McHale Fusion 3 Operator's Instruction Manual
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McHale Fusion 3 Operator's Instruction Manual

Baler & wrapper
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Fusion 3
Baler & Wrapper
Operator Instruction Manual
Issue 3
McHale
Ballinrobe
Co. Mayo
F31 K138 Ireland
Tel: +353 94 9520300
I.S. EN ISO 9001:2015
Email: sales@mchale.net
Website: www.mchale.net
CLT00485_4.02

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  • Page 1 Fusion 3 Baler & Wrapper Operator Instruction Manual Issue 3 McHale Ballinrobe Co. Mayo F31 K138 Ireland Tel: +353 94 9520300 I.S. EN ISO 9001:2015 Email: sales@mchale.net Website: www.mchale.net CLT00485_4.02...
  • Page 2 If there is any conflict as to the accuracy or content, of any translation, the English source manual remains the authorised document. No part of this manual may be reproduced, distributed or translated, in any form or by any means, without prior written permission by McHale.
  • Page 3 It is vital to replace defective parts of the machine immediately and to use only genuine McHale spare parts, as these are designed and manufactured to the same standard as the original machine. Spare parts can be obtained from your McHale dealer.

  • Page 4: Table Of Contents

    McHale Fusion 3 Baler & Wrapper Table of contents Introduction Product information Designated use of the machine Front view Rear view General specifications Tractor specifications Machine specifications Tyre specifications Optional equipment* General safety Be aware of all safety information Follow all safety instructions...
  • Page 5 McHale Fusion 3 Baler & Wrapper Hydraulic spool valve setup Making connections to the tractor 5.10 Connecting the control box 5.11 Lighting system Machine requirements & preparation Net requirements Care of the net roll Care of the net wrapping system Loading &...
  • Page 6 McHale Fusion 3 Baler & Wrapper 10.10 Setting chamber pre-charge pressure 10.11 Chamber door lock 10.12 Spare film holders & door latch safety 10.13 Brake overview 10.14 Adjusting pick-up float springs 10.15 Chain adjustments Attachments 11.1 Side-tip Machine maintenance 12.1 Maintenance intervals 12.2...
  • Page 7 McHale Fusion 3 Baler & Wrapper This page is intentionally left blank.

  • Page 8: Introduction

    If you have any questions in relation to the instructions in the manual, please contact your McHale dealer. It is highly recommended that training be sought from your local McHale dealer. The operator is solely responsible for the safe use and maintenance of the machinery, in accordance with this manual.

  • Page 9: Product Information

    The relevant health and safety requirements, that may be in force in the  country of use, will be strictly followed. No other equipment or accessories, other than released by McHale, are  installed in the machine. The use of any other equipment or accessory is entirely at the owner/operator’s risk.

  • Page 10: Front View

    McHale Fusion 3 Baler & Wrapper 2.2 Front view No. Machine function Netter unit Net tension bars Hydraulic section (inside cover) Chamber door pressure clock Drawbar & stand Crop guard or crop roller Platform Pick-up reel Chopper unit Wheel chocks & knife blanks (inside cover)

  • Page 11: Rear View

    McHale Fusion 3 Baler & Wrapper 2.3 Rear view No. Machine function Hose carrier Netter unit Top chamber door Spare film section (inside cover) Dispenser ring Dispenser Tip arm roller Cut & hold unit Dispenser access door Drive side...

  • Page 12: General Specifications

    McHale Fusion 3 Baler & Wrapper 2.4 General specifications Units are given in both metric and UK imperial values, with the latter shown in brackets. *May not be available in all countries, check with your McHale dealer for availability in your country. Transport length 5.8 m (228”)

  • Page 13: Machine Specifications

    McHale Fusion 3 Baler & Wrapper 2.6 Machine specifications Bale chamber diameter 1.25 m (49”) Bale chamber width 1.23 m (48”) Pick-up width 2.10 m (83”) Net width Max. 1.26 m (49.6”) Net wrap Max. roll weight 40 kg (See warning below) Film width 750 mm (29.5”)

  • Page 14: Optional Equipment

    Hydraulic/Air brakes Side-tip Trailed fold up side-tip *May not be available in all countries, check with your McHale dealer for availability in your country. Side-tip option The side-tip option is used for knocking the bale onto its side and is very useful for...

  • Page 15: General Safety

    & instructions explained’). The spare part codes for each decal are also listed, which are available from your McHale dealer. If safety decals are damaged or missing due to wear and tear or component replacement, ensure that they are replaced. As with all machinery, learn all operations and use controls by reading this manual thoroughly.

  • Page 16: Store All Items Carefully

    McHale Fusion 3 Baler & Wrapper 3.3 Store all items carefully Store all attachments in a secure and safe manner so as to prevent items from falling. Keep storage areas clear of bystanders and children. 3.4 Personal protective equipment (PPE)

  • Page 17: Trained Operator Criteria

    McHale Fusion 3 Baler & Wrapper 3.7 Trained operator criteria Age related requirements General requirements The operator needs to be fully The operator must be in full  trained in the use of this machine control of his/her senses and 18 + and have a valid tractor driver’s...

  • Page 18: General Safety Warnings

    Read and understand this operator manual before using the machine. If any of the instructions appear unclear do not hesitate to contact your McHale dealer. Only competent persons who have read and fully understood this manual are qualified to operate this machine.
  • Page 19 McHale Fusion 3 Baler & Wrapper Danger Zone The ‘Danger Zone’ is the area around the rotating dispensers (approx.  2 metres radius from the rotating centre axis) & (a minimum of 5 metres) at the back of the machine to allow for safe bale discharge.
  • Page 20 McHale Fusion 3 Baler & Wrapper The operator must ensure that there is no person in the ‘Danger Zone’.  Always be familiar with the health and safety requirements that may be in  force in the country of use.
  • Page 21 Maintenance and repair work exceeding the content of this manual should  only be carried out by qualified persons or your McHale dealer. When conducting maintenance work tie long hair behind your head. Do not ...
  • Page 22 Regular clean down is recommended in order to maintain the machine in a  safe and reliable working condition. McHale recommend that the machine be blown down with an air line, as opposed to a pressure washer, due to the dangers involved with pressure washing and to protect the overall paint work on the machine.
  • Page 23 McHale Fusion 3 Baler & Wrapper Keep matches in a safe place.  Danger of lightning strike If there is a risk of lightning in the area, stop all work.  If there is a risk of lightning when travelling, find a safe place to pull over and ...

  • Page 24: Specific Safety Warnings

    Do not work on hydraulic systems unless you are qualified to do so. This work  should only be carried out by qualified persons or your McHale dealer. 4.3 Noise level The European directive 2003/10/EC directs employers and employees to ...

  • Page 25: Fire Precautions

    McHale Fusion 3 Baler & Wrapper In normal conditions, whilst driving the machine, the noise level to the driver’s  ear does not exceed 70 dB (A) with the rear screen of the tractor cabin open. The common noise level of the machine and the tractor is primarily influenced by the tractor noise (radio is an additional noise source).

  • Page 26: Safety Instruction Decal Locations

    McHale Fusion 3 Baler & Wrapper 4.6 Safety instruction decal locations Decals on the front of the machine Decals on the rear of the machine...

  • Page 27: Safety Warnings & Instructions Explained

    Therefore it has to be ensured that all safety warnings and instructions are understood and followed. If any of the decals are damaged or missing, they are available from your McHale dealer. The relevant part numbers are shown in brackets. The decals featured on the machine are displayed with their meanings below:...
  • Page 28 McHale Fusion 3 Baler & Wrapper Lifting hook location (CST00032) Check tyre pressure and wheel nuts daily (CST00038) Grease daily (CST00060) Do not stand on the platform or elsewhere on the machine when the machine is moving or working (CST00107)
  • Page 29 McHale Fusion 3 Baler & Wrapper Knives of the cutting device should only be removed with an appropriate tool and protective gloves (CST00112) Turn off and remove key from tractor. Read and understand the manual before working on or performing maintenance on the machine.
  • Page 30 McHale Fusion 3 Baler & Wrapper Disconnect machine feed line and turn off the control box during road use. Read the operation instruction manual before proceeding. (CST00135) Dispenser park rotation decal (CST00137) Side-tip: Not for road use (Placed on side-tip only)
  • Page 31 McHale Fusion 3 Baler & Wrapper Stay clear of the rotating PTO shaft. Never use the machine if the PTO guarding is missing or damaged. Entanglement in rotating drive line can cause serious injury or death. It is important to ensure that the rotating guard on the driveline rotates freely.
  • Page 32 McHale Fusion 3 Baler & Wrapper Stand clear (CST00244) Do not powerwash (CST00248) Electrical hazard (CST00249) Float decal. Indicating that during operation of the baler, the control lever of the spool operating the pick-up reel should be in the float position.
  • Page 33 McHale Fusion 3 Baler & Wrapper Keep hands out of crush area (CST00754) Lock the chamber door before working on the open bale-forming chamber (CST00756) Always use correct specification chain oil for automatic chain lubrication (CST00776) Tie down points. (CST00901) Jacking points.

  • Page 34: Hydraulic Control Valve Decal

    If the decal becomes damaged or missing, a replacement part CST00245 can be ordered from your McHale dealer. CAUTION: Use only for troubleshooting or in an emergency! Normally, these levers should never be tampered with apart from troubleshooting or in an emergency situation.

  • Page 35: Description Of The Serial Number Plate

    McHale Fusion 3 Baler & Wrapper 4.9 Description of the serial number plate The following is a description of the serial plate content: Product description Model name/number of the machine Year of manufacture of the machine Model year of the machine...

  • Page 36: Machine Lifting Guidelines

    McHale Fusion 3 Baler & Wrapper 4.10 Machine lifting guidelines WARNING: Machine lifting Only use chains or strapping that are rated for a minimum load  of two tonnes (2,000 kg) per chain or strap when using the four lift eye locations on the chassis, shown below.

  • Page 37: Jacking Guidelines

    McHale Fusion 3 Baler & Wrapper 4.11 Jacking guidelines Ensure the machine is on flat solid ground and attached to a tractor. Apply the tractor hand brake, switch off the tractor and remove the key, disconnect the hydraulics and PTO. Use wheel chocks on the opposite wheel to secure against unexpected movement.

  • Page 38: Tractor Requirements & Preparation

    On flat ground McHale recommends a tractor size of approximately 85 kW. On hilly ground or difficult conditions, an additional 10 to 15 kW is advisable.

  • Page 39: Attaching To Drawbar

    Detach in reverse order of attachment. CAUTION: Tractor drawbar and coupling device must be compatible Check that the tractor drawbar is compatible with the coupling device on the machine. If in doubt, consult your McHale dealer.

  • Page 40: Attaching 'Break-Away' Brake

    McHale Fusion 3 Baler & Wrapper 5.4 Attaching ‘break-away’ brake The machine is fitted with a hand brake which must be applied when the machine is detached from the tractor. The hand brake handle has a rope fitted to a calibrated ring which must have the other end securely fixed to the tractor, each time the machine is attached to the tractor.

  • Page 41: Machine Set-Up & The Tractor Hydraulic System

    (control valve is set to open-centre setup and flow is set to 45 l/min from the tractor). McHale do not recommend operating the machine in this setup, as controlling the oil flow is too variable from one tractor to another, and there is also a 20 kW PTO power loss with it’s associated over heating of...

  • Page 42: Which Hydraulic System Is Used

    McHale Fusion 3 Baler & Wrapper 5.7 Which hydraulic system is used? 1. Open-centre 2. Closed-centre 3. Load-sensing Set as open-centre Set as closed-centre / (default factory setting) load-sensing Does the tractor have a ‘Power Beyond’ & ‘Sensing Line’ connection fitted?

  • Page 43: Making Connections To The Tractor

    McHale Fusion 3 Baler & Wrapper 5.9 Making connections to the tractor WARNING: Turn off tractor and remove key before connecting hydraulic hosing When connecting hydraulic hosing to the tractor, ensure that the tractor engine is turned off and that the ignition key is removed. Ensure that all hydraulic connections are correctly tightened.

  • Page 44: Connecting The Control Box

    McHale Fusion 3 Baler & Wrapper 5.10 Connecting the control box The electronic control box must be located inside the tractor cab in the operator’s field of vision and within easy reach of the red emergency stop button. (See ‘Electronic control system’).

  • Page 45: Machine Requirements & Preparation

    A general rule to follow is to apply the amount of net that will maintain the bale size. The maximum bale size recommended is a 1.3 m diameter bale. McHale recommend the use of a net roll which meets the following specifications: Material: High quality, high density polyethylene ...

  • Page 46: Care Of The Net Wrapping System

    McHale Fusion 3 Baler & Wrapper 6.3 Care of the net wrapping system Before operating the machine, ensure that the following procedure is followed to ensure improved netter operation: Clean off rubber and metal feed rollers and check for any tacky material ...
  • Page 47 McHale Fusion 3 Baler & Wrapper WARNING: Always think 'Safety First'! Ensure the PTO is disengaged, the tractor is shut down and ignition key has been removed. The following is the procedure for changing a roll or fitting the first roll: 1.
  • Page 48 McHale Fusion 3 Baler & Wrapper 4. Before threading the net, ensure that the net knife is in the re-set position. The net knife can be re-set by pulling upwards on the knife frame bar until the hook sits on the net adjustment handle.

  • Page 49: Net Layer Adjustment Setting

    McHale Fusion 3 Baler & Wrapper 6.5 Net layer adjustment setting In an automatic cycle, the netter starts feeding net once the set bale density has been reached. The bale is then wrapped with the predetermined net length and the net knife is tripped.
  • Page 50 McHale Fusion 3 Baler & Wrapper Knife frame bar Less Net More Net   Knife tripped Knife not tripped (re-set) Net adjustment The following table shows the exact amount of net applied for each specific notch. Notch (#) Layers of Net* (#) Length of Net* (m) 2.25...

  • Page 51: Net Tension Bar Setting

    McHale Fusion 3 Baler & Wrapper NOTE: Figures in the table are approximate Figures are calculated assuming a bale circumference of 3.77 m (diameter of 1.2 m). The values of the layers and length of net will be approximate due to differing bale diameters, varying crop conditions, etc.
  • Page 52 McHale Fusion 3 Baler & Wrapper 5. The knife lock/unlock lever (B) is located on the left-hand side of the chopper unit, just behind the pick-up reel. It must be pulled outwards at first, to disengage it from the lock pin (X), then turned 90° downwards, to the unlock position, as shown below.
  • Page 53 McHale Fusion 3 Baler & Wrapper 5 - 10 mm 9. Now push the knife forwards, continuing to maintain this 5 - 10 mm clearance under the front of the slot. The keyhole slot on the front end of the knife should now guide itself over the ‘flats’...
  • Page 54 McHale Fusion 3 Baler & Wrapper 13. Installation is simpler, in that they only engage with the lock shaft in front and not with the actuator arm. The knife blank is dropped into a slot, towards the front, again maintaining the 5 - 10 mm gap (G), push forward (P), allowing the keyhole slot to engage with the lock shaft.
  • Page 55 McHale Fusion 3 Baler & Wrapper 6.7.1 Knives/blanks storage The knife blank holster has two methods of retention, L and S. Upper pin L can be pulled out from the left by first removing the linch-pin on the right. The lower pin S is used as a clamping device, to prevent knives/blanks from vibrating and can be loosened by turning anti-clockwise and tightened by turning clockwise.

  • Page 56: Automatic Lubrication System

    500 bales. It should be kept between the minimum and maximum markings at all times. McHale recommend the use of only top quality chain oil and grease, this will prolong the life of the machine components. A grease cartridge is required after every 300 bales approximately.
  • Page 57 Replacing refill grease cartridge and releasing airlock: McHale recommend using a multipurpose, extra high performance grease such as Mobilgrease XHP 222 or equivalent NLGI number 2 grade grease. This will prolong the life of the machine components.

  • Page 58: Gearbox Oil

    McHale Fusion 3 Baler & Wrapper 6. Slowly and gently, rotate the cartridge holder open and closed, a quarter turn, several times. Air between the grease pump and the cartridge will escape. When a bead of grease starts to leak out, the cartridge can be tightened fully.

  • Page 59: Tyre Inflation Pressures

    McHale Fusion 3 Baler & Wrapper 1. Remove the filler plug (A), followed by drain plug (B), using an 8 mm Allen key and drain oil into a suitable container. This is best carried out while the oil is still warm, i.e. soon after use.

  • Page 60: Wheel Chocks

    McHale Fusion 3 Baler & Wrapper 6.11 Wheel chocks Wheel chocks are provided to secure the machine wheels anytime the machine is to be detached from the tractor, or if the machine is to be stored or parked up. They are located on the left of the machine, inside the main panel, while in the transport position.
  • Page 61 McHale Fusion 3 Baler & Wrapper Type A - The following applies to the swing down fixed length stand (low hitch): Transport working position: While using the machine, ensure that the drawbar  stand (1) is raised fully with stand pin (3) in the alternate hole position.
  • Page 62 McHale Fusion 3 Baler & Wrapper Type B - swing down screw stand (low hitch) Transport (working) position Storage position Type C - The following applies to the fixed screw down stand (high hitch): Stand type C is the only type supplied with the high drawbar hitch option and ...

  • Page 63: Drawbar Adjustment

    McHale Fusion 3 Baler & Wrapper 6.13 Drawbar adjustment There are two types of drawbar hitch options (high/low drawbar) available on the machine. Depending on the country of use, one will come as standard. WARNING: Adjustment to be completed by qualified persons only...

  • Page 64: Pto Shaft Adjustment & Maintenance

    McHale Fusion 3 Baler & Wrapper 6.14 PTO shaft adjustment & maintenance (See ‘Adjusting the PTO shaft to the tractor’) CAUTION: Ensure the tractor is shut down Ensure that the tractor engine has been shut down, the key removed and the brakes applied before carrying out the following procedure.
  • Page 65 McHale Fusion 3 Baler & Wrapper After measuring carefully, the PTO shaft halves should be cut equally so that the PTO shaft assembly is kept as long as possible, whilst just allowing enough room for its removal. This will ensure that a maximum overlap (ideally 200 mm minimum) is maintained, when extended.
  • Page 66 McHale Fusion 3 Baler & Wrapper The recommended quantities of grease in grams for each grease point are shown below. WARNING: Ensure PTO guarding is in good condition Never use the machine if the PTO guarding is missing or damaged.
  • Page 67 McHale Fusion 3 Baler & Wrapper This page is intentionally left blank.

  • Page 68: Electronic Control System

    McHale Fusion 3 Baler & Wrapper Electronic control system (Software Version EPS301-009) 18 19 FUSION RESUME RE-WRAP RESET UNBLOCK EXPERT PLUS 3...

  • Page 69: Control Box Functions

    McHale Fusion 3 Baler & Wrapper 7.1 Control box functions Function Manual Automatic Stop button - Twist clockwise to turn Menu button Select Automatic Mode Select Manual Mode Four soft keys (A, B, C & D) with interchangable functions (each function relates to the...

  • Page 70: Control Box Features

    7.2 Control box features 7.2.1 Working display When the control box is first switched on it displays “McHale Fusion” followed by the software version number, followed by the selected language. The language can be changed at this point by pressing the arrow up (Softkey A) or arrow down (Softkey B) button to scroll until the required language is selected.
  • Page 71 If the voltage falls below 10 volts the “LOW BATT” symbol is flashed on the display. 7.2.8 Dispenser speed rpm The wrapper ring rotation speed, in revolutions per minute, is displayed over the wrapper of the Fusion 3 image on the screen (Shown at No. 18).
  • Page 72 McHale Fusion 3 Baler & Wrapper 7.2.9 Manual wrapping Softkeys B & C on the main screen 1 are used to manually rotate the wrapper ring. Pressing and holding the forward (Softkey C) or reverse (Softkey B) once will rotate the ring slowly.
  • Page 73 When the control box is switched on, Automatic mode can be selected by pressing button 3. AUTO will be displayed in the top right of the screen and the Fusion 3 image shows crop moving into the pick-up on the screen to show that baling is ready to start.
  • Page 74 McHale Fusion 3 Baler & Wrapper The roll of net can be replaced and “Net Feed” (Button 6) is pressed to start netting again. Transfer: After the set number of net layers are applied to the bale, the net is cut and the chamber opens, transferring the bale to the wrapping rollers, unless there is a wrapped bale waiting to be tipped first, which will be indicated by a “Tip bale”...

  • Page 75: Menu Structure

    McHale Fusion 3 Baler & Wrapper 7.3 Menu structure Press “Menu” (Button 2) to display the Machine Menu 7.3.1 Machine menu...
  • Page 76 McHale Fusion 3 Baler & Wrapper 7.3.2 Operator setup menu...
  • Page 77 McHale Fusion 3 Baler & Wrapper Machine setup 1 Use the following buttons to navigate the Machine Setup 1: Toggle key to move the arrow head to each of the  parameters + and - keys to change the value of the selected ...
  • Page 78 McHale Fusion 3 Baler & Wrapper Machine setup 2 Use the following buttons to navigate the Machine Setup 2: Toggle key to move the arrow head to each of the  parameters + and - keys to change the value of the selected ...
  • Page 79 McHale Fusion 3 Baler & Wrapper 1 Dispenser Only Out of Film Lube dose Lube dose is factory set to 3. This should be increased if it is taking a long period of time to make the bale or in very dry and dusty conditions, as this determines the amount of lubrication oil applied to the chains.
  • Page 80 7.3.3 Technician menu The technician menu has a lot of critical settings and is reserved for McHale engineers only. A pin code needs to be entered to access the menu.

  • Page 81: Warning Messages

    McHale Fusion 3 Baler & Wrapper 7.4 Warning messages Check net The passage of net through the netting unit is monitored. If the net cutting knife does not trip within 20 seconds of the netter starting, the net warning is displayed, an alarm sounds and the cycle is halted.
  • Page 82 Motor speed sensor This warning will be shown if pulses are not seen from the motor speed sensor, once the wrapper ring starts to rotate. Contact your McHale dealer if you see this. (2008) 1 dispenser only When the film sensor is switched on, failure of one...
  • Page 83 McHale Fusion 3 Baler & Wrapper Transfer not complete If “Stop” (Button 1) is pushed during the transfer of a bale, this error is displayed when the control box is next switched to “Auto”. To correct the error, Button 9 is pushed for one second to transfer the bale and advance the cycle.
  • Page 84 McHale Fusion 3 Baler & Wrapper Unblock This is not really an error message but it signifies that unblock is active. A quick push on “Reset unblock” (Button 10) on the control box will restore everything to a working condition.

  • Page 85: Simulating A 'Bale To Wrapping' Cycle

    McHale Fusion 3 Baler & Wrapper Low voltage If the voltage drops below 10 volts, then this warning will be displayed. The usual causes are nearly always either an inadequate power lead cable or corroded connections. Ensure the cable connection to euro socket is of good quality.

  • Page 86: Knife Selection System

    McHale Fusion 3 Baler & Wrapper 7.6 Knife selection system Fusion 2/Fusion 3 machines have various chopping knife system arrangements. Software version EP301-130 / EPS301-009 onwards can be set up to correctly operate any of these knife systems. CAUTION: Ensure that the correct knife selection option is set!
  • Page 88 FUSION 3 INSTRUCTION GUIDE FUSION Sets the number of wrapper Revolutions. ON: Automatically tips the wrapped bale as the bale in the chamber nets. OFF: Doesn’t tip the bale until the tip button is pressed. SILAGE = Wrapper on Crop: Silage...

  • Page 89: Wrapper Operation

    McHale Fusion 3 Baler & Wrapper Wrapper operation The machine is designed with a wrapping system having two plastic film dispensers. Differing to conventional wrappers, the dispensers move vertically around the bale. The dispenser carrier system is mounted directly behind the baler chamber. Although the...
  • Page 90 McHale Fusion 3 Baler & Wrapper 3. Remove the old core and ensure it is disposed of responsibly. 4. Push the new roll on the central pin, engage the film roll lock and reinsert the linch pin. 5. Thread the film through the dispenser...
  • Page 91 McHale Fusion 3 Baler & Wrapper 8. Open safety door and load film, as before. Thread the film through the dispenser rollers, as per the threading diagram, taking care not to trap fingers between the rollers. 9. Pull approx. 1.5 m of film away from the dispenser and make a knot at the end, as before.

  • Page 92: Plastic Film Requirements

    McHale Fusion 3 Baler & Wrapper WARNING: Do not clamp film in the ‘cut & hold’ mechanism Do not attempt to clamp plastic film in the ‘cut & hold’ mechanism as this action may result in serious injury! NOTE: Resume a cycle interrupted by ‘Out of film’ error symbol Pushing the ‘Resume’...
  • Page 93 McHale Fusion 3 Baler & Wrapper Example: Number of ‘Wrapping ring rotations’ to cover bale: 3.5 = (x)  Number of rotations to apply 4 layers of film to bale = (3.5 + 0.5) x 2 = 8  Important Notes: (x) ‘Wrapping ring rotation’...

  • Page 94: Wrapping Process

    McHale Fusion 3 Baler & Wrapper 8.3 Wrapping process The wrapping process starts automatically as soon as the bale has been transferred from the bale chamber to the wrapping table (chamber door closed, rear roller in fully raised position and the access door closed). After the bale is wrapped with the selected number of film layers, two (2) cut &...

  • Page 95: Dispenser Gear Options

    The dispenser rollers are set for a standard film stretch of 70%. Optional sets of dispenser gears for both 55% and 64% film stretch are available from your McHale dealer. One kit (A) is necessary for each dispenser on the machine.

  • Page 96: Cut And Hold System

    McHale Fusion 3 Baler & Wrapper 8.5 Cut and hold system WARNING: Beware of knives & accumulators during maintenance The cut and hold system utilises knives and accumulators in order to function. Beware of serious injury when carrying out any maintenance in this area.
  • Page 97 McHale Fusion 3 Baler & Wrapper WARNING: Wear proper safety equipment & follow all instructions Ensure to wear proper safety equipment at all times when working with the machine, such as gloves, eye protection, etc. and follow all safety decals and instructions.
  • Page 98 McHale Fusion 3 Baler & Wrapper The cut and hold knife blade condition is very important for the proper operation of the cut and hold system. A blunt blade may not cut the film cleanly or possibly not at all. As such, the knives must be changed under part number CKN00011.
  • Page 99 McHale Fusion 3 Baler & Wrapper 3. Insert a 24 mm open ended spanner into slot (H) until it engages with the hexagon on adjuster cam (E). Loosen M12 nyloc nut (F) on adjuster slightly, just enough to be able to turn adjuster (which works on a cam principle).

  • Page 100: Road Traffic Safety & Operation

    McHale Fusion 3 Baler & Wrapper Road traffic safety & operation 9.1 Before travelling on any public roadway WARNING: Complete a full inspection before travelling on the road Ensure that a full inspection is completed every time before attempting to go on to a public roadway, always think and practice safety!

  • Page 101: Road Transportation With Side-Tip Attached

    McHale Fusion 3 Baler & Wrapper Lift the pick-up reel completely and close the lever on the hydraulic line (if  fitted). The pick-up guide wheels must be fixed in the road transport position and the  drawbar/PTO stands secured in a working position.

  • Page 102: Break-Away' Brake

    McHale Fusion 3 Baler & Wrapper 9.3 ‘Break-away’ brake The machine is fitted with a hand brake which must be applied when the machine is detached from the tractor. The hand brake handle has a rope fitted to a calibrated ring which must have the other end securely fixed to the tractor, each time the machine is attached to the tractor.

  • Page 103: Field Operation & Machine Adjustments

    Field operation & machine adjustments 10.1 Break-in period McHale recommend a break-in period of approximately the first 50 bales or until the paint within the machine has lost its shine. During this break-in period, the sides of the bales may appear untidy, but once the side-walls have been polished smooth, then bale sides should look neater.

  • Page 104: Pick-Up Reel Height Adjustment

    McHale Fusion 3 Baler & Wrapper Continuous weaving is not recommended as this will result in excessive material being placed towards the centre of the bale. In the case of wider swaths, i.e. >1.5 m; this size of windrow should be avoided, as in this case a greater amount of material will continue to be fed to the outside of the baler.

  • Page 105: Crop Guard Adjustment

    McHale Fusion 3 Baler & Wrapper 10.4 Crop guard adjustment The function of the crop guard plate is to hold down the baling material in order to achieve an even flow. The height of the crop guard can be adjusted to suit the material type and volume, by means of adjusting the chain length.

  • Page 106: Unblocking System

    McHale Fusion 3 Baler & Wrapper 10.6 Unblocking system The machine is equipped with an unblock system. In the case of a blockage in the feeding channel, the PTO overload clutch will disengage and a loud clicking noise will be heard. Once this sound is heard, immediately turn off the tractor PTO and push “Unblock”...

  • Page 107: Chopping System

    McHale Fusion 3 Baler & Wrapper 10.7 Chopping system The machine is equipped with a 25 knife chopping system for fine cutting. If a coarser chop is required, some of the knives can be removed. (See ‘Chopper unit knife removal &...

  • Page 108: Bale Density Gauge

    This can cause the gauge to go into the red and this is normal operation. However, pressure should never go above 200 bar, if it does consult your McHale dealer. 10.10 Setting chamber pre-charge pressure The bale density gauge is divided up into increments of...

  • Page 109: Chamber Door Lock

    McHale Fusion 3 Baler & Wrapper pressure the door must be opened, then turn the adjustment screw and close the door again to check the gauge. Grass-Silage or Hay-Straw adjustment (located behind the hydraulic section, on the non-drive side of the chamber, inside the front right hand door of the machine). The bale chamber features a quick adjustment sensor position plate.

  • Page 110: Spare Film Holders & Door Latch Safety

    McHale Fusion 3 Baler & Wrapper WARNING: The operator must be aware of all related warnings, safety decals and dangers The operator must be aware of all related warnings, safety decals and dangers before attempting to carry out any work or maintenance from within the baling chamber.

  • Page 111: Brake Overview

    McHale Fusion 3 Baler & Wrapper Safety latch types Spare film roll holders 10.13 Brake overview The machine comes with either hydraulic or air brakes. The machine is fitted with a hand brake which must be applied when the machine is detached from the tractor. This also serves as a ‘break-away’...
  • Page 112 McHale Fusion 3 Baler & Wrapper The yellow hose is the service line which controls the rate of braking of the  machine. The red hose is the emergency line, which if disconnected applies the brakes  on the machine.
  • Page 113 The brakes squeal or grate heavily when activating the foot brake.  WARNING: Must be qualified to work on the brake drums This work should only be carried out by qualified persons or your McHale dealer, who are familiar with braking systems. 10.13.3 Hydraulic brakes (optional) The machine is equipped with hydraulic drum brakes, using single-line activation.
  • Page 114 McHale Fusion 3 Baler & Wrapper 10.13.4 Brake adjustment Machines fitted with brakes, either air or hydraulic, must be initially checked after the first 50 hours of use and every 100 hours or yearly thereafter (whichever comes first). WARNING: Ensure safety before working on brake adjustment Before attempting to carry out brake adjustment, ensure that the tractor engine has been switched off and the key removed.
  • Page 115 McHale Fusion 3 Baler & Wrapper 3. Ensure the spring-loaded locking collar is returned, to the locked position, to prevent any further movement of the adjuster screw. Repeat the procedure for both sides of the machine and ensure brakes are being applied evenly.

  • Page 116: Adjusting Pick-Up Float Springs

    McHale Fusion 3 Baler & Wrapper 10.13.5 Brake maintenance Drain condensation water from the air reservoir (air brake only) Actuate the manual drain valve as necessary by pulling the ring, each day before operating for a few seconds or until the water droplets disappear.
  • Page 117 McHale Fusion 3 Baler & Wrapper The method of adjustment can be either Type A or Type B, which are shown below. Type A: Loosen the collar by slacking off the bolts, then tap the collar in the direction (R) if increased float is required, or in direction (F) if less float is required.

  • Page 118: Chain Adjustments

    McHale Fusion 3 Baler & Wrapper 10.15 Chain adjustments It is important for the efficient operation of the machine that all drive chains are kept correctly tensioned. The following is a general guide to chain adjustment. The sag is measured at the midpoint of the chain between the sprockets. Always ensure one side of the chain is tight so that the correct reading is obtained.
  • Page 119 McHale Fusion 3 Baler & Wrapper 10.15.2 Bottom chamber door chain adjustment Adjust M12 nyloc nut and nut (B) until compression of spring (C) has reached the same length as spring guide (A). Spring guide (A) is an indicator only and always inspect chain tension after adjustment, as greater spring compression may be required, due to chain wear, chain damage, etc.
  • Page 120 McHale Fusion 3 Baler & Wrapper 10.15.4 Bottom door to main drive chain adjustment Adjust turn buckle (A) until the gap (D) is 25 mm. As the chain wears the gap (D) will need to be reduced. 10.15.5 Pick-up reel tine chain adjustment To adjust the tine reel chain, the use of a 17 mm spanner and socket is required.
  • Page 121 McHale Fusion 3 Baler & Wrapper 10.15.6 Reel drive chain adjustment To adjust the reel drive chain the use of both a 17 mm and 19 mm spanner and socket are required. Using 17 mm tools, loosen (A) anti-clockwise by approx.1 turn.

  • Page 122: Attachments

    McHale Fusion 3 Baler & Wrapper Attachments 11.1 Side-tip When the machine tips off the wrapped bale, the outer wrapper roller moves down to ground level and ejects the bale. This eliminates problems associated with bales being tipped from a height and getting damaged as they roll away.
  • Page 123 McHale Fusion 3 Baler & Wrapper Fitting the side-tip to the machine 1. It may be easier when fitting the side-tip to lower the rear cradle halfway down. This may be done either directly from the control box within the tractor, or using the external tip control on the back left corner of the machine (control box must be in Manual mode).
  • Page 124 McHale Fusion 3 Baler & Wrapper 8. Fit the bracket, using four M16 x 55 bolts (CFA00349) and nyloc nuts. (H) Ensure bolts are tightened fully. 9. Fit U-shaped mounting plates (CZH04868), for the suspension unit to brackets on left side of the cradle, using the bushings and fasteners supplied. (I) 10.
  • Page 125 McHale Fusion 3 Baler & Wrapper 12. Swing both U-shaped plates over the suspension cylinder pivot and secure using the latch pin (ABD00080) and linch pin. (O) 13. Fit the flow-restrictor valve (CVA00276) under the main hydraulic valve, as shown, by removing the cradle supply hose and mounting valve, fittings and washers.
  • Page 126 McHale Fusion 3 Baler & Wrapper 15. When the side-tip is being transported, the transport pin must be in the transport position. The transport pin must be removed from its storage position on the suspension mount (S) and repositioned into the transport position (T) on the rear cradle.

  • Page 127: Machine Maintenance

    Replace any electrical or hydraulic devices immediately, at the first sign of malfunction or failure, as these components affect the functionality, sequencing and thus safety of operation. Never use a machine where a malfunction exists! Contact your McHale dealer to achieve a solution. Always think ‘Safety First’! WARNING: Wear proper safety equipment &...
  • Page 128 Carefully clean all machine sections, inside and out. Dirt and foreign objects are likely to draw moisture and cause rusting of steel components. McHale recommend that the machine be blown down with an air line, as opposed to a pressure washer, due to the dangers involved with pressure washing and to protect the overall paint work on the machine.
  • Page 129 McHale Fusion 3 Baler & Wrapper Any damaged paintwork should be touched up. Any maintenance or repairs should be carried out at this stage. The electronic control box is not waterproof, so it must always be stored in a dry environment. All exposed hydraulic cylinder rods should be greased.

  • Page 130: Tightening Torque Values

    McHale Fusion 3 Baler & Wrapper 12.2 Tightening torque values It is important that the correct torques for fasteners are adhered to. Below are tables of recommended torques for these. These are to be used unless torques are otherwise specified. These values are for general use only. Check tightness of all fasteners periodically.

  • Page 131: Storage

    Carefully clean all machine sections, inside and out. Dirt and foreign objects  are likely to draw moisture and cause rusting of steel components. McHale recommend that the machine be blown down with an air line, as opposed to a pressure washer, due to the dangers involved with pressure washing and to protect the overall paint work on the machine.

  • Page 132: Start Of Season

    McHale Fusion 3 Baler & Wrapper 13.2 Start of season Fully review this operators instruction manual.  Check and fill gearbox oil level, if necessary. (See ‘Gearbox oil’)  Lubricate all pivot points.  Tighten all bolts, nuts and setscrews.

  • Page 133: Troubleshooting

    McHale Fusion 3 Baler & Wrapper Troubleshooting 14.1 Troubleshooting overview This section has been compiled by McHale service personnel in conjunction with McHale importers and dealers. It outlines some common problems which can occur and acts as a quick reference section or check list to resolve the problem.
  • Page 134 McHale Fusion 3 Baler & Wrapper Symptom Reason Solution PTO slip clutch going off Poor swath preparation Prepare the swath in line easily with the recommendations in the machine setup (See ‘Swath preparation’) PTO slip clutch going off Knives blunt...
  • Page 135 McHale Fusion 3 Baler & Wrapper 14.1.7 Chamber losing pressure Symptom Reason Solution Chamber losing pressure Oil leak Find leak and resolve Chamber losing pressure Relief valve loose / Contact McHale dealer restriction in relief 14.1.8 Issues with bale rotation/intake...
  • Page 136 McHale Fusion 3 Baler & Wrapper 14.1.11 Chopper knives won’t move (activate/disengage) Symptom Reason Solution Knives won’t move Faulty hydraulic valve Contact McHale dealer (activate/disengage) Knives won’t move Low power supply to the Check power source (activate/disengage) control box 14.1.12 Net not cut correctly...

  • Page 137: Certification & Warranty

    The PDI (pre-delivery inspection) form that is filled out on the commissioning of every new machine, should also be used during the transfer of ownership of a McHale machine. The same check list must be completed and any areas requiring attention addressed before the re-sale of the machine should occur.
  • Page 138 McHale Fusion 3 Baler & Wrapper Declaration of Conformity DECLARATION OF CONFORMITY We hereby certify that the machinery stipulated below complies with all the relevant provisions of the EC Machinery Directive 2006/42/EC and the national laws and regulations adopting this directive.
  • Page 139 McHale Fusion 3 Baler & Wrapper Pre-delivery inspection form...
  • Page 140 McHale warranty system. These conditions are subject to the following exceptions: Parts of the machine which are not of McHale manufacture, such as tyres, PTO  shafts, slip clutches, hydraulic cylinders, etc. are not covered by this Limited Warranty, but are subject to the warranty of the original manufacturer.
  • Page 141 A printed version of the PDI form has been signed and dated by the original retail  purchaser. This copy is to be stored by the dealer and made available to McHale when requested. The warranty claim is submitted using the McHale online claims system.

  • Page 142: Appendix

    Appendix 16.1 Adjusting the PTO shaft to the tractor 10 - 13 A - H 10 - 13 A - H...

  • Page 143: Unit Conversion Tables

    16.2 Unit conversion tables Length inch (in) foot (ft) yard (yd) mile (mi) 0.001 0.000001 0.03937 0.003281 0.001094 6.21e-07 0.01 0.00001 0.393701 0.032808 0.010936 0.000006 1000 0.001 39.37008 3.28084 1.093613 0.000621 1000000 100000 1000 39370.08 3280.84 1093.613 0.621371 25.4 2.54 0.0254 0.000025 0.083333...
  • Page 144 Flow rate l/sec l/min /min gal/min US brl/day 2.119093 127.1197 15.85037 543.4783 0.016666 0.06 0.035317 2.118577 0.264162 9.057609 0.277778 16.6667 0.588637 35.31102 4.40288 150.9661 0.4719 28.31513 1.69884 7.479791 256.4674 0.007867 0.472015 0.02832 0.01667 0.124689 4.275326 0.06309 3.785551 0.227124 0.133694 8.019983 34.28804 0.00184 0.110404...
  • Page 145 Preventing unauthorised use To prevent unauthorised use, McHale recommend using the padlock and the locking device provided. Both items are stored in the tool box on the machine and should be fitted to the drawbar coupling when the machine is not in use.

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