Malone 2600TC User manual

Procut 2600TC & 3000TC —User Manual
Operation Manual
PROCUT 2600TC & 3000TC
Malone Farm Machinery
Ballyglass, Claremorris
Co. Mayo, Ireland.
Tel [phone]
ISSUE: 1

2
Table of Contents
Section 1 General information ··························· 3
Section 2 Safety precaution······························· 4
Section 3 Assembly to tractor ···························· 7
Section 4 Transport ········································ 9
Section 5 Working position····························· 10
Section 6 Adjustments ···································11
Section 7 Operation······································ 14
Section 8 Storage ········································ 15
Section 9 Spare parts ···································· 15
Section 10 Maintenance and lubrication ··············· 16
Section 11 Troubleshooting ······························ 25

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Procut 2600TC & 3000TC —User Manual
Section 1 General information
Thank you for purchasing a Malone product. You have purchased one of the finest,
most advanced trailed disc mowers available. To fully utilize the qualities of the
mower, please ensure you read the manual, you will be rewarded in terms of longer
working life, greater safety, and better performance.
BEFORE INSTALLING AND USING THIS MACHINE READ
CARFULLY THE INSTRUCTIONS GIVEN IN THIS MANUAL
USING YOUR OPERATOR'S MANUAL
Read, Understand, and Follow the Messages in this Manual - doing so will promote
safe, productive, and reliable service.
This manual was prepared to help you properly use, service, and maintain your new
investment and to operate it safely. Reading your operator's manual will help you
and others avoid personal injury or damage to the machine. Pay close attention to all
cautions and warnings in this text. This machine can cause serious property damage,
personal injury, or even death if it is misused. For your safety, as well as the safety
of bystanders, you must follow the safety precautions in this operator’s manual.
This manual is an important part of your machine. It should remain with the ma-
chine if and when it is sold. If it is damaged or lost, you may contact your dealer, or
contact Malone at [phone] or www.malonefm.com to get a replace-
ment.
Before delivering this machine, your dealer performed a pre-delivery inspection to
ensure best performance.
If you have any queries, please contact Malone who will be able to give you the cor-
rect assistance and advice as soon as possible.
EC DECLARATION OF CONFORMITY
Conforms to EU Engineering regulations and other relevant EU guide-
lines.

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Section 2 Safety precautions
This symbol is used to call attention to instructions concerning per-
sonal safety.
Be sure to observe and follow these instructions.
WARNING: BEFORE ATTEMPTING TO OPERATE THIS MOWER, READ
AND STUDY THE FOLLOWING SAFETY INFORMATION. IN ADDITION,
MAKE SURE THAT EVERY INDIVIDUAL WHO OPERATES OR WORKS
WITH THE MOWER, WHETHER FAMILY MEMBER OR EMPLOYEE, IS
FAMILIAR WITH THESE SAFETY PRECAUTIONS.
• DO NOT operate, service, inspect or otherwise handle this mower until all op-
erators have read this Owner’s Manual and have been properly trained in the
intended usage of the mower.
• Do not allow minors (children) or inexperienced persons to operate this mower.
• Always shut off power and disconnect PTO drive shaft and unhook hydraulic
hoses (relieve hydraulic pressure) from tractor to prevent accidental start-up or
unexpected movement before working on machine.
• Do not clean, adjust, or lubricate while mower is in motion.
• Make sure all hydraulic fittings are tight and that all hoses are in good condi-
tion. Hydraulic fluid escaping under pressure can have sufficient force to pene-
trate skin and cause serious injury. Never investigate for hydraulic leaks by us-
ing a part of the body to feel for escaping fluid.
• Inspect when first delivered and regularly thereafter; that all connections and
bolts are tight and secure before operating.
• Do not operate until all shields, covers, and guards are in place.
• Make certain everyone is clear of the mower before applying power.
• Keep hands, feet and clothing away from moving parts. Loose or floppy cloth-
ing should not be worn by the operator.
• Do not step over the power take-off shaft. Stay clear of the PTO at all times..
• Never operate PTO above normal 1000 RPM rating. Tractors PTO MUST
match implement PTO.
• Never exceed a safe travel speed when transporting this mower
• Check local laws for all highway lighting and marking requirements.

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Procut 2600TC & 3000TC —User Manual
THE OPERATOR’S MANUAL AND DECALS ON THE MACHINE ITSELF
WARN YOU OF DANGERS AND MUST BE READ AND OBSERVED
CLOSELY. STUDY THE ABOVE SAFETY RULES - FAILURE TO HEED
MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
MEANING OF SAFETY LABELS
Stay clear of articulation area while the engine is running
The cutting unit can pose a crush hazard when the machine has
articulated.
Do not open or remove safety shields while engine is running
Removal of safety guards are not permitted while engine is operating.
Do not open or remove safety shields while engine is running
Removal of safety guards are not permitted while engine is operating.

6
Keep a safe distance from this machine.
Keep a safe distance from the machine. Do not allow any persons near
the machine. If any guard is broken, it must be replaced.
Shut off engine and remove key before performing maintenance or
repair work.
The tractor engine must always be turned off and the ignition key be
removed before carrying out any maintenance, cleaning or lubrication to
the machine.
Stay clear of mower blade as long as engine is running.
Safety guards must always be in place. Never place hands near moving
objects.
Wait until machine components have completely stopped before
touching them.
Do not come near the machine moving parts while the machine is in
operation. Stop the machine before coming near the unit.

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Procut 2600TC & 3000TC —User Manual
Section 3 Assembly to tractor
Attaching mower to tractor
It is designed to mount on Category II, 3-point hitch tractors. Two double-acting hy-
draulic connection must be available on the tractor.
Hydraulic Connection
Keep hands and body away from pressurised hydraulic lines.
Hydraulic fluid under pressure can penetrate skin and cause serious injury.
Only connect hydraulic hoses only when system is depressurised.
Two double-acting hydraulic connection must be available on the tractor.
FunctionHydraulic hose use for
Drawbar (Green) +Left
- Right
Cutting unit (Red) +Up
- Down
Light Connections
The mower comes with two connections.
• Connection 1—7 Pin socket for rear lights, indicators and side white lights
• Connection 2—a 3pin 12V socket used for the spot light that is located over the
cutter bed

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Attaching driveline to tractor
The Malone Procut mower require 1000RPM PTO power.
• Slide driveline end with safety cone over the splined shaft of the gearbox and
secure with attaching device.
• Slide driveline over the tractor’s splined PTO shaft and secure with locking de-
vice of driveline.
• Move driveline back and forth to ensure that it is secure on the PTO shaft of the
tractor and the mower gearbox.
• Attach over-run clutch to mower.
• Should the driveline require shortening then -
1. Raise the tractor 3-point hitch so the gearbox shaft is in line with the PTO shaft
of the tractor. Shut down the tractor leaving cutter in shortest distance between
shafts, refer to ‘A’ dimension. Securely block mower in position.
2. Pull the driveline apart. Reattach outer sections to tractor and gearbox. Pull on
driveline section to be sure that yoke locks in place
3. Hold driveline sections parallel to each other and mark the shield approx.
25mm (B Dimension) short of the shield cone on opposite section. Do this for
both sections.
4. Cut off shield where marked (X Dimension). Cut shaft the same amount (X1
Dimension). Repeat this on other driveline half and remove all burrs and cut-
tings.
5. Lubricate the shaft halves with multi-purpose grease and reassemble.
6. Pull on each driveline section to ensure yokes lock into place.

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Procut 2600TC & 3000TC —User Manual
Section 4 Transport
When travelling on public roads use accessory lights when necessary and
devices for adequate warning to other road users.
1. Raise the cutting unit by retracting the cutting unit cylinder.
2. Make sure the support leg is secured in the high position.
3. Swivel the drawbar into centre using drawbar cylinder.
4. Set drawbar locking plate in transport position.
5. Lift left and right side covers and secure with clips.
6. Close the hydraulic shut off valve.
7. If travelling on public roads ensure a ‘slow moving vehicle’ emblem is visible
to oncoming traffic.
8. If travelling on public roads always select a safe driving speed and allow faster
moving vehicles pass you safely.
Lift side covers and secure with clip
Fasten drawbar locking plate as shown
Retract cutting unit cylinders to raise
cutting unit
Shut off hydraulic transport valve

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Section 5 Working position
1. Ensure support leg is secured in the raised posi-
tion.
2. Release locking plate and fasten in working po-
sition (see detail below).
3. Open double-action hydraulic cylinder to swing
drawbar into working position.
4. Lower the cutting unit. Ensure the cutter bed
rams are fully extended.
5. When the cutter bed is on the ground, ensure
spool valve for cutter bed rams is in neutral po-
sition.
6. Ensure the tractor lower links are set at 70cm
above ground.
7. Ensure the side covers are in the working position.
8. Adjust swath board for width of swath required.
Locking plate in working position Set lower links at 70cm from
ground level.
Side covers in their working position

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Procut 2600TC & 3000TC —User Manual
Section 6 Adjustments
GROUND PRESURE ADJUSTMENT
The ground pressure of the mower beam is
adjusted by 4 tension springs, 2 on the left
and 2 on the right of the mower. The diago-
nal pull of the machine is therefore kept to a
minimum.
The spring tension is adjusted by means of
threaded spindles on each spring.
ADJUSTING CUTTING HEIGHT
The cutting height is adjusted by turning the
adjustment threaded bar. First remove the
locking handle and turn the adjustment bar
clockwise to lower cutter bar, anticlockwise
to raise cutter bar. Lock bar in position us-
ing handle.
Adjusting Conditioning
The mower conditioning can be adjusted
with three different settings. To adjust the
settings, pull back the locking pin, and move
the lever to the desired position.
Position 1 is for light crops/ swarthing
Position 2 is for moderate crops
Position 3 is for heavy crops/ spreading
3
2
1
- +
+
-

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ADJUSTING SWARTH WIDTH
The width of the swarth’s can be adjusted
by loosening the M10 nut on top of the cut-
ting unit and slide the door inwards or out-
wards to the desired positions.
SWITCHING BETWEEN SWARTH AND
SPREADER VANES
The swarth gates can be removed from in-
side the cutting unit by removing the retain-
ing M10 nut on the top of the frame and the
door can be placed and bolted onto top of
the mower for future use.
ADJUSTING OFF CENTRE POSITION
The off centre position in relation to the
centre of the tractor can be simply adjusted
by moving the pin holding the drawbar ram.
Position 1 will draw the main body closer to
the tractor and position 3 would achieve the
maximum offset of mower compared to the
tractor. 1
2
3

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Procut 2600TC & 3000TC —User Manual
ADJUSTING SWARTH PLATE
The swarth plate is used to knock material to
the ground that is coming from the condition-
er. The angle of the material exiting can be
adjusted by loosing the two M10 nuts (1),
and adjust the plate (2) to the desired angle.
If the swarth plate is in the highest angle (flat
to the body), the material can be proceeded
onto the spreading vanes.
1
1
2
ADJUSTING SPREADER VANES
The vanes can he adjusted to desired direc-
tion to throw the grass in whatever direction.
Loosen the bolts (1) and set it to the desired
angle. The angle of which the grass is damp-
ened to the ground can also be adjusted by
loosening the 2 nuts indicated by 2. Also the
gate can be angled up to be out of the way of
the grass thrown from the conditioner.
1
2

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Before starting operation ensure there are no people or animals in the vicini-
ty of the mower.
Section 7 Operation
Do not operate mower in rocky conditions.
Do not operate the mower without covers in place.
1. Engage the PTO drive and gradually increase the speed to 1000 RPM. Do not
reduce speed below 1000 RPM when mowing as this may cause plugging.
2. Start the forward motion of the tractor. Generally a ground speed of 6-10 KPH
will produce best results. Reduce speed on hilly/uneven ground, around corners
(especially left corners).
3. Reduce speed if the mower leaves uncut material.
4. Cut around fields in a clockwise direction.
5. In some conditions such as newly seeded fields, dirt or debris may build up be-
tween the stone guards resulting in a reduced performance. Clean the cutter bar
frequency to maintain a good cut and prevent premature blade wear.
6. When finished, gradually reduce PTO speed and disengage PTO drive.
Danger of tipping exists when turning left or going downhill.
Reduce speed accordingly.

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Procut 2600TC & 3000TC —User Manual
Section 8 Storage
To prepare the mower for storage -
1. Clean the mower of all dirt and debris. Dirt attracts moisture and causes corro-
sion
2. Inspect the mower for worn or damaged parts and replace if necessary.
3. Touch up the paintwork, bare metal must be covered with rust preventative.
4. Drain the oil from the cutter bar and gearboxes, replace with fresh SAE 90 (EP)
oil.
5. Store on a clean dry surface.
6. Loosen the drive belt, or remove and store in dry place.
7. Lubricate all points and slides to prevent corrosion.
8. Jack up the mower to prevent damage to the tyres. Protect the tyres from sun-
shine, grease and oil.
Start-up after storage -
1. Wipe off any excess grease and oil used for protection.
2. Spin the friction clutch to release the friction surfaces if stuck.
3. Check for worn or damaged parts.
4. Run the mower in low/idle rpm speed for a few minutes to ensure all compo-
nents are running smoothly.
Section 9 Spare Parts
Refer to the spare parts manuals for the dedicated models. Always use Malone rec-
ommended parts for optimum performance and longer working life.
To order spare parts or for technical information contact Malone at +353 (0) 94
9360500 or [email protected].

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Section 10 Maintenance and lubrication
Disc and blade maintenance
For cutting and a longer service life carefully check discs, blades and bolts daily. Re-
place worn or damaged blades and hardware immediately using only Malone recom-
mended parts.
Replace blades, bolts and nuts in pairs to maintain balance. Ensure the cutting edge
of blades face the disc rotation direction.
Before performing inspections, maintenance or adjustments of the
mower, stop the tractor engine, remove the key and secure parking
brake. Wait for all moving parts to stop and disconnect the driveline
shaft. Use blocks on mower and tractor to prevent movement.
Cutter bed blade rotation direction
2600TM
3000TM

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Procut 2600TC & 3000TC —User Manual
Cutter bar lubrication
Oil to be changed after first 50 operating hours, then every 600 operation hours
under normal operating conditions. Use SAE 90 (EP) gear oil or equivalent. Filler
plug is situated on top of cutter bar between 2nd & 3rd discs. To drain the oil from the
bar, leave the cutter bed supported the opposite side higher than the drain plug by
placing the bed on a block of wood, remove drain plug on underside of bar and
remove filler plug to aid draining oil. Ensure the oil has fully drained before putting
in fresh oil.
Product Oil Quantity
2600TC 3.6 Litres
3000TC 4.2 Litres
Cutter bed tilted for draining oil
Oil drain plugOil fill plug

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Ensure the bed is level.
Remove the oil filler plug and using a
measuring dip stick to measure the oil
depth.
If the oil is below the recommended oil
level, put in addition fresh EP-90 oil.
Min. 09mm Max. 12mm
Periodic Cutter Bed Oil Check
Check the oil after every 100 hours.

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Procut 2600TC & 3000TC —User Manual
Main Gearbox lubrication
Oil to be changed after first 50 operating hours
then every 600 hours and/or annually used under
normal operating conditions. Use SAE 90 (EP)
gear oil or equivalent. Oil level to be checked after
every 40 operating hours. Check oil level in the
gearbox by removing the oil fill plug and checking
the dipstick, if level is below line on dipstick add
oil. To drain the oil from the gearbox remove drain
plug on underside of gearbox. (Oil quantity ap-
prox. 2.2Ltr)
Swivel Gearbox lubrication
Oil to be changed after first 50 operating hours
then every 600 hours and/or annually used under
normal operating conditions. Use SAE 90 (EP)
gear oil or equivalent. Oil level to be checked after
every 40 operating hours. Oil level in the gearbox
to be level with oil level hole. To drain the oil from
the gearbox remove drain plug. (Oil quantity ap-
prox. - 1.5Ltr top, 1.2Ltr lower).
Accumulator
The mower has been installed with a hydraulic accumulator to act like a soft ride for
the cutter bed unit during road transportation and drops rams 25mm to allow to float.
If the transport of the mower seems to be more severe on the unit during transport,
get a qualified person to check the condition of the accumulator or get it recharged.
The pre-charge pressure in the accumulator is set at 35 Bar.

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Pulley Tensioner Spring Settings
The mowers factory setting on the conditioner belt tension is set at 120mm (X)
between the washers
X
Cutter Bed Spring Settings
When calibrating the springs on the cutter bed, ensure the cutter bed has been
lowered to the ground. Loosen the lock nut (A) and turn the threaded bar until the
desired tension has been achieved. After setting the spring tension, ensure the lock
nut (A) has been tightened again. The recommend setting (X) is
Product Spring setting (X)
2600TC 150mm
3000TC 125mm
X
A