Pottinger NOVACAT 8600 ED Operating instructions

/PERATOR@S MANUAL

GB

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4RANSLATION OF THE ORIGINAL /PERATING -ANUAL

Ihre / Your / Votre • Masch.Nr. • Fgst.Ident.Nr.

.R

• Disc mower

99 384.GB.80J.0

NOVACAT 8600

(Type PSM 384 : + . . 01403)

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. 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. As your

agricultural partner, we offer you quality and efficiency 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.

Pöttinger Newsletter

www.poettinger.at/landtechnik/index_news.htm

The latest expert information, useful links and entertainment

Dokument D

GB-0600 Dokum D Anbaugeräte

PÖTTINGER Landtechnik GmbH

Industriegelände 1

A-4710 Grieskirchen

Tel. 07248 / 600 -0

Telefax 07248 / 600-2511

T Machine checked according to delivery note. All attached parts removed. All safety equipment, drive shaft and operating

devices at hand.

T Operation and maintenance of machine and/or implement according to operating instructions explained to the customer.

T Tyres checked re. correct pressure.

T Wheel nuts checked re. tightness.

T Drive shaft cut to correct lenght.

T *VYYLJ[WV^LY[HRLVɈZWLLKPUKPJH[LK

T Fitting to tractor carried out: to three-point linkage

T Trial run carried out and no defects found.

T Functions explained during trial run.

T Pivoting in transporting and operating position explained.

T Information given re. optional extras.

T 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 or via the internet to www.poettinger.at

- document B stays with the specialist factory delivering the machine.

- document C stays with the customer.

- 4 -

GB

TABLE OF CONTENTS

0800_GB-Inhalt_384

Recommendations

for work safety

All points refering

to safety in this

manual are

in di ca ted by this

sign.

Table of contents

WARNING SIGNS

CE sign ............................................................................5

Meaning of warning signs ...............................................5

ATTACHING TO TRACTOR

Attaching implement to tractor .......................................6

To make the connection to the tractor ............................7

Connecting the Sensor and valve cables from front

mower unit .......................................................................7

Fitting drive shaft ............................................................7

Hydraulic connection.......................................................8

Observe rotation direction of cutting discs .....................9

Combination 3 ...............................................................10

Combination 2 ...............................................................11

TRANSPORT

Conversion from working to transport position .............12

Raising for road transport..............................................12

Lowering into field transport position ............................12

Driving on public roads .................................................13

Transport position ..........................................................13

Unhitch device from tractor ...........................................14

Working on slopes .........................................................15

”DIRECT CONTROL” DEVICE

Meaning of the buttons on the control device ..............16

How to carry out desired hydraulic function .................16

Settings before initial operation .....................................17

Other settings ................................................................18

Setting time difference – Raising/lowering front mower

and side mower .............................................................19

Conversion from working to transport position .............20

ISOBUS - TERMINAL

Operation ISO-terminal .................................................22

Button indication ...........................................................23

Joystick - Mower Configuration ....................................25

Setting the Joystick .......................................................25

OPERATION

Important points before starting work ...........................26

Mow ...............................................................................27

Collision safety device ...................................................27

CONDITIONER

Mowing with the conditioner .........................................28

Correct belt tension .......................................................28

700 r.p.m. for rotor .........................................................28

Position of the rotor prongs ...........................................28

Dismounting and mounting the conditioner ..................29

Mowing without Conditioner .........................................32

Optional extra ................................................................32

ROLLER CONDITIONER (NOVACAT 266 F, 306

F)

Settings .........................................................................34

Cleaning and maintenance ............................................34

SET THE POSITIONS OF THE GUIDING PLATES

"Extra dry" system.........................................................35

Swathes .........................................................................35

Spread width .................................................................35

Dismount guide plate ....................................................36

Mount guide plate .........................................................36

SWATH DISCS

Swath Discs ...................................................................37

Flat cone conveyor (Optional extra) ..............................37

MAINTENANCE

Safety point ...................................................................38

General maintenance hints ............................................38

Cleaning of machine parts ............................................38

Parking in the ope .........................................................38

Winter storage ...............................................................38

Drive shafts ....................................................................38

Hydraulic unit ................................................................38

Oil change on cutter bar ................................................39

Gearing maintenance ....................................................40

Installing cutter blades .................................................40

Setting the field transport position (end-of run turns) ...41

Disruptions and remedies to power failure ...................42

Checking wear on mowing blade holders .....................44

Holder for a quick change of cutter blades ...................45

Checking the mowing blade suspension ......................45

Changing the Cutter Blades (up to 2003 model) ...........45

Changing the Cutter Blades (from 2004 model) ............46

Storing the lever ............................................................46

TECHNICAL DATA

Technical data ...............................................................47

Necessary connections .................................................47

The defined use of the mower unit ................................48

Position of Vehicle Identification Plate ..........................48

SUPPLEMENT

Recommendations for work safety ..............................51

Driveshaft ......................................................................52

Lubrication chart ...........................................................54

Lubricants ......................................................................57

Sensor diagnostic function ............................................59

Display for Software version..........................................59

Function check for "Direct Control" operating unit and

job calculator .................................................................59

Repairs on the cutter bar ...............................................63

TAPER BUSHES

Taper bushes installation instructions ...........................64

Combination of tractor and mounted implement ..........65

- 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 out ward ly that this machine

con forms 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 ma nu fac tu r er 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

in di ca ted by this

sign.

bsb 447 410

495.167

- 6 -

0700_GB-ANBAU_3841

GB

ATTACHING TO TRACTOR

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.

- The drive shaft (GW) should be about horizontal

when mowing.

This height allows optimal evenness when working on

uneven ground and need not be changed for swinging

cutter bar up.

TD 79/98/01

15

Attaching implement to tractor

Safety hints:

see supplement-

A1 points 7.), 8a.

- 8h.)

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)

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.

- 7 -

0700_GB-ANBAU_3841

GB

ATTACHING TO TRACTOR

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.

Connecting the Sensor and valve cables from front mower unit

Electrical able connections between front mower

unit and mower combination

• 3 channel cable for sensor kit (1)

To make the connection to the tractor

Operation:

- Connect the 3-channel plug to the DIN 9680 socket

on the tractor

Lighting:

- Connect 7-channel plug to tractor

- Check that lighting is functioning on wagon

For tractors with ISO Bus control

- Connect 9-channel ISO plug to ISO Bus socket on the

tractor

Important!

Before putting

the tractor into

operation check

vehicle safety

(lights, brake

unit, protective

covering, .....).

- 8 -

0700_GB-ANBAU_3841

GB

ATTACHING TO TRACTOR

7

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

Settings

Screw (7) on the hydraulic unit must also be adjusted

accordingly.

Important!

Disconnect electrical connection

Tractors with a "Load sensing" system

- 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

- Screw (7) on the hydraulic unit must be screwed in all

the way

Tractors with a open hydraulic system

- Completely unscrew screw (7) on the hydraulic unit

Hydraulic connection

- 9 -

0700_GB-ANBAU_3841

GB

ATTACHING TO TRACTOR

- Select appropriate rotation direction for the drive

- If the necessary p.t.o. rotation direction cannot be

selected from the tractor, rotate the mechanism (G)

180°.

Note!

Before reinstalling a gearing on the

machine:

- Swap ventilation screw and drain plug

positions.

- The correct ventilation screw position is

on top.

180°

G1

Observe rotation direction of cutting discs

- 10 -

0600_GB-ANBAUTEILE_384

GB

ATTACHING TO TRACTOR

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)

- when doing this, please note instructions in chapter

on Adjustments

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).

- 11 -

0600_GB-ANBAUTEILE_384

GB

ATTACHING TO TRACTOR

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

Combination 2

- 12 -

0700_GB-TRANSPORT_384

GB

TRANSPORT

Raising for road transport

This button will only function when all cutting bars are in

the field transport position (FT)

- Turn drive off and wait for standstill

- Swing in all hoop guards on the cutting bars

Variant with "Power Control"

Press button to activate its function

Press button and all cutting bars swivel until

the end position is reached.

Variant with "ISOBUS-Terminal"

Briefly press Softkey button,

function is activated

Briefly press Softkey buton,

all mower units swivel to the end position

Lowering into field transport position

Variant with "Power Control"

Press button to activate its function

Press button and all mower units swivel to

field transport position (FT)

Variant with "ISOBUS-Terminal"

Briefly press Softkey button,

function is activated

Briefly press Softkey button,

all mower units swivel to field transport position

(FT).

- Swing out all hoop guards on the mower

• 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.

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!

- 13 -

0700_GB-TRANSPORT_384

GB

TRANSPORT

Transport position

Driving on public roads

• Observe the official regulations of your country.

• Driving on public roads must be carried out in the

transport position only

• Protection devices must be in proper condition.

• Before travelling bring all swivelling parts into their

correct positions and secure against dangerous

changes 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) in such a way that the

machine cannot swing out sideways.

max. 4000

200

3000

- 14 -

0700_GB-TRANSPORT_384

GB

TRANSPORT

Unhitch device from tractor

Caution!

Only park the mower combination in the

working position (both mower units are

folded down). Maximum danger of tipping

over if the mower combination is parked

in the transport position.

278-09-16

Safety

note:

Only park the disc

mower on firm,

level ground and

ensure a secure

position.

0100-GB HANGFAHRT_384 - 15 -

OPERATION GB

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

Working on slopes

GB

- 16 -

1000-GB DIRECT CONTROL_384

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.

1. Press the button for desired function (11-15)

- 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

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)

• “load sensing” hydraulic system (LED 11)

12 Swings front mower up and down

13 Swings left mower unit up and down

Rotor r.p.m on the conditioners

1019 min-1/844 min-1

14 Swings right mower unit up and down

Rotor r.p.m on the conditioners

771 min-1/639 min-1

15 Swings all mower units up and down in the

field transport position (headland turns)

A1 Downward swing movement "Lower"

Closed hydraulic system (LED A1)

B1 Upward swing movement "Raise"

Open hydraulic system (LED B1)

Meaning of the buttons on the control device

Note!

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

Control light (LED)

If one of the

control lights

(LEDs) lights up,

it means that

that particular

function has been

activated.

Example:

- The top left

integrated control

light (LED) is on

- Swing action

of left mower

unit has been

activated

”DIRECT CONTROL” DEVICE

GB”DIRECT CONTROL” DEVICE

- 17 -

1000-GB DIRECT CONTROL_384

In general

Before initial

operation, various

selections must

be made using the

“Direct Control”

operation unit.

These selections

are particularly

important so that

the electronic

monitoring

systems are

functioning

correctly.

Settings before initial operation

After turning on the operation panel (ON)

The following LED will light up for about 0.5 secs:

* the LED for the selected hydraulic system

* the LED for the r.p.m. of the conditioner rotors

Selecting the hydraulic system

1. Make the connection to the switch box (E1)

Couple power supply cable to tractor (E2)

2. Press and hold down the button for the hydraulic system

needed

A1 = closed hydraulic system (LED A1)

B1 = open hydraulic system (LED B1)

11 = “load sensing” hydraulic system (LED 11)

3. Zusätzlich die Taste "I/O" (10) drücken.

After about 5 seconds the relative LED lights up briefly

and the selected hydraulic system is stored.

When the storing process is completed, a short signal

is heard.

4. Release the button (A1, B1, 10, 11)

Setting the r.p.m of the conditioner

rotors

1. Make the connection to the switch box (E1)

2. Press and hold down the button for the drive variant

needed

Variant 1: Button 13

Rotor r.p.m on the left and right conditioner: 1019

min-1

Rotor r.p.m on centre conditioner: 844 min-1

Variant 2: Button 14

Rotor r.p.m on the left and right conditioner: 771 min-

1

Rotor r.p.m on centre conditioner: 639 min-1

3. Couple power supply cable to tractor (E2)

After about 5 seconds the relative LED lights up briefly

and the selected drive variant is stored.

When the storing process is completed, a short signal

is heard.

4. Release the button (13, 14)

GB”DIRECT CONTROL” DEVICE

- 18 -

1000-GB DIRECT CONTROL_384

In general:

During operation the desired r.p.m of each individual

conditioner is monitored.

If the desired r.p.m. of a conditioner drops more than 180

min-1, a signal is heard and the LED of the respective button

on the switch panel blinks quickly (12, 13, 14).

Other settings

Monitoring the r.p.m. of the conditioner rotors

Elapsed time will start to be counted as soon as the r.p.m

of the p.t.o exceeds 300 min-1.

Elapsed time can be read on the LCD indicator inside the

job calculator housing.

Elapsed time is displayed in the following format

alternating with sensor diagnostics:

Elapsed time < 100:

14:36

Elapsed time < 100>

0346

Cancelling: When the r.p.m increases again, the whistling

and blinking passes at a slow rate. Only now can the

button be pushed (cancelling) and the whistling and

blinking will cease.

Note: In every instance the reason for the drop in r.p.m must

be eliminated otherwise cancelling cannot take place.

- Decrease speed,

- remove blockage,

- repair plug connection and cable.

- replace faulty sensor.

Monitoring only functions when the sensor is plugged in

and is not faulty.

The p.t.o is monitored in order to prevent any damage to

the cardan shaft when swinging the side mower unit out

over the field transport position

The button 11 function (road transportation)

can only be selected when the p.t.o sensor

hasn’t sent any impulses for at least 8

seconds.

- Drive shafts should no longer be turning.

Monitoring the r.p.m. of the p.t.o.

Elapsed time meter

GB”DIRECT CONTROL” DEVICE

- 19 -

1000-GB DIRECT CONTROL_384

Setting time difference – Raising/lowering front mower and side mower

Note!

The set times

remain stored

until altered

Switching “time difference function” on/off:

Switching function on:

- Briefly press button 10 “I/O”

- The LEDs change colour to green

- By pressing button 15 all set time differences are

active

Switching function off:

- Briefly press button 10 “I/O”

- The LEDs change colour to red

- By pressing button 15 all mower units are

simultaneously raised or lowered

From 2007 model

Control with dual coloured light emitting diodes

(LEDs)

1. Change to other operation mode

- Briefly press button I/O

- the (LED) changes to green

2. Switch on programming mode:

- Press button 15 for 5 secs.

- The button LED should blink green

Setting time difference - raising

- Put control into programming mode

- Press button B1 (front mower raised)

To set the desired time difference keep pressing

button B1

- When button is released both side mowers are

raised and the time difference is stored.

- Programming mode ends automatically

Setting time difference - lowering

- Put control into programming mode

- Press button A1 (front mower lowered)

To set the desired time difference keep pressing

button A1

- When button is released both side mowers are

lowered and the time difference is stored

- Programming mode ends automatically

GB”DIRECT CONTROL” DEVICE

- 20 -

1000-GB DIRECT CONTROL_384

Conversion from operating to transport

position

1. Press button 15

2. Briefly press button B1

Mower units swing into the field transport position

(headland 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 11

3. Press button A1 and hold

Mower units swing into the field transport position

(headland turns FT)

4. Briefly press button A1

The mower units swing downwards (with delayed

action);

First the front mower, and then both side mowers; the

swivel cylinders remain in the floating position.

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.

Conversion from operating to field transport

position (headland turns FT)

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 FT) to operating position

1. Button 15 must be activated (LED lights up)

2. Briefly press button A1

The mower units swing downwards (with delayed

action);

First the front mower, and then both side mowers; the

swivel cylinders remain in the floating position.

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)

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