Pottinger NOVADISC 400 User manual

/PERATOR@SMANUAL
GB
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Ihre / Your / Votre • Masch.Nr. • Fgst.Ident.Nr.
.R
• Disc mower
99 389.GB.80I.0
NOVADISC 400 (Type PSM 389 : + . . 01001)

ALLG./BA SEITE 2 / 0000-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. Conrmation 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. As your
agricultural partner, we offer you quality and efciency 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 - 3 -
ALOIS PÖTTINGER Maschinenfabrik GmbH
A-4710 Grieskirchen
Tel. [phone]
Telefax [phone]
GEBR. PÖTTINGER GMBH
D-86899 Landsberg/Lech, Spöttinger-Straße 24
Telefon [phone] / 112
Telefax (0 81 91) 92 99-188
GEBR. PÖTTINGER GMBH
Servicezentrum
D-86899 Landsberg/Lech, Spöttinger-Straße 24
Telefon [phone] / 231
Telefax (0 81 91) 59 656
Machine checked according to delivery note. All attached parts removed. All safety equipment, drive shaft and operating
devices at hand.
Operation and maintenance of machine and/or implement according to operating instructions explained to the customer.
Tyres checked re. correct pressure.
Wheel nuts checked re. tightness.
Drive shaft cut to correct lenght.
Correct power-take-off speed indicated.
Fitting to tractor carried out: to three-point linkage
Trial run carried out and no defects found.
Functions explained during trial run.
Pivoting in transporting and operating position explained.
Information given re. optional extras.
Absolute 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
(in case of Landsberg equipment: to the company Landsberg)
- document B stays with the specialist factory delivering the machine.
- document C stays with the customer.

GB
TABLE OF CONTENTS
0800_GB-INHALT_389 - 4 -
Safety hints to observe in supplement!
Table of contents
WARNING SIGNS
CE sign .............................................................................................. 5
Meaning of warning signs ................................................................. 5
ATTACHING TO TRACTOR
Attaching implement to tractor.......................................................... 6
DISMOUNTING IMPLEMENT FROM TRACTOR
Dismounting implement from tractor................................................. 7
Parking in the open ........................................................................... 7
TRANSPORT POSITION
Transport position (T)......................................................................... 8
Starting position ................................................................................ 8
Changing to transport position.......................................................... 8
Road Transport.................................................................................. 9
Lighting during use on roads............................................................. 9
WORKING POSITION
Working position.............................................................................. 10
Changing to working position ......................................................... 10
STARTING WORK
Important points before starting work............................................. 11
Safety hints...................................................................................... 11
Turning manoeuvre when mowing .................................................. 11
Take care when turning on slopes!.................................................. 12
MOWING
Mowing............................................................................................ 13
General Guidelines when Working with Implement........................ 13
Collision Safety Device.................................................................... 13
Hint.................................................................................................. 14
Fitting optional extras...................................................................... 14
SWATHFORMER
Swath Disc ...................................................................................... 15
Conveyor drums (Optional extra) .................................................... 15
Flat cone conveyor (Optional extra) ................................................ 15
MAINTENANCE
Safety point ..................................................................................... 16
General maintenance hints.............................................................. 16
Cleaning of machine parts .............................................................. 16
Parking in the ope ........................................................................... 16
Winter storage ................................................................................. 16
Drive shafts...................................................................................... 16
Hydraulic unit .................................................................................. 16
Angular gear oil level check ............................................................ 17
Ölwechsel Winkelgetriebe ............................................................... 17
Cutter bar oil level check .............................................................. 18
Cutter bar ........................................................................................ 19
Installing cutter blades ................................................................... 19
V-belt Drive...................................................................................... 20
Checking wear on mowing blade holders....................................... 21
Holder for a quick change of cutter blades..................................... 22
Checking the mowing blade suspension ........................................ 22
Changing the Cutter Blades ........................................................... 22
Changing the Cutter Blades (from 2004 model).............................. 23
Storing the lever .............................................................................. 23
TECHNICAL DATA
Technical data ................................................................................. 24
The dened use of the mower unit.................................................. 24
Optional equipment:........................................................................ 24
Necessary connections ................................................................... 24
Position of Vehicle Identication Plate ............................................ 24
SUPPLEMENT
Driveshaft ........................................................................................ 28
Lubrication chart ............................................................................ 30
Lubricants ....................................................................................... 32
Attachment variations...................................................................... 34
Repairs on the cutter bar................................................................. 36
Combination of tractor and mounted implement............................ 37

- 5 -
9700_GB-Warnbilder_361
GB
Warning signs
Stay clear of swinging area of implements
Close both side protective coverings before engaging
p.t.o..
Never reach into the crushing danger area as long as
parts may move.
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.
Recommendations
for work safety
All points referring
to satety in this
manual are
indicated by this
sign.
bsb 447 410
495.167

- 6 -
0400-GB ANBAU_389
GB
attaching to tractor
Attaching implement to tractor
1. Horizontally set lifting gear's lower link
2. Attach implement to three-point linkage.
- Attach mower unit so that gap between inner cutting discs
and tractor tyres is 0 - 10 cm.
- Insert lower link pins (1) into supporting frame accoeding to
three-point category and track width.
- with dual wheels or particularly wide tyres, see notes in the
supplement of this operating manual.
3. Connect hydraulic snap-connector (DW)
DW = double-action hydraulic
connection
4. Run stop-lock support release rope (S) into tractor
Safety hints:
see supplement-A1 Pkt. 8a. - h.)
5. Set upper link spindle
- By turning upper link spindle (16) cutter is brought into a
horizontal or a slightly forward inclined position.
6. Secure lower link (4) against sideways movement.
7. Swing support stand (5) up and secure.
• The implement is now completely attached to the tractor.
- Before initial operation, check drive shaft length and adapt if
necessary (see chapter “Adapting to Drive Shaft” in Supplement
B also).
0 - 10 cm
Td 39/96/3
174-04-11

- 7 -
0400-GB-ABBAUEN_385
GB
Dismounting implement from tractor
3. Swing support stand down and secure (F)
4. Lower implement to the ground using lifting gear.
5. Dismount implement from
tractor
Safety note!
Beforedismounting, check
thelockingdeviceproperly
(F), otherwise danger of
tipping!
- disconnect hydraulic lines
- disconnect upper link
- remove rope from tractor cabin
- disconnect lower link
- disconnect drive shaft and lay it down (GW)
Parking in the open
When parking in the open for long periods of time, clean plunger
rods and then coat with grease.
Note
A rusty plunger
rod can damage
cylinder's sealing
elements.
At season's end
- clean plunger rod and all other shiny parts, then grease them
ST-24-11-2003
FETT
Td 39/96/18
Dismounting implement from tractor
1. Raise stop-lock support rope (S)
- Stop-lock support to position "B"
2. Lower cutter bar
hydraulically to the
ground
- actuate servo-valve (ST)
- release the rope (S) during
lowering

- 8 -
0401-GB-TRANSPORT_385
GB
transport position
Changing to transport position
1. Fold front protection covers back (1).
This is necessary with many tractor types. It prevents damage
to the rear window or the mud guard later on when raising the
mower bar.
2. Raise stop-lock support using the rope (S).
- stock-lock support to position "B"
3. Raise cutter bar hydraulically
- actuate servo-valve (ST)
- release rope (S) during raising
- let stop-lock support engage (T1)
4. Briefly move servo-valve (ST) into "LOWER" position
(S)
This enables stop-lock support to sit firmly in the catch (T1) and
secures cutter bar in the raised position (T)
NOVADISC 225, 265, 305, 350 NOVADISC 400
Transport position (T)
Safety Precaution!
see supplement-A1 points 7.), 8c. - 8h.)
Changingfromworkingpositiontotransportposition
is only to be carried out on even, firm ground.
Never let the mowing mechanism run with the
mower raised.
- Before you leave the tractor, lower the machine on to ground!
Starting position
Implement is attached to tractor
- see chapter "Ataching implement to tractor"
Support stand swung up and secured.

- 9 -
0401-GB-TRANSPORT_385
transport position GB
NOVADISC 225, 265, 305, 350
NOVADISC 400
Lighting during use on roads
If desired, a lighting unit can be supplied (1).
For single parts see spare parts list.
- Connect lighting and raise appliance for transport.
Road Transport
• Observe the regulations issued by your country's legislative
body.
• Travelling on public roads may only be undertaken as is described
in the chapter "Transporting Position".
• Fasten lower hydraulic link so that implement cannot swing out
sideways.

- 10 -
0400-GB ARBEITSSTELLUNG_385
GB
Working position
Working position
Safety Precaution!
see supplement-A1 Pkt. 7.), 8c. - 8h.)
Changingfromtransportpositionto workingposition
is only to be carried out on even, firm ground.
• Make sure that
swivel area is free
and that nobody
is standing in the
danger area.
Starting position for lowering the cutter bar
1. Implement is attached to tractor
- see chapter "Attaching implement to tractor"
2. Cutter bar in transport position
3. Support stand swung up and
secured
3. Set height of lifting gear (H1)
This lifting gear position (H1) does not need to be changed when
mowing or turning (see next page).
Using the tractor's lifting gear, raise or lower the implement until
a gap of about (H1 = 0) is achieved.
Adjusting the floor bearing load of the mowing bar
H1 = 0 Carry out basic setting
H1 + Decrease bearing pressure
H1 – Increase bearing pressure
4. Close front protection covers (5a)
• Operation only with closed protection covers.
Changing to working position
Swinging the cutter bar down.
1. Raise stop-lock support using rope (S)
- Put hydraulic control device (ST)briefly at "lift", in so doing the
fixing of the stop-lock support is eased in the catch.
- Stop-lock support to position "B"
2. Lower cutter bar hydraulically to the ground
- Move hydraulic control valve (ST) to the “LOWER” position
(S)
- release rope (S) during lowering
- Move hydraulic control valve (ST) to the “FLOAT POSITION”
(only with double-action hydraulic control valve)
122-02-14
H1
A
E
TD 26/92/16
s
h
0
ST

0200-GB INBETRIEBN_385 - 11 -
GB
starting Work
After any contact with foreign objects
• Check the condition of knives and the knife holder.
• Retighten all knife screw fittings.
5. 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.
6. 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.
• Ifanoiselevelof85 dB(A)isreachedorexceeded,
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).
Turning manoeuvre when mowing
The cutter bar can be raised hydraulically (22°).
- The drive must not be turned off to do this.
- The lifting gear's (H1) position does not need to be altered
when turning.
Attention!
Do not enter the mower unit area as long as the
drive is running.
Important points before starting work
Safety hints:
see supplement-A Pkt. 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.
- Check cutting drums for damage (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.
• Turn thep.t.o.on onlywhenallsafety devices(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!
• The surface to be mowed must be free of obstructions or foreign
objects.Suchobjects (e.g. largestones,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 (4a).
• Have the implement checked also by a specialist workshop if
necessary.
bsb 447 410
540 Upm 100 0 U pm
Td8/95/6a
Td 18/96/1
4a

(358) 9500-GB HANGfAHRT - 12 -
Working on slopes GB
Take care when turning on slopes!
Thetractor'stravelling characteristicsare 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 unit is facing downhill and in a raised position,
- when travelling in a left-hand curve with the mower unit raised,
- whentravelling in a left-handcurve in the transportposition(mower
unit completely raised).
Safety advice
• Reduce speed in left-hand curves accordingly.
• Travel so that the raised mower unit is facing uphill.
• It is better to travel in reverse on a slope than to carry out a risky
turning manoeuvre.
TD15/95/3
G
TD15/95/2
TD15/95/4

- 13 -
0400-GB EINSATZ_385
GB
moWing
General Guidelines when Working with
Implement
- The mower unit is suitable for gradients of between +22° and
-30°.
Collision Safety Device
Whenmowingaroundtrees,fences,boundarystonesetc.,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
deviceto prevent damagetothe machinewhen working
at full speed.
- Overload device (34) enables cutter bar to swing away when it
collides with an obstacle.
- The overload device is engaged again by reversing.
Adjustment:
In case the safety
device trips to
easy adjust he-
xagonal nut.
Adjusting measurement:
NOVADISC 225 = 127 mm
NOVADISC 265 = 120 mm
NOVADISC 305 = 116 mm
NOVADISC 350 = 112 mm
NOVADISC 400 = 108 mm
If you are not shure whether the cutting area is really
free of obstacles, please work at an appropriate slow
speed!
Mowing
1. Horizontally set lifting gear's lower link (Sp)
2. Adjust cutting height by turning upper link spindle
(16)
- cutter disc inclination: max. 5°
3. Set height of lifting gear (H1).
Adjusting the floor bearing load of the mowing bar
H1 = 0Carry out basic setting
H1 + Decrease bearing pressure
H1 – Increase bearing pressure
4. Before mowing, throw-in p.t.o. slowly outside crop and
bring mower drums up to full speed.
Noises conditional to p.t.o. free-wheel system can be prevented
through an even continious increase in r.p.m.
- Travelling speed is set according to ground conditions and
crop.
5. Hydraulic control valve (ST)
- Single action hydraulic control valve (ST) to “LOWER”
- Double-action hydraulic control valve (ST) to “FLOAT
POSITION”
122-02-17
16
495.779
kg
kg
H1+
H1–
H1 = 0

- 14 -
0400-GB EINSATZ_385
moWing GB
Hint
If the band A leads to interruption (accumulation of crop) under difficult conditions on the field (e.g. very long grass, low driving speed, mowing
on hillside), you can dismount the band with types Nova Disc 225 and 265. With type 305, 350 and 400 you are not permitted to dismount it.
So far you use one or two swathformers on the right side you must have mounted this band A at any time, valid for all types.
Variante
Variation
Varianta
Fitting optional extras

GB
- 15 -
0400-GB ScHwAdfORmER_389
sWathformer
Swath Disc
With the swath disc a narrower swath is formed when mowing.
This prevents them from being run over by the tractor‘s wide
tyres.
Flat cone conveyor (Optional extra)
Flat cone conveyors are recommended:
- to improve the conveyance rate of swath deposits, particularly
with heavy, thick fodder components
- For individual parts see Spare Parts List
122-02-39
Conveyor drums (Optional extra)
With the both conveyor drums two narrower swaths is formed
when mowing. This prevents them from being run over by the
tractor‘s wide tyres.

- 16 -
GB
0400_GB-BA-Allg. Wartung
Parking in the ope
When parking in the open for
long periods of time, clean
piston rods and then coat
with grease.
FETT
Safety
points!
• Turn engine off
when adjustment,
service and repair
work is to be
done.
• Do not work un-
der the machine
without safe
support.
• Retighten all
screws after the
first hours of
operation..
General maintenance hints
In order to keep the implement in
good condition after long periods
of operation, please observe the
following points:
- Tighten all screws after the first
hours of operation.
In particular check:
- blade screws on the mowers
- tine screws on the swather and tedder.
Spare part
a. The original components and accessories have
been designed especially for these machines and
appliances.
b. We want to make it quite clear that components and
accesories that have not been supplied by us have
not been tested by us.
c. The installation and/or use of such products can,
therefore, negatively change or influence the
construction characteristics of the appliance. We are
notliablefordamagescausedbytheuseofcomponents
and accessories that have not been supplied by us.
d. Alterations and the use of auxiliary parts that are
not permitted by the manufacturer render all liability
invalid.
Cleaning of machine parts
Attention! Do not use high-pressure washers for the
cleaning of bearing- and hydraulic parts.
- Danger of rust!
- After cleaning, grease the machine according to the
lubrication chart and carry out a short test run.
- Cleaning with too high pressure may do damage to
varnish.
Safety point
• Turn engine off when adjustment, service and repair
work is to be done.
Hydraulic unit
Caution! Danger of injury or infection!
Under high pressure, escaping fluids can penetrate
the skin. Therefore seek immediate medical help!
After the first 10 operating hours and then every
consecutive 50 operating hours
- Check the hydraulic unit and lines for tightness and
retighten screw connections if necessary.
Before operation
- Check hydraulic hoses for wear.
Replacewornordamagedhydraulichosesimmediately.
The replacement hoses must meet the manufacturer’s
technical requirements.
Hose lines are subject to natural ageing. The period of
use should not exceed 5 – 6 years.
Winter storage
- Thoroughly clean machine before storage.
- Put up protection against weather.
- Change or replenish gear oil.
- Protect exposed parts from rust.
- Lubricate all greasing points according to lubrication
chart.
Drive shafts
- see notes in the supplement
For maintenance please note!
The instructions in this operating manual are always
valid.
In case there are no special instructions available, then
thenotesintheaccompanyingdriveshaft manufacturer´
instructions are valid.
Repair In-
structions
Please refer to
repair instructions
in supplement (if
available)
maintenance

0800-GB WARTUNG_389
GB
Maintenance and Service
- 17 -
Angular gear oil level check
- Change oil after the first 50 operating hours.
Under normaloperating conditions,oilis tobereplenishedannually
(OIL LEVEL).
- Change oil after 300 ha at the latest.
Quantity:
0,95 lt. SAE 90
OIL LEVEL
Angular gear oil change
1. Raise cutter bar and bring into vertical position
* See transport position
2. Place suitable container underneath
3. Remove hexagonal screw (E) completely and drain old
oil into container
- Dispose of old oil properly
4. Lower cutter bar and bring into horizontal position
* See working position
5. Close the drain outlet with the hexagonal screw (E)
6. Fill with oil
• Too much oil leads to the mower bar overheating
during operation.
• Too little oil does not guarantee the necessary
lubrication. 1)
1) The oil filler plug (63) is also the level screw (OIL LEVEL)

0800-GB WARTUNG_389
GB
Maintenance and Service
- 18 -
Cutter bar oil level check
• Under normal operating conditions, oil is to be replenished
annually.
1. Lift one side of the mower bar (X1) and support.
NOVADISC 400: X1 = 35,5 cm
• The side where the oil refill screw is located remains on the
ground.
• Lift the other side of the mower bar about X1 and support with
a suitable prop.
2. Let mower bar stand in this position for some 15
minutes.
• This time is necessary to allow the oil to gather in the lower
area of the mower bar.
3. Remove oil refill screw (63).
The oil level is measured at the oil refill screw hole.
Important!
In doing so the cutter bar must be in horizontal position.
- Take out oil filler plug (63) and top up oil „SAE 90“ up to the level
screw1).
4. Oil level check
The oil level is correct when the oil comes up to the level screw1)
(OIL LEVEL).
• Too much oil leads to the mower bar overheating
during operation.
• Too little oil does not guarantee the necessary
lubrication
1) The oil filler plug (63) is also the level screw (OIL LEVEL)

0800-GB WARTUNG_389
GB
Maintenance and Service
- 19 -
Cutter bar-oil change
Changing oil
- Change oil after the first 50 operating hours or after 100 ha at the latest.
Note:
• Change oil when at operating temperature.
The oil is too viscid when cold. Too much old oil remains stuck to the gearwheels and because of
this any suspended matter present cannot be removed from the gearing
Quantity:
NOVADISC 400: 5,0 liter SAE 90
- Raise tractor’s lifting gear completely.
- Move hydraulic control device (ST) to
”LOWER”
- The outer end of the cutter bar must hang
down.
- Take out oil drain plug (62), let run out and
duly dispose waste oil
ST-24-11-2003
Installing cutter blades
Take note!
The arrow on the cutter blade shows
the cutter disc‘s direction of turn.
-To install, clean back plates from
varnish.
TD 121-02-06
NOVADISC 265
NOVADISC 225
NOVADISC 350
NOVADISC 400
NOVADISC 305

0800-GB WARTUNG_389
GB
Maintenance and Service
- 20 -
V-belt Drive
- check V-belt tension
after 1 hour, after 5 hours, after 20 hours, then as necessary
Setting range:
0.5 – 3 mm
• Retensioning is only necessary when the setting becomes more than 3 mm.
• If one of the 4 V-belts is damaged or stretched, then all 4 V-belts should be exchanged
IMPORTANT!
If the V-belts are tensioned too taut, the danger exists of the bearing and shafts becoming damaged.
540 min
-1
1000
min
-1
122-02-19
540 min
-1
1000 min
-1
0,5 - 3mm