE FIRST 50 HOURS Hydrostatic oil filter, 1. Change the hydrostatic oil filter after the first 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.
  • Page 57 SECTION 3 - LUBRICATION EVERY 50 HOURS 1 U-joint drive, gearbox to lower roll - 2 fittings 10004590 1 Roll pressure crank trunnion and threads 10004591 1 Jack assembly, if equipped with this style jack 10004716...
  • Page 58 SECTION 3 - LUBRICATION 1 Tongue pivot - 1 fitting 2 Oil the tongue latch pin HYDROSTATIC RESERVOIR OIL LEVEL IMPORTANT: Park the mower-conditioner on level ground, and lower the header before checking oil level in the tongue reservoir. Clean trash and dirt from the area around the dipstick.
  • Page 59 SECTION 3 - LUBRICATION RIGHT SIDE DRIVES Add API GL-5 80W-90 gear oil as needed to keep oil level with the bottom edge of the check plug holes, 1, in the sickle drive gearboxes. 10004719 1 Hex shaft bearing This is located under the header just forward of the lower conditioner roll.
  • Page 60 SECTION 3 - LUBRICATION 3-10...

  • Page 61: Maintenance

    SECTION 4 MAINTENANCE GENERAL INFORMATION Complete all checks and services in this section at Always clean the area around the dipstick, cap, or the hour interval shown. Use the hour meter in the plug before checking any fluid levels. Allowing any tractor as a guide for determining when maintenance contamination to enter will cause damage to the is required.
  • Page 62 SECTION 4 - MAINTENANCE PRESEASON MAINTENANCE Prior to beginning the harvest after winter storage, 3. Have someone start the unit and engage the take the following steps to be certain the unit is in header. Carefully walk around the unit while it is good condition.
  • Page 63 SECTION 4 - MAINTENANCE BELT AND CHAIN MAINTENANCE V-BELT CARE AND MAINTENANCE spot. Replace the belt immediately to prevent other problems. Drive belts transmit power by friction and a wedging action against the sheaves. Belts and sheaves are Vibration can also be caused by a lumpy V-belt. therefore subject to wear and should be checked Check belts for swells and lumps.
  • Page 64 SECTION 4 - MAINTENANCE CARE OF CHAINS thoroughly. Drive chains should be checked and lubricated daily. Before starting the unit, clean the chains and Maintain correct tension. Over tightening stretches lubricate them with a heavy oil or grease. When the chain and exerts excessive side loads on removing the unit from storage, reclean the chains sprockets, shafts, and bearings.
  • Page 65 SECTION 4 - MAINTENANCE MAINTENANCE SCHEDULE NOTE: The items listed at the first 5 hours and first 50 hours are very important. If they are not performed, it could cause early failures of components and severely lower the life expectancy of the unit. AFTER EVERY 10 EVERY 50...
  • Page 66 SECTION 4 - MAINTENANCE BEARING INSTALLATION When installing a new bearing, clean the shaft, and remove paint from the surface of the flangettes which will contact the bearing. 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.
  • Page 67 SECTION 4 - MAINTENANCE BELTS AND CHAINS 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.
  • Page 68 SECTION 4 - MAINTENANCE Adjust eyebolt and nuts, 1, so idler spring, 2, measures 305 mm (12″) between the hooks. 10004722 When idler spring is adjusted to 305 mm (12″), idler arm, 3, should clear stop, 2, by about 13 mm (1/2″). Move the V-idler, 1, back for more clearance.
  • Page 69 SECTION 4 - MAINTENANCE 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.
  • Page 70 SECTION 4 - MAINTENANCE 4. Remove brace, 1. 10004726 5. Remove bolts, 1. Note location of shims, 2, so they can be replaced in the original position. Pull the pulley mount away. Remove the old belts and install the new ones. 6.
  • Page 71 SECTION 4 - MAINTENANCE 9. Tighten bolts, 1, and nuts, 2. 10004725 4-11...
  • Page 72 Section 6, Optional Equipment, of this manual for additional information. IMPORTANT: Black, overserrated, fully-bolted knife sections are original factory equipment on Model 499 mower-conditioners, serial number 539686 and above. Below serial number 539686, black, underserrated, riveted sections were original equip- ment.
  • Page 73 SECTION 4 - MAINTENANCE Smooth sections provide good cutting action in grass hay, but require resharpening, good guards, and frequent knife clip adjustment. Chrome knife sections may stay sharp longer but may be nicked by gravel or small stones. If the sections are sharpened, be sure to maintain the original bevel and angles as shown.
  • Page 74 SECTION 4 - MAINTENANCE REMOVING AND REPLACING KNIFE ASSEMBLIES WARNING When removing or installing a knife assembly, do not hold down the sections with fingers or any short object that could slip and result in loss of, or injury to, fingers. Removal To remove a knife assembly, remove knife head bolt, 1.
  • Page 75 SECTION 4 - MAINTENANCE Installation WARNING Be very careful when installing a knife assembly. Do not touch the sections if another person is installing the knife assembly. If the end of the knife hits, use a hammer handle or other tool to force the knife to line up with the opening in the guard.
  • Page 76 SECTION 4 - MAINTENANCE KNIFE ASSEMBLIES RIGHT KNIFE LEFT KNIFE RIGHT KNIFE LEFT KNIFE RIGHT KNIFE LEFT KNIFE 4-16...
  • Page 77 3, and one bottom countersunk section, 4. The bottom countersunk section on the The model 499 is equipped with one of three (3) left knife is the same section as used on the right styles of knife assemblies shown. Determine the knife, however it is installed with the bevel down.
  • Page 78 SECTION 4 - MAINTENANCE KNIFE SECTIONS, REPLACEMENT Riveted Knife Assemblies To replace a section on a riveted knife assembly, 1, remove the rivets from the knife back. Support the knife back when driving the rivets out of the knife back. Special rivet removal and installation tools are available to replace a section with the knife installed in the machine.
  • Page 79 SECTION 4 - MAINTENANCE Open the vise jaws, 1, just enough for the rivet head to clear the jaws or support the knife back on a solid surface on each side of the rivet(s) to be removed. Use a punch to drive the rivets out of the knife back. Install new rivets in the knife back.
  • Page 80 SECTION 4 - MAINTENANCE Knife Section Bolts Several different length knife section bolts, 1, are used. The knife head and knife back extension require longer bolts than those used for the knife back. Special flat head bolts are also required at the knife overlap area.
  • Page 81 SPECIAL GUARDS End Guards The Model 499 uses several special guards. The guards at each end of the cutter bar have the top lip, 1, shortened to clear the knife drive rocker arms. The channel, 2, for the knife back is deeper to clear the nuts on the knife head bolts.
  • Page 82 SECTION 4 - MAINTENANCE Center Guards A modified center guard allows the knives to overlap. Standard style guards, 1, used on machines with a single overlap section have a larger opening, 2, between the top lip and the ledger surface on the left guard point.
  • Page 83 SECTION 4 - MAINTENANCE GUARDS USED Qty. Center Left & right end Standard Guard Installation When the machine is equipped with standard guards Shim the guards, 1, and hold down clips, 2, to allow the install a 3 mm (0.120″) shim, 4, under the center knives to overlap properly.
  • Page 84 SECTION 4 - MAINTENANCE Guard Inspection Inspect the edge of the guard ledger surface at 1. If the edge is rounded or severely damaged, the guard should 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.
  • Page 85 SECTION 4 - MAINTENANCE 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.
  • Page 86 SECTION 4 - MAINTENANCE Usually when the guard’s alignment needs to be adjusted it is because the cutter bar and not the guards are bent. A homemade guard straightening tool, 1, or heavy hammer can be used to align the guards.
  • Page 87 NOTE: The Model 499 with standard guards may have either one piece hold down clips or two piece, adjustable hold down clips as shown.
  • Page 88 SECTION 4 - MAINTENANCE Adjustable Hold Downs for Standard Guards The adjustable hold down clips, 1, are spaced across the cutter bar. There is not a clip at every guard as the top lip on the guard helps to hold the knife from lifting too far.
  • Page 89 SECTION 4 - MAINTENANCE The front of the clip should be adjusted by bending it up or down to obtain a clearance of less than 0.50 mm (0.020″) between the front of the clip and the knife section at 4, Figure 40. The knife assembly must move freely after the clips are adjusted.
  • Page 90 SECTION 4 - MAINTENANCE SICKLE DRIVE ADJUSTMENT Knife sections should be 0.08 mm-0.8 mm (0.003″-0.030″) above the ledger surface of the WARNING guards. Disengage the PTO, turn off the tractor engine and remove the key. Wait for all movement to stop before leaving the operator’s position.
  • Page 91 SECTION 4 - MAINTENANCE 1. Loosen upper rocker arm bolt, 1. 10004728 2. Remove connecting rod bolt, 1, knife head bolt, 2, and hub cap, 3. 10004729 4-31...
  • Page 92 SECTION 4 - MAINTENANCE 3. Remove cotter pin, 2, slotted nut, 3, and front shim washers, 4. 4. Remove the connecting rod and front bearing cone, 8. Use care to keep dirt out of the bearings. 5. Remove: Rear bearing cone with seal, 7; Washer, 6;...
  • Page 93 SECTION 4 - MAINTENANCE IMPORTANT: Rotate the conditioner rolls so the knives are at mid-stroke before tightening the two bolts. Tighten these two bolts and upper rocker arm bolt, 1, to 115 N⋅m (85 ft. lbs.). Turn the rolls so the knives make a full stroke. Check to be sure the sickle drives and knives move freely.
  • Page 94 SECTION 4 - MAINTENANCE Disassembly 1. Remove crank pin bearing cups, 9, with a hammer and punch. 2. Remove the grease fitting from the rocker arm end of the connecting rod. Place the connecting rod in a vise with front spacer, 11, up. Use a punch through the bolt hole to drive out the rear spacer, 12.
  • Page 95 SECTION 4 - MAINTENANCE Assembly 1. Clean the connecting rod. Pack bearing cones with multipurpose grease as they are as- sembled. Use a mild steel rod, not a punch, to install the bearings. NOTE: The rocker arm bearing must be installed as a complete assembly because the cup spacer and cone spacer control the bearing adjustment.
  • Page 96 SECTION 4 - MAINTENANCE 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.
  • Page 97 SECTION 4 - MAINTENANCE REEL MAINTENANCE TINES Tine bars from the left and right side of the header are shown overlapping at the center of the header. Left and right tines and clips will not interchange. The mounting eye of the tine, the tine clip, and the lock nut must be on the FRONT side of the tine bar.
  • Page 98 SECTION 4 - MAINTENANCE TINE BAR BEARINGS Tine bars are removed from the spider legs as detailed in the “Tine Bars” portion of this section. 1. Carefully remove the dust cap from the bearing housing. Remove the snap ring. Remove the bearing from the bearing housing by placing the nut on the threaded end of the bearing stud and tapping against the nut.
  • Page 99 SECTION 4 - MAINTENANCE REEL TUBE BEARING AND HOUSING (2) ROLLER PLATE SHIMS (DOTTED LINES) SPECIAL WASHERS BEARING (2) THICK SPACER (2) CAM TRACK SNAP RING (2) .010″ TO .125″ UNIVERSAL (.25 TO 3.175 MM) CLEARANCE DIRECTION OF ROLLER PLATE ROTATION ROLLER SPECIAL WASHERS...
  • Page 100 SECTION 4 - MAINTENANCE Be sure special washers are installed on roller plate bolts at 1. NOTE: If the clearance is excessive, more than 3.175 mm (0.125 ), at all four cam track rollers, the ″ cam track may have moved out from the reel. Move the cam track in before reshimming the roller plates.
  • Page 101 SECTION 4 - MAINTENANCE REEL U-JOINTS Each spider is attached to the reel tube with a universal joint. REEL TUBE BEARING AND HOUSING (2) ROLLER PLATE SHIMS (DOTTED LINES) SPECIAL WASHERS BEARING (2) THICK SPACER (2) CAM TRACK SNAP RING (2) .010″...
  • Page 102 SECTION 4 - MAINTENANCE REEL TUBE BEARING AND HOUSING (2) ROLLER PLATE SHIMS (DOTTED LINES) SPECIAL WASHERS BEARING (2) THICK SPACER (2) SNAP RING (2) CAM TRACK .010″ TO .125″ UNIVERSAL (.25 TO 3.175 MM) CLEARANCE DIRECTION OF ROLLER PLATE ROTATION ROLLER SPECIAL WASHERS...
  • Page 103 SECTION 4 - MAINTENANCE CONDITIONER ROLLS AND GAP 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.
  • Page 104 SECTION 4 - MAINTENANCE If the bolt slots are not long enough, remove bolt, 1. Move hub, 2, to the next flat on the hex shaft, 3. Retighten clamp bolt, 1. Readjust roll timing. When timing is correct, tighten all hardware securely. IMPORTANT: Check roll timing at each end of the rolls.
  • Page 105 SECTION 4 - MAINTENANCE HYDRAULIC AND HYDROSTATIC SYSTEMS WARNING HYDRAULIC SYSTEM The tractor hydraulic pump and reservoir supply oil Fluid under pressure can have sufficient force to to raise the header and to pivot the tongue. Lower the penetrate the skin, causing serious personal header before checking the oil level in the tractor injury.
  • Page 106 Because of the high pressures in these systems, used for a reservoir. use only genuine New Holland parts and hoses for repairing these systems. The hydrostatic system must be kept free of dirt, dust, water, rust, etc., or the hydrostatic pump or...
  • Page 107 7. Clean the mower-conditioner and repaint the 4. Disassemble and repack the right and left wheel bare or rusted parts with New Holland touch-up bearings with a good grade of wheel bearing enamel. Your New Holland dealer has cans of grease.
  • Page 108 SECTION 4 - MAINTENANCE MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS METRIC NON-FLANGED HARDWARE AND LOCKNUTS CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT NOMINAL CL.8 SIZE UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED W/CL8.8 W/ZnCr W/ZnCr W/ZnCr BOLT 1.7 (15)*...
  • Page 109 SECTION 4 - MAINTENANCE MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS INCH NON-FLANGED HARDWARE AND LOCKNUTS SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B GR.C NOMINAL SIZE W/ZnCr...
  • Page 110 SECTION 4 - MAINTENANCE 4-50...

  • Page 111: Troubleshooting

    SECTION 5 TROUBLESHOOTING PROBLEM CORRECTION POSSIBLE CAUSE Depositing conditioned material in Improper swath gate adjustment. Raise swath gate one latch hole. bunches or piles when swathing. Improper ground speed to reel Run reel 10% faster than ground speed relationship. speed. See Reel Speed Chart (Section 2).
  • Page 112 SECTION 5 - TROUBLESHOOTING PROBLEM CORRECTION POSSIBLE CAUSE Excessive breakage of guards Cutting too low in stony condi- Raise cutting height with adjust- and knives. tions. able skid shoes.* Guards, knives, and hold-down Align guards and knives and clips not properly aligned. adjust hold-down clips so knife assembly runs freely.
  • Page 113 SECTION 5 - TROUBLESHOOTING PROBLEM CORRECTION POSSIBLE CAUSE Knocking in the sickle drive. Replace the rubber bushing. Rubber bushing has worn out in knife head. Adjust or replace bearings. Loose connecting link bearings. Adjust ledger and back clearance Knife not adjusted properly. at knife head end.
  • Page 114 SECTION 5 - TROUBLESHOOTING...

  • Page 115: Optional Equipment

    SECTION 6 OPTIONAL EQUIPMENT CROP DIVIDERS A crop divider bundle includes dividers for both ends of the header. The right crop divider is shown, the left crop divider is similar. 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.
  • Page 116 SECTION 6 - OPTIONAL EQUIPMENT HYDRAULIC GUARD ANGLE ADJUSTMENT KIT The hydraulic guard angle adjustment kit allows “on-the-go” guard angle selections between 4 degrees and 10 degrees below horizontal. Also, the angle adjustment range can be locked at 4 degrees or limited to 7 degrees.
  • Page 117 SECTION 6 - OPTIONAL EQUIPMENT STUB GUARDS Stub guards should be used for cutting heavy, thick or wet undergrowth where material hairpins over the points of standard guards. Stub guards require more maintenance than standard guards. In extreme conditions, wet or dead undergrowth or fine, wet grass may plug the cutter bar or the material may build up on the points of the standard guards.
  • Page 118 SECTION 6 - OPTIONAL EQUIPMENT RIGHT LEFT SIDE SIDE 10004737 DESCRIPTION PART QUANTITY NUMBER REQUIRED* 0.3 mm″ (0.010) shim. Use as needed under all knife clips. 244500 1 mm ()0.036″ shim. Use as needed under all knife clips. 199283 3 mm (0.120″) shim. Use one between cutter bar and all guards to left of special center guard.

  • Page 119: Specifications

    SECTION 7 SPECIFICATIONS Overall Width Transport position ......4191 mm (165″) Field position ....... . 5994 mm (236″) Overall Length Transport position...
  • Page 120 SECTION 7 - SPECIFICATIONS Reel Type Rolareel™ Effective tine tip speed ..... . . 7.7 km/hr – 12.7 km/hr (4.8 MPH – 7.9 MPH) (in direction of travel) 6.5 km/hr –...
  • Page 121 SECTION 7 - SPECIFICATIONS Operating Speed ......0 km/hr – 12.9 km/hr (0 to 8 MPH) Capacity at 8 km/hr (5 MPH) 12′...
  • Page 122 SECTION 7 - SPECIFICATIONS...

  • Page 123: Index

    INDEX Bearing Installation ......Minimum Hardware Tightening Torques ..4-48 Belt and Chain Maintenance .
  • Page 124 Trailing Lights ......1-14 Type and Quantity of Oil Used ....Transport Locks .

  • Page 125: Delivery Report

    OWNER COPY DELIVERY REPORT ® MODEL 499 HAYBINE MOWER-CONDITIONER Delivery Date Owner’s Name Address Dealer’s Name Address Model Using the operator’s manual as a guide, instruction was given as indicated by the check marks. __ Proper use of the operator’s manual...
  • Page 127 DEALER COPY DELIVERY REPORT ® MODEL 499 HAYBINE MOWER-CONDITIONER Delivery Date Owner’s Name Address Dealer’s Name Address Model Using the operator’s manual as a guide, instruction was given as indicated by the check marks. __ Proper use of the operator’s manual...
  • Page 128 7-10...

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