Table of Contents
Related Manuals for McHale Issue 5
Summary of Contents for McHale Issue 5
- Page 1 Fusion Vario Baler & Wrapper Operator Instruction Manual Issue 5 (valid from serial number 900340) McHale Ballinrobe Co. Mayo F31 K138 Ireland ISO 9001:2015 Tel: +353 94 9520300 Email: sales@mchale.net Website: www.mchale.net CLT00911_1.02...
- 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.
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Page 4: Table Of Contents
McHale Fusion Vario 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 Vario Baler & Wrapper Which hydraulic system is used? Hydraulic spool valve setup 5.10 Making connections to the tractor 5.11 Connecting the control box 5.12 Lighting system Machine requirements & preparation Net requirements Care of the net roll Care of the net wrapping system Loading &...
- Page 6 McHale Fusion Vario Baler & Wrapper 10.9 Setting the bale density 10.10 Net tension gauge 10.11 Chamber door lock 10.12 Tension arm lock 10.13 Spare film holders & door latch safety 10.14 Brakes overview 10.15 Adjusting pick-up float springs 10.16 Chain adjustments 10.17 Adjusting belt alignment...
- Page 7 McHale Fusion Vario Baler & Wrapper This page is intentionally left blank.
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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 Vario Baler & Wrapper 2.2 Front view 9 10 No. Machine function Hydraulic section (inside cover) Stop switch B (inside cover) Netter unit Chamber door pressure clock Drawbar & stand Crop guard or crop roller Chopper unit Pick-up reel... -
Page 11: Rear View
McHale Fusion Vario Baler & Wrapper 2.3 Rear view No. Machine function Hose carrier Chamber door/tailgate Spare film section (inside cover) Dispenser ring Dispenser Tip arm roller Cut & hold unit Stop switch A Dispenser access door Drive side Platform... -
Page 12: General Specifications
McHale Fusion Vario 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 6.3 m (248”) -
Page 13: Machine Specifications
McHale Fusion Vario Baler & Wrapper 2.6 Machine specifications Bale chamber diameter (Baling & Wrapping) 1.1 - 1.5 m (43.3 - 59”) Bale chamber diameter (Baling only) 1.0 - 1.65 m (39.4 - 65”) Bale chamber width 1.23 m (48”) Pick-up width 2.10 m (83”) -
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 Vario 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 Vario 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 Vario Baler & Wrapper Stop switch B located on Stop switch A located on back left hand right hand side inside front right panel corner of back left panel Danger Zone The ‘Danger Zone’ is the area around the rotating dispensers (approx.
- Page 20 McHale Fusion Vario Baler & Wrapper Before operation Never operate farm machinery while under the influence of drugs or alcohol. The physiological effects of drugs and alcohol impair performance and can lead to operators taking risks or putting others at risk. This includes over-the- counter cold/flu and allergy medications or prescription drugs that are not recommended to be taken whilst driving a car or operating machinery.
- 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 Never use a machine where a malfunction exists! Contact your McHale dealer to achieve a solution. Always think ‘Safety First’! Avoid heating near pressurised fluid lines, as pressurised lines can be ...
- Page 23 McHale Fusion Vario Baler & Wrapper Always exclude children from potentially dangerous areas (they will often get into apparently inaccessible places). Do not allow them in farm yards on busy days. Contractors should always be made aware of the presence of children.
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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 Vario 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 Vario 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 Vario 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 Vario 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 Vario 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 Vario 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 Vario Baler & Wrapper 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. (CST00609) The PTO wide angle joint must never exceed 80 degrees, both when stationary or during operation.
- Page 33 McHale Fusion Vario Baler & Wrapper Always use correct specification chain oil for automatic chain lubrication (CST00776) Lock the chamber door before working on the open bale-forming chamber (CST00785) Tie down points. (CST00901) Jacking points. (CST00923)
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Page 34: Hydraulic Control Valve Decal
If the decal becomes damaged or missing, a replacement part CST00243 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 Vario 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 Vario 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 Vario 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: Preventing Unauthorised Use
McHale Fusion Vario Baler & Wrapper 5.4 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. -
Page 41: Attaching 'Break-Away' Brake
McHale Fusion Vario Baler & Wrapper 5.5 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 42: 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 43: Which Hydraulic System Is Used
McHale Fusion Vario Baler & Wrapper 5.8 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 44: Making Connections To The Tractor
McHale Fusion Vario Baler & Wrapper 5.10 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 45: Connecting The Control Box
McHale Fusion Vario Baler & Wrapper WARNING: Machine must be connected to free flow tank return The machine must be connected to a free flow tank return at all times during it’s operation, otherwise damage to the machine components may occur. -
Page 46: Machine Requirements & Preparation
A general rule to follow is to apply the amount of net that will maintain the bale size. McHale recommend the use of a net roll which meets the following specifications: Material: High quality, high density polyethylene ... -
Page 47: Care Of The Net Wrapping System
Never use cleaning agents such as benzene, petrol, turpentine oil or similar cleaning solvents to clean rubber feed roll, otherwise damage may occur! McHale recommend using either of the following: A cloth soaked in dish washing liquid Soapy water ... - Page 48 McHale Fusion Vario Baler & Wrapper 1. Ensure the PTO is disengaged, the tractor is shut down and ignition key has been removed. Slide the new roll of net onto the net storage space on the platform. NOTE: Ensure that the roll is orientated in the correct direction.
- Page 49 McHale Fusion Vario Baler & Wrapper 4. Pull approximately 0.8 m of net off the roll. Spread the net across the rubber feed roller. Roll the feed roller forward, to feed the net into the netter. See CST00869. NOTE: The net should only be fed in to a maximum of 70 cm past the rubber feed roller.
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Page 50: Net Layer Adjustment Setting
McHale Fusion Vario Baler & Wrapper 7. Pull the net roll bar down onto the roll. Adjust the roll guides equally, allowing 2 to 4 mm clearance each end, so the roll is centred and tighten securely. 8. The roll of net is now threaded and ready for baling. - Page 51 McHale Fusion Vario Baler & Wrapper NOTE: Hay or straw with a high % dry matter needs more net When the control box is set to ‘Bale only’, for hay or straw being baled with high percentage dry matter, more net must be applied. Dry conditions and very high densities require up to twice as many layers to ensure a good bale shape.
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Page 52: Chopper Unit Knife Removal & Installation
McHale Fusion Vario Baler & Wrapper Baling position Netting position 6.6 Chopper unit knife removal & installation CAUTION: Ensure knives are installed correctly Incorrectly installed knives can cause irreparable damage to both the knives and the rotor, leading to serious destruction within the machine! - Page 53 McHale Fusion Vario Baler & Wrapper 4. Shut down the tractor, remove the ignition key, apply the parking brake and prevent any machine movement with wheel chocks. 5. The knife lock/unlock lever (B) is located on the left-hand side of the chopper unit, just behind the pick-up reel.
- Page 54 McHale Fusion Vario 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 55 McHale Fusion Vario 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.
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Page 56: Automatic Lubrication System
McHale Fusion Vario Baler & Wrapper 6.6.1 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 57 12 working hours. 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 58 McHale Fusion Vario Baler & Wrapper 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.
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Page 59: Additional Greasing
McHale Fusion Vario Baler & Wrapper 7. Clean off this bead of grease so dust and debris does not stick to it. This dirty grease could get into the grease pump at the next cartridge change, causing a blockage of the grease system. -
Page 60: Gearbox Oil
The above instructions only cover the main components that must be greased daily (250 bales). (See ‘Machine maintenance’) 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 61 McHale Fusion Vario Baler & Wrapper WARNING: Ensure the tractor is shut down before changing oil Ensure that the tractor engine has been shut down, the key has been removed from the ignition and the brakes have been applied before changing oil.
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Page 62: Tyre Inflation Pressures
McHale Fusion Vario Baler & Wrapper 6.10 Tyre inflation pressures CAUTION: Check the tyre pressure weekly Check the tyres weekly for the pressures outlined in the following table. Field Road Details Type Part No. pressure pressure 650/50R22.5 157 D (Vredestein) Flo-Pro 1.65 bar... -
Page 63: Drawbar & Pto Shaft Stand Usage
McHale Fusion Vario Baler & Wrapper In most cases, both wheel chocks should be used on one wheel, front and back, as shown. The only exception to this is when the machine is parked on hilly ground. In that case,... - Page 64 McHale Fusion Vario Baler & Wrapper Type A - swing down fixed length stand (low hitch) Transport (working) position Storage position Swing down the PTO shaft stand (2) in an upright position in order to support the PTO shaft (4).
- Page 65 McHale Fusion Vario Baler & Wrapper 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 is available as an option on the low drawbar hitch machines.
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Page 66: Drawbar Adjustment
McHale Fusion Vario 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 67: Pto Shaft Adjustment & Maintenance
McHale Fusion Vario 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 68 McHale Fusion Vario 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 69 McHale Fusion Vario 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.
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Page 70: Electronic Control System
McHale Fusion Vario Baler & Wrapper Electronic control system (Software Version IS302-004) 9 10 Manual Screen 1 (The buttons/displays that vary on Manual Screen 2 are also shown) 9 10 Auto Screen 1 (The buttons/displays that vary on Auto Screen 2 are also shown) -
Page 71: Control Box Functions
McHale Fusion Vario Baler & Wrapper 7.1 Control box functions Manual Automatic Screen 1 Screen 2 Screen 1 Screen 2 Select automatic mode Select manual mode Display menu Net feed Film clamp open No function Net cut Film clamp release... -
Page 72: Control Box Features
McHale Fusion Vario Baler & Wrapper 7.2 Control box features 7.2.1 Working display When the control box is first switched on it displays ‘Loading’. After a short delay, the working display appears. The working display features an image of the machine, which is surrounded by general working information. -
Page 73: On-Screen Feedback
McHale Fusion Vario Baler & Wrapper Customer Wraps completed & total details for number of wraps to be Wrapping Bale bale count Rotations completed Diameter Bale Density Bale count/ sub total Wrapper ‘Auto’ is Bale shape shown when indicators Auto-tip is activated. - Page 74 McHale Fusion Vario Baler & Wrapper Bale counters The bale count sub total is displayed on the top panel of Screen 1. The control box contains ten different bale counters (A-J) which can be reset and a grand total counter which cannot be reset.
- Page 75 McHale Fusion Vario Baler & Wrapper Manual wrapping Buttons L5 and R6 on Screen 2 (Manual Mode) are used to manually rotate the wrapper ring. Pressing and holding forward (Button R6) or reverse (Button L5) once will rotate the ring slowly. Pressing forward (Button R6) twice and holding it will rotate the ring forward at full speed.
- Page 76 McHale Fusion Vario Baler & Wrapper Completely black when the knives are up Only an outline of the knife will be shown if they are down Standard knife operation (Automatic) Selectable knives operation is an optional extra with the Fusion Vario which allows the selection of 0, 7, 8 or 15 knives (0, 12, 13 or 25 with 25 knife option) from the control unit.
- Page 77 McHale Fusion Vario Baler & Wrapper Selectable knife operation (Automatic) 7.3.2 Bale Shape Indicator This is used to tell the operator which side of the bale needs to be filled with crop when baling narrow swathes. When the bale formation is even, no direction arrows are shown and both bar graphs are full.
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Page 78: Automatic Operation
McHale Fusion Vario Baler & Wrapper 7.4 Automatic operation Automatic operation is the preferred method of operation on a day-to-day basis, allowing the machine to free-flow through each cycle. Manual operation is generally used when the user wants to have direct control over individual functions for service/ maintenance reasons. - Page 79 McHale Fusion Vario Baler & Wrapper Wrapping rotations Film layers are set by the number of ring rotations. Count the number of rotations required to cover the bale once and add 0.5 of a rotation, then multiply this resultant figure by half the number of layers required, e.g.
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Page 80: Menu Structure
McHale Fusion Vario Baler & Wrapper 7.5 Menu structure Press ‘Menu’ (Button L2) to enter the main menu. The main menu is displayed as a series of 6 tabs, with the first tab selected i.e. machine setup. The first item in the tab will be selected. When a menu item is selected its border will change. - Page 81 McHale Fusion Vario Baler & Wrapper 7.5.1 Machine setup Auto tip This setting can be set to On/Off/x2 (//x2). When set to “On” the bale tips automatically during netting of the next bale in the chamber. When set to “x2”, two bales will be tipped together.
- Page 82 McHale Fusion Vario Baler & Wrapper Diameter correction This is used to nudge the bale size +/- 5 cm if the actual bale size does not match the diameter setting. Tip down speed This is used to adjust the speed of the tip down function.
- Page 83 McHale Fusion Vario Baler & Wrapper 7.5.2 Bale count Bale count - There are ten bale sub totals to choose from (A-J). When a bale total is selected it will have a tick, see A above. Select the appropriate parameter and then use the up &...
- Page 84 McHale Fusion Vario Baler & Wrapper 7.5.3 Net settings Bale diameter This can be set from 60 - 168 cm. (Wrapping is automatically disabled if the diameter is below 100 cm & above 145 cm) Bale density The bale density can be set from 1 to 10.
- Page 85 McHale Fusion Vario Baler & Wrapper 7.5.4 Display settings Backlight This sets the brightness of the screen from 1 to 10. Volume The volume of the controller can be adjusted from 1 to Clock/date adjust Select the clock/date adjust menu item.
- Page 86 McHale Fusion Vario Baler & Wrapper Auto The screen will automatically toggle between the main screen and camera 1 during various stages of the machine cycle. The toggle button can also be used to manually switch between camera and main screen.
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Page 87: Warning Messages
McHale Fusion Vario Baler & Wrapper 7.5.6 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. The same applies to the final ‘diagnostics’... - Page 88 The rear door switch warning should always appear on the control box when the rear door is open. If this is not the case or if the warning appears with the rear door fully closed, contact your McHale dealer. Wrapper too fast This warning message will be displayed if the wrapper speed goes above 40 rpm.
- Page 89 McHale Fusion Vario Baler & Wrapper Unblock This is not really an error message but it signifies that unblock is active. A quick push on ‘Reset unblock’ (Button R2) on the control box will restore everything to a working condition.
- Page 90 No net cut If the net doesn’t cut or the machine hasn’t detected it was cut, this message is displayed. Contact your McHale dealer if you see this. (2022) Dispenser position error This message is displayed when the dispenser is in the wrong position for tipping the bale.
- Page 91 This indicates that wrapping has started but the wrapper ring is still not turning. Check that the tractor oil supply is connected and turned on. Contact your McHale dealer, if the problem is not resolved. (2007) Wrap not complete If ‘Stop’ (Button 11) is pushed during wrapping of a bale, this error is displayed when the control box is next switched to ‘Auto’.
- Page 92 Then, check that there is no loose grass sitting on the bale detect sensor paddle. If loose grass is not the cause of the warning then contact your McHale dealer. (2025) Timeout This warning is shown and the AUTO cycle halted if a machine function has not completed its action within the allowed time frame.
- Page 93 McHale Fusion Vario Baler & Wrapper Side-tip warning This warning is shown to alert the operator that the side-tip (if fitted) is in the transport position and must be moved to the working position, before operating the machine. This is...
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- Page 96 FUSION VARIO MENU GUIDE Baler setup Baler setup Auto-tip: When set to ‘On’ ( Auto-tip: When set to ‘On’ ( ), the bale tips automatically during ), the bale tips automatically during netting of the next bale in the chamber. When set to ‘Off ( netting of the next bale in the chamber.
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Page 97: Wrapper Operation
The rear door switch warning should always appear on the control box when the rear door is open. If this is not the case or if the warning appears with the rear door fully closed, contact your McHale dealer. WARNING: Keep out of the ‘Danger Zone’... - Page 98 McHale Fusion Vario Baler & Wrapper 2. Remove the linch pin and release the dispenser film roll lock. Push down on the spring-loaded dispenser roller frame and engage the latch, to hold the rollers away from the central pin. 3. Remove the old core and ensure it is disposed of responsibly.
- Page 99 McHale Fusion Vario Baler & Wrapper 7. Close the dispenser safety door. Push the rear mounted dispenser park button, for approx. two seconds, in order to rotate the next dispenser to the loading or ‘home’ position. The dispenser ring can only rotate when...
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Page 100: Plastic Film Requirements
McHale Fusion Vario Baler & Wrapper 12. Close the door firmly making sure that both primary and secondary latches have been engaged. 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’... - Page 101 McHale Fusion Vario Baler & Wrapper 8.2.1 Determining the number of wrapping ring rotations Extra care, regarding the amount of wrapping ring rotations must be taken when wrapping bales with the Fusion Vario. This is because of the following reasons and...
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Page 102: Wrapping Process
McHale Fusion Vario 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 (bale transfer cradle in the home position, chamber door closed, rear wrapping roller in the set wrapping position and the access panel door closed). -
Page 103: 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 104: Cut And Hold System
McHale Fusion Vario 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 105 McHale Fusion Vario 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 106 McHale Fusion Vario 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 107 McHale Fusion Vario 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).
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Page 108: Road Traffic Safety & Operation
McHale Fusion Vario 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 109: Road Transportation With Side-Tip Attached
McHale Fusion Vario 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 110: Break-Away' Brake
McHale Fusion Vario 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 111: 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 112: Pick-Up Reel Height Adjustment
McHale Fusion Vario Baler & Wrapper Swath widths - correct & incorrect 10.3 Pick-up reel height adjustment Before working in the field secure the pick-up guide wheels, in their operating position, as shown. Use the appropriate hole in the adjusting bar so that the pick-up is balanced and at the optimum working height with the pick-up tines being 2 cm above the ground. -
Page 113: Unblocking System
McHale Fusion Vario Baler & Wrapper chain links together. Once adjusted, the crop roller should run along the top of the swath. In lighter conditions it should be adjusted as low as possible, but still ensure that the stops do not rest on the rubber bumpers. -
Page 114: Chopping System
McHale Fusion Vario Baler & Wrapper Unblock mode, knives retracted and channel floor lowered 10.6 Chopping system The machine is equipped with a 15 (or 25) knife chopping system. If a coarser chop is required, some of the knives can be removed. -
Page 115: Bale Density Gauge
When baling drier materials such as straw or hay McHale recommend setting the bale density pressure between 70 and 110 bar pressure (setting 4 - 5). -
Page 116: Net Tension Gauge
McHale Fusion Vario Baler & Wrapper 10.10 Net tension gauge The net tension gauge is used to indicate the pressure being generated by the tension on the net during application, depending on the 'net stretch' setting on the control box. The pressure is determined by the control unit, depending on the net tension setting. -
Page 117: Tension Arm Lock
McHale Fusion Vario Baler & Wrapper 10.12 Tension arm lock The tension arm lock is provided so that the hydraulic and spring pressure can be released from the belts when clearing a blockage within the machine or carrying out specific maintenance operations. (See the following decal CST00689) -
Page 118: Spare Film Holders & Door Latch Safety
McHale Fusion Vario Baler & Wrapper The hydraulic and spring pressure is now released allowing the operator to clear any blockage inside the chamber or carry out specific maintenance operations. In order to grease the bottom two tension arm rollers the tailgate should be closed completely before applying the tailgate lock. - Page 119 McHale Fusion Vario Baler & Wrapper 10.14.1 Hand brake The machine is equipped with a manual parking brake (hand brake). Pull the lever to activate the brake. The brake performance increases as you pull the brake (using a normal pulling force), reaching a maximum when the lever stops.
- Page 120 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. 10.14.3 Hydraulic brakes (optional) The machine is equipped with hydraulic drum brakes, using single-line activation.
- Page 121 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. 10.14.4 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).
- Page 122 McHale Fusion Vario Baler & Wrapper The following is the procedure for checking brakes: 1. Check dimension ‘X’ before applying brakes and again when brakes are applied. The value for ‘X’ should be between 12 and 18 mm. On hydraulic brakes (top picture) this is usually the amount of exposed chrome visible on cylinder rod.
- Page 123 McHale Fusion Vario Baler & Wrapper 4. Once the brake levers have been set, the hand brake cables will need to be adjusted. Set the threaded adjusters of both cables, at the hand brake lever, so that most of the available thread is towards the lever (as shown).
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Page 124: Adjusting Pick-Up Float Springs
McHale Fusion Vario Baler & Wrapper Check the brake hoses regularly Check the condition of the brake hoses monthly for any signs of cracking or abrasion. Ensure there is no contact from surrounding objects that could cause damage or wear over time. - Page 125 McHale Fusion Vario Baler & Wrapper complete adjustment. For normal ground conditions, the circlip should be positioned on the 3rd groove. Lower the pick-up reel. Both left-hand and right-hand ‘float spring’ rams should be adjusted in exactly the same way so that the load is balanced and equal.
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Page 126: Chain Adjustments
McHale Fusion Vario Baler & Wrapper 10.16 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 127 McHale Fusion Vario Baler & Wrapper 10.16.3 Pick-up reel tine chain adjustment To adjust the tine reel chain, the use of a 17 mm spanner and socket is required. Loosen (A) and turn tine sprocket (D) anti-clockwise, as shown below.
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Page 128: Adjusting Belt Alignment
McHale Fusion Vario Baler & Wrapper 10.16.5 Rotor duplex chain adjustment To adjust the duplex chain the following tools are required; two 24 mm spanners. Hold the lower nut and loosen the upper nut. To tighten - screw down the lower nut in the direction (T). - Page 129 McHale Fusion Vario Baler & Wrapper Different machines may have either 1 (wide) or 3 (narrow) belt(s), depending on the available options at the time of purchase. WARNING: Ensure safety first! Before approaching the machine, make sure that the tractor is shut down, with the hand brake applied and the ignition key removed.
- Page 130 McHale Fusion Vario Baler & Wrapper 2. With the chamber door pressurised closed, check that the door pin rollers are tight against the door lock hooks. If not, then the chamber door must be wedged back, until full contact is established. A thin wedge can be...
- Page 131 McHale Fusion Vario Baler & Wrapper 6. Once adjusted, tighten the remaining locknut, bolt (B) and grease pipe and with the Danger Zone clear, run the machine to see if the belt(s) are tracking evenly. The belt(s) will take one or two minutes, running at 540 rpm, to respond to the change and settle into the adjustment.
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Page 132: Attachments
McHale Fusion Vario 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 133 McHale Fusion Vario Baler & Wrapper External tip control There is an external tip control located on the back left corner of the machine for the convenience of the operator when raising/lowering the side-tip, without having to go into the tractor. The external tip...
- Page 134 McHale Fusion Vario Baler & Wrapper 7. To fit the left mounting bracket (ACH01346) to the idle end of the roller, remove the four M16 nuts and bolts. 8. Fit the bracket, using four M16 x 55 bolts (CFA00349) and nyloc nuts. (H) Ensure bolts are tightened fully.
- Page 135 McHale Fusion Vario Baler & Wrapper 11. Swing both V-shaped plates (CZH03852) over the main side-tip pivots on the left and right mounting brackets and secure onto the stub shafts using linch pins. (N) 12. Swing both U-shaped plates over the suspension cylinder pivot and secure using the latch pin (ABD00080) and linch pin.
- Page 136 McHale Fusion Vario Baler & Wrapper 15. Once the rear cradle is raised to the home position the side-tip is automatically swung into the vertical transport position, allowing it to be transported safely, as shown below. Finally an additional linch pin must be installed, as shown, to secure the gravity latch in position.
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Page 137: 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 138 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 139 McHale Fusion Vario Baler & Wrapper Never climb onto any part of the machine, while pressure washing, due to the fact that all metal surfaces become extremely wet and slippery and always ensure that the tractor has been shut down, with the ignition key removed.
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Page 140: Tightening Torque Values
McHale Fusion Vario 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 141: Net Tension Pump
McHale Fusion Vario Baler & Wrapper 12.3 Net tension pump If the pressure of the net tension gauge drops below 50 bar, it may be an indication that the tension pump is low in oil. Remove the filler cap and top-up with any ISO 32 hydraulic oil until almost full, then replace the cap. -
Page 142: 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 143: Start Of Season
McHale Fusion Vario 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 144: Troubleshooting
McHale Fusion Vario 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 145 McHale Fusion Vario Baler & Wrapper 14.1.3 PTO slip clutch going off easily Symptom Reason Solution PTO slip clutch going off Rotor chain loose Tighten the rotor chain easily and check, as specified PTO slip clutch going off Poor swath preparation...
- Page 146 McHale Fusion Vario 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 147 McHale Fusion Vario 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...
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Page 148: 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 149 McHale Fusion Vario 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 150 McHale Fusion Vario Baler & Wrapper Pre-delivery inspection form...
- Page 151 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 152 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.
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Page 153: Appendix
Appendix 16.1 Adjusting the PTO shaft to the tractor 10 - 13 A - H 10 - 13 A - H... -
Page 154: 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 155 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...
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