Pottinger NOVACAT 7800 User manual

• Disc mower
Operator's manual
+ INSTRUCTIONS FOR PRODUCT DELIVERY . . . Page 3
Nr. 99 383.GB.80D.1
GB
NOVACAT 7800
(Type PSM 383 : + . . 01001 - . . 01035)
Ihre / Your / Votre • Masch.Nr. • Fgst.Ident.Nr.

ALLG./BA SEITE 2 / 9300-GB
Important information concerning
Product Liability.
According to the laws governing product liability, the manufacturer and
dealer are obliged to hand the operating manual to the customer at the time
of sale, and to instruct them in the recommended operating, safety, and
maintenance regulations. Confirmation is necessary to prove that the
machine and operating manual have been handed over accordingly.
For this purpose,
-document A is to be signed and sent to Pöttinger,
-document B remains with the dealer supplying the machine,
- and the customer receives document C.
In accordance with the laws of product liability, every farmer is an
entrepreneur.
According to the laws of product liability, property damage is damage
caused by a machine and not to it. An excess of Euro 500 is provided for
such a liabilioty.
In accordance with the laws of product liability, entrepreneurial property
damages are excluded from the liability.
Attention! Should the customer resell the machine at a later date, the
operating manual must be given to the new owner who must then be
instructed in the recommended regulations referred to herein.
GB Dear Farmer
You have just made an excellent choice.
Naturally we are very happy and wish to
congratulate you for having chosen Pöttinger.
Asyouragriculturalpartner,weofferyouquality
andefficiency combined with reliable servicing.
In order to assess the spare-parts demand for
our agricultural machines and to take these
demands into consideration when developing
new machines, we would ask you to provide us
with some details.
Furthermore, we will also be able to inform you
of new developments.

Dokument D
GB-0600 Dokum D Anbaugeräte
PÖTTINGER Landtechnik GmbH
Industriegelände 1
A-4710 Grieskirchen
Tel. 07248 / 600 -0
Telefax 07248 / 600-2511
TMachine checked according to delivery note. All attached parts removed. All safety equipment, drive shaft and operating
devices at hand.
TOperation and maintenance of machine and/or implement according to operating instructions explained to the customer.
TTyres checked re. correct pressure.
TWheel nuts checked re. tightness.
TDrive shaft cut to correct lenght.
T*VYYLJ[WV^LY[HRLVɈZWLLKPUKPJH[LK
TFitting to tractor carried out: to three-point linkage
TTrial run carried out and no defects found.
TFunctions explained during trial run.
TPivoting in transporting and operating position explained.
TInformation given re. optional extras.
TAbsolute need to read the operating manual indicated.
Please check. X
According to the product liability please check the above mentioned items.
INSTRUCTIONS FOR
PRODUCT DELIVERY
GB
In order to prove that the machine and the operating manual have been properly delivered, a confirmation is necessary.
For this purpose please do the following:
- sign the document A and send it to the company Pöttinger or via the internet to www.poettinger.at
- document B stays with the specialist factory delivering the machine.
- document C stays with the customer.

GB TABLE OF CONTENTS
INHALT_384.GB.80E.0
- 4 -
Table of contents
Meaning of warning signs ................................................... 5
Warning signs ..................................................................... 5
Attaching implement to tractor ............................................ 6
Attaching to tractor .............................................................. 6
Hydraulic connection ........................................................... 7
Settings (up to 2001 model) ................................................ 8
Settings (from 2002 model) ................................................. 8
Observe rotation direction of cutting discs .......................... 9
Combination 3 ................................................................... 10
Combination 2 .................................................................... 11
Establish power supply ...................................................... 11
Driving on public roads ..................................................... 12
Transport position ............................................................. 12
”SELECT CONTROL” device ............................................ 12
How to carry out desired hydraulic function ...................... 12
”SELECT CONTROL” device ............................................ 13
Conversion from working to transport position .................. 13
Take care when turning on slopes! ................................... 14
WORKING ON SLOPES ................................................... 14
Important points before starting work ................................ 15
Safety hints ....................................................................... 15
starting work ...................................................................... 15
Operation .......................................................................... 16
Adjustment: ....................................................................... 16
Collision safety device: ..................................................... 17
How the hydraulic collision safety device functions .......... 17
Mowing with the conditioner .............................................. 18
Correct belt tension ........................................................... 18
Position of the rotor prongs ............................................... 18
Conditioner ........................................................................ 18
Dismounting and mounting the conditioner ....................... 19
Take particular notice when the conditioner is detached
from the cutter bar ............................................................. 22
"Extra dry" system ............................................................. 25
Swathes ............................................................................ 25
Spread width ..................................................................... 25
Dismount guide plate ........................................................ 26
Mount guide plate ............................................................. 26
Mower unit with swath discs ............................................. 27
SWATH DISCS.................................................................. 27
Flat cone conveyor (Optional extra) .................................. 27
Safety points ..................................................................... 28
General maintenance hints ............................................... 28
Repair Instructions ............................................................ 28
Safety hints to observe in supplement!
Cleaning of machine parts ................................................ 28
MAINTENANCE ................................................................ 28
Parking in the open ........................................................... 28
Winter storage ................................................................... 28
Drive shafts ....................................................................... 28
Hydraulic unit .................................................................... 28
Cutter bar oil level check ................................................... 29
MAINTENANCE ................................................................ 29
Angular gear ..................................................................... 30
Installing cutter blades ...................................................... 30
Cutter bar .......................................................................... 30
Adjustment of sensors ...................................................... 31
Setting the field transport position (end-of-run turns) ........ 31
Maintenance ..................................................................... 31
Gear (G2) .......................................................................... 32
Gear (G1) .......................................................................... 32
Disruptions and remedies to power failure ........................ 33
Mounting of Mowing Blade ................................................ 34
Checking Wear.................................................................. 34
Attention ! Danger of accident if wearing parts are worn .. 34
Danger of accident if: ........................................................ 34
Holder for a quick change of cutter blades ....................... 35
Checking the mowing blade suspension ........................... 35
maintenance and service .................................................. 35
Changing the Cutter Blades (up to 2003 model) ............... 35
Storing the lever ................................................................ 36
Changing the Cutter Blades (from 2004 model) .............. 36
Technical data ................................................................... 37
Necessary connections ..................................................... 37
The defined use of the mower unit .................................... 38
Electrical / Electronic pin configuration ............................. 38
Position of Vehicle Identification Plate .............................. 38
SUPPLEMENT ____________________ 39
Recommendations for work safety .................................... 41
DRIVESHAFT ................................................................... 42
Lubrication chart ............................................................... 43
Repairs on the cutter bar .................................................. 47
Important! Additional Information ...................................... 50
Combination of tractor and mounted implement ............... 50

CE sign
The CE sign, which is affixed by the manufacturer, indicates outwardly that this machine conforms
to the engineering guideline regulations and the other relevant EU guidelines.
EU Declaration of Conformity (see supplement)
By signing the EU Declaration of Conformity, the manufacturer declares that the machine being
brought into service complies with all relevant safety and health requirements.
Meaning of warning signs
Danger - flying objects; keep safe distance from the
machine as long as the engine is running.
Wait until all machine components have stopped
completely before touching them.
Stay clear of mower knife area as long as tractor
engine is running with PTO connected.
Shut off engine and remove key before performing
maintenance or repair work.
Stay clear of swinging area of implements
Closebothsideprotectivecoveringsbeforeengaging
p.t.o..
Never reach into the crushing danger area as long
as parts may move.
Recommendations for work safety
Allpoints referring tosatety in this manual
are indicated by this sign.
495.151
bsb 447 410
495.167
- 5 -
(361) AZB 9700-GB
GB
WARNING SIGNS

Attaching implement to tractor
Safety hints:
see supplement-A1 points 7.), 8a. - 8h.)
Centre-mount (M) mower unit to tractor
- Adjust lower link accordingly.
- Secure the lower hydraulic link so that the appliance cannot swing
sideways.
Frame in horizontal position
- Bring frame into horizontal position by adjusting linkage arm spindle (15).
Setting lower link height
- Adjust tractor's hydraulics (ST) using bottom stop.
- Thedriveshaft(GW) shouldbe abouthorizontal
when mowing.
This height allows optimal evenness when
working on uneven ground and need not be
changed for swinging cutter bar up.
Hydraulic connection
- see next page.
Connect hydraulic lines
TD 79/98/01
15
0200-GB Anbau_384
GB
ATTACHING TO TRACTOR
- 6 -

0400-GB Anbau_384
GB
ATTACHINGTOTRACTOR
- 7 -
Setting upper link height using spindle
- By turning upper link spindle (16) the cutting height is adjusted
.
A hydraulic upper link is recommended.
(double-action hydraulic connection)
Fitting drive shaft
- Before operating for the first time, drive shaft is to be checked
and adapted if necessary. See alse chapter "Drive Shaft" in
supplement B.
134-01-10
DW
DW
EW LS
T
Hydraulic connection
Minimal hydraulic system:
1 x single-action hydraulic connection (EW) with unpressurized backflow (T)
1 x double-action hydraulic connection (DW), for the starting lock
Optimal hydraulic system:
1 x single-action hydraulic connection (EW) with unpressurized backflow (T)
1 x double-action hydraulic connection (DW) for the starting lock
1 x double-action hydraulic connection (DW) for the hydraulic upper link
or
Load-sensing hydraulic connection (LS) (Optional equipment)
1 x double-action hydraulic connection (DW) for the starting lock
1 x double-action hydraulic connection (DW)for the hydraulic upper link
TD25/90/8
16

0400-GB Anbau_384
GB
ATTACHINGTOTRACTOR
- 8 -
Settings (up to 2001 model)
A so-called ”jumper”, which must be connected up
in keeping with the tractor´s hydraulic system, is
located in the electric distribution box.
Screw (7) on the hydraulic unit must also be
adjusted accordingly.
Disconnect electrical connection (E2, E3).
Tractors with a "Load sensing" system
- Jumper in position ”J1” (factory-preset)
- Screw (7) on the hydraulic unit must be screwed in all the way
Tractors with a closed hydraulic system
JOHN DEERE, CASE MAXUM, CASE MAGNUM, FORD Series 40 SLE
- Jumper in position ”J1” (factory-preset)
- Screw (7) on the hydraulic unit must be screwed in all the way
- Remove valve plug connector (7a) from the hydraulic unit
- Install a dummy plug in its place
Tractors with a open hydraulic system
- Jumper in position ”J2”
- Completely unscrew screw (7) on the hydraulic unit
Settings (from 2002 model)
A switch is located in the electrical distribution
box which must be set relative to the tractor´s
hydraulic system.
Screw (7) on the hydraulic unit must also be
adjusted accordingly.
Disconnectelectricalconnection(E2,E3).
Tractors with a "Load sensing" system
- Switch in position ”LS” (factory-preset)
- Screw (7) on the hydraulic unit must be screwed in all the way
Tractors with a closed hydraulic system
JOHN DEERE, CASE MAXUM, CASE MAGNUM, FORD Series 40 SLE
- Switch in position ”LS” (factory-preset)
- Screw (7) on the hydraulic unit must be screwed in all the way
- Remove valve plug connector (7a) from the hydraulic unit
- Install a dummy plug in its place
Tractors with a open hydraulic system
- Switch in position ”ON”
- Completely unscrew screw (7) on the hydraulic unit
LS
069-02-13
ON
069-02-14
J2
J1
+ 2002
- 2001
E2
E3
069-02-15
E2
E3
069-02-15

0400-GB Anbau_384
GB
ATTACHINGTOTRACTOR
- 9 -
Observe rotation direction of cutting discs
• Select appropriate rotation direction for the drive
- if the necessary r.p.m. cannot
be preselected on the tractor,
then turn both gearings (G1,
G2) 180°.
Note!
Before reinstalling a
gearingon themachine,
swap ventilation screw
and drain plug
positions.
- The correct ventilation screw position is on top.
083-01-031
083-01-032
NOVACAT 8600
NOVACAT 7800
Safety hints
This appliance is designed only for use with tractors
(not for automotive machines).
In the case of automotive machines, the driver´s visual
range is restricted when the two outer mower bars are
raised in the transport position.
TD 79/98/53
G1
G2
G1
134-01-06
G2

0400-GB Anbau_384
GB
ATTACHINGTOTRACTOR
- 10 -
Combination 3
Safety hint: see supplement A1/ pt. 7, 8a-8h
Take note!
The lifting gear cannot be progressively raised or
lowered. When the hydraulic control valve is activated,
the central cutter bar is either completely raised or
lowered (danger of crushing).
Should it be necessary to convert from Combination 2 to Combination
3, the following steps must be carried out:
1. Remove adapter (pos. 5)
2. Detach attaching axle and install
in pos. 4a
3. Install lifting gear (pos. 1)
4. Set up hydraulic connection (pos.
3)
5. Set up electric connection (pos. 2)
6. Attach mower unit to lifting gear
(1)
- Attach expander (EX)
7. Attach both chains (7)
- whendoingthis,please noteinstructions inchapter onAdjustments
12 -16
cm
134-01-14
7b 7
W
7a
L1
7c
134-01-09

0400-GB Anbau_384
GB
ATTACHINGTOTRACTOR
- 11 -
134-01-08
Combination 2
Should it be necessary to convert from Combination 3 to
Combination 2, the following steps must be carried out:
1. Disconnect electrical connection (pos. 2)
- Attach the cable to a suitable place on the frame
2. Disconnect hydraulic connection (pos. 3)
3. Detach lifting gear (pos. 1)
4. Mount attachment axle (pos. 4)
5. Attach adapter (pos. 5)
6. Attach mower unit to tractor´s lifting gear
Attach front mower to the lifting gear
When doing this, please also note instructions in the chapters
on
- Adjustments Front-Mower
- Special Attaching Kits
Establish power supply
Important!
* Observe the cable connection sequence, otherwise
operation through the control console will not function.
1. Connect the control console cable to the switch box (E1)
2. Connect the power supply cable from the tractor (E2,E3)
E2
E3

Driving on public roads
• Observe the official regulations of your country.
• Travellingon open roadsmayonly be carried outasdescribed
in chapter "Transport position".
• Protection devices must be in proper condition.
• Before travelling bring all swivelling parts into their correct
positionsandsecureagainstdangerouschanges to position.
• Check that lighting functions before travelling.
• Important information can also be found in the supplement
of this operating manual.
Hydraulic lower link
• Fix the hydraulic lower link (U)
insuch a way that the machine
cannot swing out sideways.
Transport position
134-01-17
”SELECT CONTROL” device
Press the relevant button to preselect the desired hydraulic function. If one
of the two arrow buttons (A1, B1) are pushed afterwards, the desired
hydraulic function will be carried out.
If a malfunction occurs: see "Establsih power supply" in the
chapter "ATTACHING TO TRACTOR"
How to carry out desired hydraulic function
1. Press the button for desired function
- The control light (LED) integrated in the button lights up.
- Through pressing any other button, the hydraulic function already
selected will be deactivated, and the new hydraulic function activated.
- Pressing button a second time deactivates the hydraulic function once
more.
2. Press one of the two arrow buttons (A1, B1)
- and the desired hydraulic function will be carried out
3. Deactivating the hydraulic function
- Press button, the integrated control light (LED) goes off.
- The hydraulic function has been deactivated.
Safety warning: always deactivate the selected function.
Control light (LED)
If one of the control lights (LEDs) lights up, it means that that particular
function has been activated.
The example on the illustration above shows
- The top left integrated control light (LED) is on
- Swing action of left mower unit has been activated
134-01-18
SELECT CONTROL
134-01-01
LED
A1 B1
GB TRANSPORT POSITION
- 12 -
0200-GB TRANSPORT_384

GB TRANSPORT POSITION
- 13 -
0200-GB TRANSPORT_384
”SELECT CONTROL” device
Alwaysput control devicein aweather-protected place.
Meaning of the buttons on the control device
10 ON / OFF button
Important! After switching off the control device (OFF):
- switch hydraulic control valve to the 0 position. This is
absolutely essential in the case of tractors with an open
hydraulic system - otherwise the oil will overheat.
11 Swings all mower units up and down
Conversion from operating to transport position and vice versa (see
button 15 also)
12 Swings front mower up and down
13 Swings left mower unit up and down
14 Swings right mower unit up and down
15 Swings all mower units up and down in the field transport position
(headland turns)
A1 Downward swing movement "Lower"
B1 Upward swing movement "Raise"
Conversion from working to transport position
Safety Precaution!
• Changing from working position to transport position is only to be carried out on even,
firm ground.
• Only transport the machine in the transport position!
• Before swivelling the cutter bar up, turn off the drive and wait for the mower discs to come to a complete
standstill.
• Make sure that swivel area is free and that nobody is standing in the danger area.
SELECT CONTROL
134-01-02
A1 B1
11 10
12 15
13 14
Conversion from operating to transport position
1. Press button 15
2. Briefly press button B1
Mower units swing into the field transport position (end-
of-run turns)
3. Press button 11
4. Press button B1 and hold
Mower units swing into road transport position
Conversion from transport to operating position
1. Press button 15
2. Press button A1
Conversion from operating to field transport position (headland turns)
1. Press button 15
2. Briefly press button B1
The mower units swing upwards (with delayed action);
first the front mower, and then both side mowers
Conversion from the field transport position (headland turns) to
operating position
1. Button 15 must be activated (LED lights up)
2. 2. Briefly press button A1
The mower units swing downwards (with delayed action);
First the front mower, and then both side mowers
Important
Each mower unit can also be individually swung upwards and downwards.
1. Select desired hydraulic function (12, 13, 14)
2. Press button (A1, B1)

Take care when turning on slopes!
The tractor's travelling characteristics are influenced by the
weight (G) of the mower unit. This can lead to dangerous
situations, especially on slopes.
Danger of tipping occurs
• when the mower units are in a raised position
• when travelling in a curve with the mower units raised
Safety advice
• Reduce speed in curves accordingly.
• It is better to travel in reverse on a slope than to carry out a risky
turning manoeuvre.
TD79/98/05
G
0100-GB HANGFAHRT_384
- 14 -
WORKING ON SLOPES
GB

Important points before starting work
Safety hints:
see supplement-A1 points 1. - 7.)
After the first hours of operation
• Retighten all knife screw fittings.
Safety hints
1. Check
- Check the condition of knives and the knife holder.
- Checkcutting drums fordamage(see also chapter "Maintenance").
2. Switch-on the machine only in working position and do
not exceed the prescribed power take-off speed (for
example max. 540 rpm).
A transfer, which is located near the gear, advises which p.t.o.
speed your mower unit is equipped for.
• Turnthe p.t.o. ononlywhen all safetydevices(coverings, protective
aprons, casings, etc.) are in proper condition and attached to the
implement in the correct protective positions.
3. Pay attention to correct p.t.o. direction of
rotation!
4. Damage protection!
• Thesurface to bemowedmust be freeofobstructions
or foreign objects. Such objects (e.g. large stones,
pieces of wood, boundary stones, etc.) can damage
the mower unit.
In the event of a collision
• Stop immediately and switch off the drive.
• Carefully check the implement for damage. The mowing discs
and their drive shaft must be checked in particulare.
• Have the implement checked also by a specialist workshop if
necessary.
After any contact with foreign objects
• Check the condition of knives and the knife holder (see chapter
"Maintenance and service").
• Retighten all knife screw fittings.
4. Stay clear while engine is running.
- Keep people out of the danger zone - foreign bodies which can be
ejected by the mower could injure them.
Special care is necessary on or near stony ground.
5. Wear hearing protection
The noise level in the workplace can deviate from
the measured value (see Technical Data) partly
because of the differing cabin types of various
tractors.
• If a noise level of 85 dB (A) is reached or
exceeded, the farmer must have suitable hearing
protection in readiness (UVV 1.1 §2).
• If a noise level of 90 dB (A) is reached or exceeded, the hearing
protection must be worn (UVV 1.1 § 16).
bsb 447 410
540 Upm 1000 Upm
TD8/95/6a
01-00-10
4a
0200-GB EINSATZ_384
- 15 -
GB
STARTING WORK

0200-GB EINSATZ_384
- 16 -
GB
STARTING WORK
Operation
1. Adjust cutting height by turning upper link spindle
(inclination of the cutting discs max. 5°).
2. To mow, gradually supply power to the p.t.o. before
entering the crop and bring the mowing discs up to full
revs.
Smoothly increase the p.t.o. speed, in order to avoid noises in the
free-wheel conditioned by the system.
- Adjust travel speed to terrain and crop.
Adjustment:
- The drive shaft (GW) position should be approximately horizontal
when mowing.
- Frame horizontal.
- Fixhydraulic lower links in a way that the machine cannot swing out
sideways.
TD25/90/8
16
TD 79/98/01
15

0200-GB EINSATZ_384
- 17 -
GB
STARTING WORK
Collision safety device:
Whenmowingaroundtrees, fences,boundary stonesetc.,collisions
between the cutter bar and obstacles can occur despite careful
and slow driving. Therefore, in order to prevent such damage,
collision protection has been planned for the cutting device.
Attention!
It is not the intention of the collision safety device to prevent
damage to the machine when working at full speed.
How the hydraulic collision safety device
functions
When a collision with an obstacle occurs, the cutter bar swivels
back far enough for it to pass by.
Then the cutter bar can be swivelled back hydraulically into the
operating position.
To do this, actuate the double-action control valve (ST).

GB CONDITIONER
- 18 -
0200-GB AUFBEREITER_384
Mowing with the conditioner
The conditioning effect can be modified:
- with lever (13), which adjusts the gap between adjustable plate
and rotor. The conditioning effect is most intense with the lever at
the bottom of its travel (Pos. 3).
However the crop should not be chopped.
Correct belt tension
Check X2 size
NOVACAT 7800: X2 = 164 mm(side mowers)
NOVACAT 8600: X2 = 164 mm (side mowers)
064-01-019
Stahl
steel
acier
Z1
Z2
X2
083-01-018
Position of the rotor prongs
Pos. Z1: position of the rotor prongs for normal operating conditions
Pos. Z2: for difficult operating conditions if for example the chuck
wraps around the rotor
The rotor prongs turn 180° (pos.Z2). This prong position removes the
problem in most cases. The preparation effect is thereby somewhat
reduced.
700 r.p.m. for rotor
- less damage to crop
Pulley, belt and belt guard must be replaced.
See replacement parts list for parts.

GB CONDITIONER
- 19 -
0400-GB AUFBEREITER_384
Dismounting and mounting the conditioner
Reduce spring tension before dismounting the
conditioner
Pin bolt (18) in the relative position (a)
- see chapter "MAINTENANCE"
Otherwise the danger exists that the mounting frame
of the cutter bar could swivel up in jerks and jolts
when uncoupling the lower link
1. Dismounting cutter bar from tractor
(only in cutter bar Combination 3)
2. Loosen locking mechanism (1) and swing protection (2) up.
- engage protective frame in holder (3)
- left and right
3. Remove the belt protection (15) (Front-Mower)
3a. Remove the belt protection (2) and withdraw the drive shaft
(GW) from the gear (side mowers).

GB CONDITIONER
- 20 -
0400-GB AUFBEREITER_384
Front mower
3. Remove belts (3b)
- Release the tension using lever (3a) beforehand
Side mowers
3a. Remove belts
- Release the tension using lever (3) beforehand
4. Fit transport wheels (4)
- left and right