Page 1 Fusion 2 Fusion 2 Fusion 2 Fusion 2 Technical Service Manual Issue 1 McHale Engineering Limited, Castlebar Rd, Ballinrobe Co. Mayo, Ireland. Tel: +353 94 95 20300 Fax: +353 94 95 20356 Email: sales@mchale.net WWW.MCHALE.NET WWW.MCHALE.NET WWW.MCHALE.NET WWW.MCHALE.NET...
Page 2 Introduction Table of contents Fusion 2 Getting Familiar with the General Safety Specific Safety Warnings Tractor Requirements & Preparations Baler Requirements and Preparation Wrapper Operation Baler Field Operation & Adjustments Machine Maintenance Electronic Control System Hydraulic and Lubrication Systems Drive Systems...
Page 3 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 McHale...
Page 4 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Section 1 Fusion 2 Introduction Fusion 2 01-1 McHale Introduction section...
Page 5 If any of the instructions appear unclear do not hesitate to contact your McHale supplier. 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 obtained from your McHale Supplier .
Page 6 Page 1. Introduction …...………………………………………………….. 01-1 2. Contents ……………………………………………………………... 02-1 Fusion 2 3. Getting familiar with the McHale ……………………….. 03-1 4. General Safety 4.1 Be aware of all safety information………………………….. 04-1 4.2 Follow all safety instructions………………………………... 04-1 4.3 Store all items carefully …………………………………...
Page 7: Table Of Contents
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Section Page 7. Baler requirements and preparation 7.1 Net requirements…………………………………………... 07-1 7.2 Care of the net roll ……………………………………... 07-1 7.3 Care of the net wrapping system……………………….. 07-1 7.4 Loading netter system…………………………………….
Page 8: Section Page
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Section Page 10. Machine maintenance 10.1 Maintenance intervals………………………………………. 10-1 10.2 Maintenance intervals/ recommended service……….. 10-2 10.2.1 Replace cam bearings………………………………... 10-3 10.2.2 Check key way on pick-up reel sprocket …………….
Page 9 11-24 11.6.3 Control box features…………………………………… 11-26 11.6.4 Error messages and their meaning…………………… 11-32 11.7 Running a simulated “bale to wrapping cycle”…………… 11-35 11.7 Fusion 2 input/ output tests…………………...…………… 11-36 11.7 Uploading expert plus software……………………………. 11-37 Fusion 2 02-iv McHale contents section...
Page 10 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Section Page 12. Hydraulic Systems Overview 12.1 What is the hydraulic system on the tractor and how does it Fusion 2 affect the set up………………………………………… 12-1 12.2 What hydraulic system does the tractor use?………………… 12-2 12.3 Hydraulic spool valve set up……………………………………...
Page 11 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Section Page 13. Drive Systems 13.1 Gearbox……………………………………………………………. 13-2 13.2 Chamber drive side……………………………………………… 13-2 13.3 Chopper/ pick up drive………………………………………….. 13-5 13.4 Chains and belts………………………………………………….. 13-6 13.5 Roller locations…………………………………………………… 13-7 13.5.1 Baler chamber rollers……………………………………...
Page 12 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Section Page 14. Trouble Shooting 14.1 Trouble shooting overview…………………………………. 14-1 14.2 Machine using higher than expected hp when chopping 14-1 14.3 Pick up slip clutch going off easily………………………….
Page 13 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 02-viii McHale contents section...
Page 14 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 3. Getting familiar with the McHale Fusion 2 03-1 McHale main component reference section...
Page 15 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 03-2 McHale main component reference section...
Page 16 Use the Decals section in the provided spare parts book as a handy reference for spare part codes and relevant decals, which are available from your McHale dealer. As with all machinery, learn all operations and use of controls by reading this manual thoroughly.
Page 17 PTO driven equipment. Fusion 2 4.7 Operating the McHale safely In order to avoid serious injury or even death by being pulled into the machine: Never attempt to feed net or crop into the baling chamber or attempt to unplug pick-up area while the baler is running.
Page 18 4.9 General safety warnings Read and understand this operator’s 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 Maintenance and repair work exceeding the content of this manual should only be carried out by qualified persons or your McHale dealer. Before travelling on public roads the owner of this machine is obliged by law to ensure that every operator has got a valid driving licence and is familiar with the road traffic regulations relating to the country of use.
Page 20 5 years. Only use exact specification, McHale genuine replacement parts. 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. Fusion 2 05-1...
Page 21 The noise level at field work may differ according to the tractor, to the ground, to the crops and other environmental conditions. In normal conditions the noise level next to the drivers ear of the McHale Fusion 2 round baler wrapper combination does not exceed 70 dB (A) with open rear screen of the tractor cabin.
Page 22 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 5.6 Safety/ instructions decal location Fusion 2 05-3 McHale specific section...
Page 23 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 05-4 McHale specific section...
Page 24 Therefore it has to be ensured that all safety warnings and instructions are understood and followed. If any of the decals are damaged or are missing they are available from your McHale dealer. The relevant part numbers are shown in brackets. Note: The most important instructions are shown as pictographs.
Page 25 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Lock the chamber door before working on the open bale-forming chamber. (CST00155) Beware of rotating dispensers, ring and moving wrapping table rollers! (CST00116) Do not stand on the platform or elsewhere on the machine when the machine is moving or working.
Page 26 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Check wheel nuts daily. (CST00020) Free flow return to tank. (CST00006) Maximum hydraulic pressure and maximum PTO speed. This machine must not be connected to hydraulic systems with pressure higher than 210 bar.
Page 27 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Knife release lever, horizontal position-locked, vertical position-unlocked. (CST00118) Diagram of plastic film path through dispenser. (CST00022) Diagram of net path through feeding rollers. (CST00156) Grease daily. Lifting hook location...
Page 28 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Dispenser park rotation decal. (CST00137) Automatic! CST00137 Not for road use Side Tip; Not for road use decal. (CST00138) CST00138 (CST00161) (CST00162) Free rotating transfer roller. Do not step on this roller.
Page 29 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 5.9 Machine lifting eye location points Right hand side lift hook Front view Left hand side lift hook Rear view Fig. 5.91 Machine lifting eye locations Warning! Only use chains or strapping that are rated for a minimum load of two tonnes (2,000 kg’s) per chain or strap when using the four lift eye locations on the...
Page 30 On flat ground McHale recommends a tractor size of approximately 85 kW on hilly ground or difficult conditions, an additional 10 to 15 kW are advisable.
Page 31 PTO shaft to the tractor. 6.5 Attaching to drawbar Fusion 2 The drawbar is to be attached so that the McHale is horizontal to the ground as in section 7.12, “Drawbar adjustment”. Machines are set up for hitching to tractor drawbar as shown in fig.
Page 32 50 lit./min. from the tractor), Fusion 2 McHale do not recommend operating the in this set-up, 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 the oil.
Page 33 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 6.8 What hydraulic system does the tractor use? 3. Load-Sensing 1. Open Centre 2. Closed Centre Set as Open Centre Set as Closed/Load Sensing (default factory setting, as (as shown in section 6.9)
Page 34 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 6.9 Hydraulic spool valve setup Procedure to select open or closed centre valve configuration. Using a 17 mm spanner, loosen locknut (1) as shown below. With a 4 mm ‘Allen’ Key, tighten or unscrew the bolt (2) according to the fol- lowing guidelines: (a) Open Centre (Factory Default): Screw in fully.
Page 35 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 6.10 Attaching hydraulic hosing to tractor Warning! 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 36: Baler Requirements And Preparation
The maximum bale size recommended is a 1.3 m diameter bale. In order to achieve the best possible performance, McHale recommend the use of a net roll which meets the following specifications: Material: High quality, high density polyethylene.
Page 37 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 7.4 Loading and operating the netter system Warning! Pay attention to the heavy weight of the net roll! It is recommended that full net rolls should be handled by two persons.
Page 38: Net Cutter Setting
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 7.5 Net cutter setting In an automatic cycle the netter starts feeding net when the set bale density has been reached, and the cutter is tripped when the bale is wrapped with the predetermined net length.
Page 39: Net Tension Bar Setting
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Notch Layers of Net* Length of Net* Fig. 7.5.4 Net cutter setting. 7.25 2.25 8.37 9.35 Less Net 10.18 11.00 12.00 More Net 13.11 3.75 14.23 15.21 16.18 17.30...
Page 40: Chopper Unit Knife Removal And Installation
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 7.7 Chopper unit knife removal and installation Warning! Use protective gloves for any manual work in this area! The number of knives installed determines the cut length of the material. Knife removal should be carried out in the following way: Switch the control box to manual mode.
Page 41 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Remove knives with a pair of pliers. 10. Replace with knife blanks to prevent crop catching in the slots, these are stored in the knife/ knife blank holster which is located in the front left...
Page 42: Automatic Lubrication System
500 bales, it should be kept between the min. and max. 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 43: Gear Box Oil
(D). Remove empty grease cartridge, release plunger to the fully out position, and replace. McHale recommend using a Multipurpose, extra high performance grease such as, Mobil grease XHP222 or equivalent NLGI number 2 grade grease. Caution: Avoid contact with skin.
Page 44: Drawbar And Pto Shaft Stand Usage
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 7.11 Drawbar and PTO shaft stand usage Stand type A: Fusion 2 There are three types of drawbar stands available on the , depending on the country of use one will come as standard.
Page 45 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Stand type C: The following applies to stand type C, please refer to the figures in 7.11.4: Caution: The stand must be rested on a solid footing (B), on level ground and also the supplied wheel chocks must be used.
Page 46: Drawbar Adjustment
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 7.12 Drawbar adjustment Warning! This work should only be carried out by qualified persons or your McHale dealer! The drawbar should be adjusted so that the machine is horizontal to the ground when in the working position, see figure 7.12.1 below.
Page 47 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 07-12 McHale requirements & preparation section...
Page 48: Wrapper Operation
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 8. Wrapper operation Fusion 2 The McHale is designed with a wrapping system with 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.
Page 49 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fig. 8.1.1 Rubber safety latch. Fig. 8.1.2 Film roll lock (Open). Fig. 8.1.3 Film threading diagram. Fig. 8.1.4 Film knot. Fig. 8.1.5 Dispenser park button. Fig. 8.1.6 L.H.S Film slot.
Page 50: Plastic Film Requirements
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 8.2 Plastic film requirements Besides well shaped dense bales, a good silage quality also depends on the use of top quality plastic film. Low standard film material will not produce good silage regardless of how well the machine wraps the bale.
Page 51: Wrapping Process
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 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).
Page 52: Cut And Hold System
Fusion 2 The cut and hold system on the McHale is designed to operate in conjunction with both the dispenser and table rollers to cut the plastic after a desired amount of film wrap has been applied to the bale, as set on the control box, see sections 8.2, 8.3 and 8.4 for more information on the wrapping process.
Page 53: Cut And Hold Rail Adjustment
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Change the cut and hold knives by following the procedure below and referring to figure 8.51 on the previous page: Loosen the two M6 setscrews that hold the knife clamp plate (B) in place using...
Page 54: Dispenser Gear Options
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 8.6 Dispenser gear options 70% GEAR OPTION: Item Part Code Description ADP00018 KIT DISPENSER GEARS 70% CMH00055 GEAR SPUR 1.5M 60T DISPENSER CMH00175 GEAR SPUR 1.5M 35T DISPENSER...
Page 55 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 08- 8 McHale wrapper operation section...
Page 56: Baler Field Operation And Adjustments
9. Baler field operation and baler adjustments 9.1 Break in period McHale recommend a break in period of approximately the first 50 bales or until the paint within the baler has worn off. Note: It is important to realise that roller and drive loads increase as the bale size approaches it’s maximum diameter.
Page 57: Crop Guard Adjustment
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 9.3 Pick-up reel height adjustment Before working in the field unlock and swing the pickup guide wheels forwards and lock them carefully again. Use the appropriate hole in the adjusting bar so that the pick-up is at the optimum working height with the pickup tines being 2 cm above the ground, see figure 9.3.1.
Page 58: Unblocking System
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 9.5 Unblocking system Warning! Never attempt to go near the pick up reel with the reel still rotating and the tractor on. In the rare case that the reel cannot be unblocked from using the procedure below, then the pickup reel will require manual unblocking, by removing the excess blocked material.
Page 59: Chopping System
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 9.6 Chopping system Fusion 2 The McHale is equipped with a 23-knife chopping system for fine cutting. If a coarser chop is required 11 of the knives can be removed, or all can be removed if desired, see section 7.6 on knife removal and installation.
Page 60: Bale Density Gauge
This can cause the gauge to go into the red, and is normal operation. However, pressure should Fig. 9.8.1 Chamber pressure never go above 210 bar, if so consult your McHale dealer. 9.9 Setting chamber pre-charge pressure The bale density gauge is divided up into increments...
Page 61: Chamber Door Lock
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 9.10 Chamber door lock The chamber door lock is to be used at all times that the operator may wish to enter the chamber in order to change the cutter knives for example. The lock is located in the front right hand side panel of the machine.
Page 62: Adjusting Pick-Up Float Spring
(R). Fig. 9.12.1 Adjustment of pickup float springs. Fusion 2 Warning! When baling with the McHale ensure that the control lever for the spool operating the pick-up reel height adjustment is in the float position. If the lever is not in the float position then the reel will be fixed in position and will be unable to follow the ground contour.
Page 63 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 9- 8 McHale field operation and adjustments section...
Page 64: Machine Maintenance
McHale recommend that nobody ever be in the danger zone (for additional information on the danger zone please refer to section 4.9) at any time during...
Page 65 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.2 Maintenance intervals RECOMMENDED SERVICE Page End of After & After & Season Every Every Service Bales Bales Pick Up Reel: Replace cam bearings 10-3 Check key and key way on pick-up reel sprockets...
Page 66: Replace Cam Bearings
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.2.1 Replace cam bearings Replace the four cam bearings (CBR00081) every 10,000 bales. 10.2.2 Check key and key way on pick-up reel sprockets Check the key on the pick-up reel sprockets for wear.
Page 67: Check Chain Tensioners
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.2.3 Check chain tensioners Check all chain tensioners for wear and replace if necessary. Plastic Chain Tensioner (CPL00043) Plastic Chain Tensioner (CPL00043) Plastic Chain Tensioner (CPL00043) 10.2.4 Chain tension adjustment Check and if necessary adjust all chain tensions in line with section 10.6...
Page 68: Check For Broken Magnets On The Knife Unit
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.2.5 Check for broken magnets on the knife unit. Check for broken magnets Magnet on the knives in the drop CEL00154 floor. Replace if necessary. 10.2.6 Ensure all oiler pipes to the chains & grease pipes...
Page 69: Check Roll Pins/ Bolts On The Knife Holder Bracket
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.2.7 Check roll pins/ bolts on the knife holder brackets Check roll pins for knife holders 10.2.8 Check spiral pins on tine bars Check the four spiral pins on each tine bars and replace if necessary .
Page 70: Check Spur Gears
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.2.9 Check spur gears Check spur gears for wear and ensure that they are getting 10.2.10 Replace bearing on pick-up reel shaft and fit protector plate. Replace bearings on pick-up reel shaft on machines every 10,000 bales.
Page 71: Grease Pick Up Reel Shaft And Slip Clutch Bearing
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.2.11 Grease pick-up reel shaft bearing and slip clutch shaft bearing Grease Pick-up Reel Shaft Bearing (CBR00092) Grease Slip Clutch Shaft Bearing (CBR00094) Fusion 2 10-8 McHale maintenance section...
Page 72: Check Left/ Right Auger
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.2.12 Check left/ right auger Check the left and right auger and sprocket for key wear and damage. Replace key (CFA00239) if necessary. Ensure grub screw is in place and tight.
Page 73: Replace Rotor Drive Side Bearing
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.2.13 Replace rotor bearing on drive side Replace rotor bearing on drive side of the machine every 20,000 bales. Rotor Bearing (CBR00078) Fusion 2 10-10 McHale maintenance section...
Page 74: Density Pressure Check
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.3: Density pressure check Relief Valve Cartridge Top Door Density Valve (CVA00239) Plunger Spring Cartridge Copper Housing Washer & Plunger Copper Washer (CVA00270) 1. If there is a pressure drop firstly check for any leaks, loose hoses or any oil under the machine.
Page 75: Replace Nilos Ring
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.4 Replace the nilos ring Replace the nilos ring on the roller as illustrated by the arrow Replace the nilos ring (CBR00061) on the roller assembly on the heavy roller in the bottom door (ARC00034).
Page 76 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.4.1: Check the bolts on chamber door hinges Check bolts on all door hinges. Ensure all bolts are secure and the hinge joints are tight. Replace any damaged bolts or hinges.
Page 77 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.4.2: Remove top chamber door panels and blow out Remove top panel Remove back panels Remove the three panels. Blow out grass, straw etc. from between the chamber rollers and the panels.
Page 78: Check Brake Pads On Dispenser Ring
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.4.3: Check brake pads on dispenser ring Check the brake pads on dispenser ring brake assembly. Replace the pads if they are excessively worn (2 mm or less remaining).
Page 79: Replacing Ring Brake Pads
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.4.4 Procedure for Replacing Ring Brake Pads 1. Tighten M16 (A) lock nut, to remove tension from wrapping ring. 2. Remove the brake hose from the brake cylinder.
Page 80: Lubricate Wrapper Roller Drive Chains
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.4.5: Lubricate wrapper roller drive chains Remove guard, oil both chains and replace guard. Fusion 2 10-17 McHale maintenance section...
Page 81: Grease Dispenser Springs
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.5 Check dispensers for tack/ glue build up & clean if necessary Over time a layer of tack can build up on the aluminium rollers, the rollers should be inspected every service.
Page 82: Clean Cut And Tie Rails
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.5.2: Clean cut and tie rails 1. Loosen off oil hose and drain off the oil. Be very careful when removing the hose as it is under accumulator pressure.
Page 83: Clean And Oil All Chains And Grease All Bearings
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.5.4: Clean and oil all chains and grease all bearings Clean down all the chains using high pressure air. When they are clean. Fill chain oil reservoir with chain oil & fit new grease cartridge, run PTO at approx 200 rpm and with the control box in manual mode, operate the bale tip up &...
Page 84: Start Of Season Machine Preparation
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.2.35 Remove Foreign Objects From Electrical Shelf 10.5.10 Start of season machine preparation Over the Control Valve Check and fill gear box oil level if necessary, see section 7.0.
Page 85: Chain Adjustment
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.6: 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.
Page 86: Top Chamber Chain Adjustment
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.6.3: Top chamber door chain adjustment: Adjust as discussed in #1 on previous page, but location as shown below. 10.6.4: Bottom door to main drive chain adjustment: Adjust as discussed in #1 on previous page, but location as shown below.
Page 87: Pickup Reel Tine Chain Adjustment
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.6.5: Pickup reel tine chain adjustment To adjust tine reel chain the use of a 17 mm spanner and socket is required. Loosen (A) and turn tine sprocket (D) anticlockwise as shown below.
Page 88: Chopper Unit Duplex Chain Adjustment
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 10.6.7: Chopper unit duplex chain adjustment To adjust the duplex chain the following tools are required; two 24mm span- ners. Follow the below procedure: Using the 24mm tools, loosen nyloc nut (A).
Page 89 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 10-26 McHale maintenance section...
Page 90: Component Location
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 11.1: Component location Net Cut Sensor Main Valve Chamber Full Sensor PWM Module Net Feed Clutch By-pass Valve Bottom door Bottom door Knife/Floor Diverter Solenoid Film Sensor Transmitter...
Page 91: Electrical Control Parts
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.2: Electrical control parts CEL00209 Rotate proximity sensor CEL00202 Film transmitter Even Door safety switch CEL00221 Film transmitter Odd CEL00222 Film break receiver CEL00230 Extension CEL00608 Sounder CEL00220...
Page 92: Net Feed Clutch
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 blue CEL00201 CEL00193 green PWM module A = Cut & Hold B = Tip bale Main hydraulic valve C = Rotate D = Diverter valve CEL00247 E = Open chamber...
Page 93: Chamber Fully Open Sensor
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.2.1: Net feed clutch Function In an Auto cycle the net feed clutch feeds net into the chamber for 3 seconds at the start of netting. The remainder of the net is pulled in by the rotating bale.
Page 94: Dispenser Rotation Sensor
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 11.2.3: Dispenser rotation sensor Function The dispenser rotation sensor is a 30 mm proximity sensor which detects the metal band on the bottom of the dispenser units. This sensor perform three functions •...
Page 95: Dispenser Rotate Button
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.2.5: Dispenser rotate button Function This switch is used when loading plastic film. Pushing and holding the button for 2 seconds will slowly rotate the dispenser ring by a half rotation bringing the next dispenser to the loading position.
Page 96: Safety Switch Access Door And Tip Sensor
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 11.2.7: Safety switch access door and tip sensor Function Safety circuits must never be disabled in any way. The dispenser access door and the rear tip roller safety switches prevent rotation of the dispenser ring if the access door is open or the tip roller is lowered.
Page 97: Pwm Constant Current Module
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.2.8: PWM constant current module Function The Pulse Width Modulation constant current module is connected between the control box and the proportional hydraulic valve. It’s purpose is to stabilise the slow speed against voltage and temperature variations.
Page 98: By Pass Valve
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 11.2.10: By-pass valve Function The rotation hydraulic circuit consists of four motors in series, two wrapping roller motors and two dispenser ring rotation motors. The by-pass valve can bypass hydraulic oil around the two wrapping roller motors to hold the bale at the start and final half turn to ease C&H operation.
Page 99: Film Monitoring Operation
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.2.11: Film monitoring — operation Function Film sensor monitoring can be switched on or off from the operator set-up menu on the control box. The film monitoring circuit consists of a pair of dispenser mounted...
Page 100 Replacing Film Break Receiver or Transmitters The film break system works by two radio transmitters (the plastic caps mounted on each dispenser) sending a signal to the receiver (the black box mounted on the machine). There are two different type transmitters, ”O” and “E” Two of the same type transmitters will not work on the machine.
Page 101: Control Box
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.2.12: Control Box The control box shown here is mounted in the tractor cab. It is secured to the window with a suction pad. The Power Supply Should come directly from the battery using the Lead supplied or a Euro Plug.
Page 102: Control System
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 11.3 Electronic control operation 11.3.1 Control system Fusion 2 The McHale baling and wrapping cycle is controlled by a cab mounted electronic control box operating the machine mounted hydraulic valves via a multi-core cable.
Page 103: Sensor Testing
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.4: nsor testing 11.4.1: Reed sensor testing Function The chopping knives on, net cut, bottom chamber door up rear tip roller and motor speed sensor, are 12 mm stainless steel reed sensors .
Page 104: Proximity Sensor Testing
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 11.4.2: Proximity sensor testing Function The Dispenser sensor is a 30 mm NPN inductive proximity sensor. It is connected to a 12 Volt supply and it’s output transistor switches on when metal is within 20 mm of it’s front face.
Page 105: Wiring Diagrams
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.5: Wiring diagrams 11.5.1: Safety warnings Fusion 2 Before doing any maintenance work or troubleshooting on the machine Make sure the machine can not move by using wheel chocks and applying the handbrake.
Page 106: Guide To Wiring Diagrams
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 11.5.3: Guide to wiring diagrams The wiring diagrams show the connections from the 37 pin AMP circular connector to the machine mounted components. Two ground circuits are used, one for the output circuits and the other for the inputs.
Page 107: Wiring Scheme
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.5.5: wiring scheme speed Motor speed sensor ground rot.prox film sensor index Rotate proximity sensor brown 12 volt black blue ground Film break receiver 12 volt brown yel/grn...
Page 108 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 FUSION2 WIRING DIAGRAM AMP pin no. wire colour tip sensor 30 violet ring speed 20 green/red rot.prox 9 wht/grn film sensor 31 yel/blu index switch 17 grey/brn open chamber...
Page 109: Forward Rotate Circuit
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.5. 6 Forward rotate circuit Fusion 2 11- 20 McHale electronic control system section...
Page 110: Reverse Rotate Circuit
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 11.5. 7 Reverse rotate circuit Fusion 2 11- 21 McHale electronic control system section...
Page 111: Control Box Functions
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.6: Electronic control unit 11.6.1: Control box functions Fusion 2 11- 22 McHale electronic control system section...
Page 112 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 MAN or AUTO mode Fusion 2 11- 23 McHale electronic control system section...
Page 113: Menu Structure
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.6.2: Menu structure Press the menu button Enter Pin 0000 Fusion 2 11- 24 McHale electronic control system section...
Page 114 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 11- 25 McHale electronic control system section...
Page 115: Control Box Features
Control box features Working display When the control box is first switched on it displays "McHale Fusion" followed by the programme version number, followed by the selected language.The working language can be changed at this point if required. The language is changed by pressing the arrow up or arrow down button to scroll to the desired language when the default language “English“...
Page 116 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Film layers The selected number of rotations is displayed on right side of the screen. On the left side of the screen the number of completed wraps over the target number of wraps is displayed when the wrapper is rotating.
Page 117 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual Machine menu The Expert Plus Series control box has a number of options that can be selected or adjusted by the operator. To enter the machine menu press menu button. The machine menu has five options listed: Machine Set-up 1, Machine Setup 2, Bale Count, Operator Setup, and Technician Setup.
Page 118 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Crop There are three crop options: Straw, Hay and Silage. Use the toggle soft key to move the arrow head to the crop parameter, then use + and - soft keys to change the crop type.
Page 119 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual Film sensor The film sensor monitors the passage of film through the dispenser rollers. If one dispenser stops feeding film due to a roll coming to an end the control box will give an audible alarm and flash the “1 Dispenser Only”...
Page 120 Use the arrow soft keys to move up or down to the required language and press the enter soft key to the select the language. Technician menu This menu is reserved for McHale factory technicans only. Fusion 2 11- 31...
Page 121: Error Messages And Their Meaning
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.6.4: Error messages and their meaning “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 symbol is displayed, an alarm sounds and the cycle is halted.
Page 122 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 “1 Dispenser Only” When the film sensor is switched on, failure of one dispenser to feed film will flash 1 Dispenser Only on the display and the wrapping rollers will operate in 50/50 mode giving a correct wrap with the remaining film roll.
Page 123 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual “Unblock” This is not really an error message but signifies that unblock is active, a quick push on the reset unblock switch on the control box will restore everything to a working condition.
Page 124: Running A Simulated "Bale To Wrapping Cycle
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 11.7: Running a simulated “bale to wrapping” cycle The following procedure is used to test a full “bale to wrapping” cycle in the absence of any baling material. It can be used to determine the correct operation for nearly all equipment from the start of the baling cycle to the end of the wrapping cycle.
Page 125 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 11.8: Fusion 2 11- 36 McHale electronic control system section...
Page 126: Uploading Expert Plus Software
The program for the control box can be sent via email or the latest version can also be downloaded from the McHale website. Connect "McHale-Expert" serial cable to a spare serial port, Com1 or Com2 on the computer. Connect other end of cable to Expert control box.
Page 127 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual Fusion 2 11- 38 McHale electronic control system section...
Page 128: Hydraulic Systems Overview
50 lit./min. from the tractor), Fusion 2 McHale do not recommend operating the in this set-up, 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 the oil.
Page 129: What Hydraulic System Does The Tractor Use
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.2: What hydraulic system does the tractor use? 3. Load-Sensing 1. Open Centre 2. Closed Centre Set as Open Centre Set as Closed/Load Sensing (default factory setting, (as shown in section 12.3) Does the tractor have a ‘Power...
Page 130: Attaching Hydraulic Hosing To The Tractor
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.4: Attaching hydraulic hosing to tractor Warning! 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 131 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.5: Fusion hydraulic scheme Fusion 2 12-4 McHale hydraulic systems overview section...
Page 132 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 12-5 McHale hydraulic systems overview section...
Page 133: Main Valve Overview
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.6: Main valve overview A: Open/ Closed Centre Plug: After selecting the optimum hydraulic set up for the machine in line with the diagram in section 12.2. the machine can then be set to open or closed centre (please refer to 12.3 for additional information) as in A...
Page 134: Main Valve Port Functions
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.6.1: Main valve port functions The valve can be broken down into six main segments. The first segment determines what oil flow the machine will have (open/ closed centre) and the other five segments control the Cut and hold, Tip, Ring Rotate, Knives/drop floor and Bale chamber.
Page 135 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 12-8 McHale hydraulic systems overview section...
Page 136: Hydraulic System Valve Assembly
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.6.3: Hydraulic system: valve assembly CVA00015 CVA00015 Ports Description Part Code Dowty Seals 1/2"-3/8" M/M ADAPTOR CHY02008 CHY00053 1/2"-3/8" M/M ADAPTOR CHY02008 CHY00053 1/2"-1/2" M/M ADAPTOR CHY02013 CHY00053 1/2"-3/8"...
Page 137: Bale Density Valve
The bale density gauge is divided up into increments of 20 bar per increment and has a yellow zone, green zone and a red zone as a quick reference during machine operation. When baling drier materials such as straw or hay McHale recommend setting the chamber pre-charge pressure between 70 and 110 bar pressure.
Page 138: Bale Density Valve Break Down
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.7.2 Bale density valve break down CVA00239 CVA00239 Ports Port Size 1/4" 3/8" 3/8" 3/8" ( Acc) 1/4" 1/2" 1/2" CVA00239 Fusion 2 12-11 McHale hydraulic systems overview section...
Page 139: Chamber Holding Pressure
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.7.3: Chamber holding pressure The density valve should hold the pre-charge pressure at what ever it is set to on the adjustable screw. If this does not happen there can be a number of reasons.
Page 140: Accumulator Test
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.7.4: Accumulator test. There are two accumulators on the machine. The chamber density valve: This holds the chamber shut as the crop forces against in to form a bale. The pressure on the density clock should increase gradually as the bale is nearly full.
Page 141: Knife/ Floor Valve Overview
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.8: Knife/ floor valve overview: In normal function the oil only flows through the aluminium knife section (Fig 3) of this valve to operate the Knives up and down. When the diverter is activated by pressing the Drop Floor buttons the oil flows through the Cast iron section (Fig 3) to operate the Drop Floor up and down.
Page 142: Knife/ Floor Valve Breakdown
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.8.1: Knife/ floor valve Diverter section with Aluminium Solenoid & Check Knife Section Valve Fusion 2 12-15 McHale hydraulic systems overview section...
Page 143: Valve Trouble Shooting
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.8.2: Valve trouble shooting The knife valve shown has a relief valve which allows the pressure to drop to 50 bar in the accumulator, which is chopping pressure. It should hold at this pressure while a bale is being formed.
Page 144: Rotate, Tip, Bypass Valve
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.9: Rotation, tip, bypass valve If the plastic breaks or runs out on one dispenser the plastic break sensor trans- mits a message back to the control box, on receiving this message the control box activates the bypass valve in 50/50 mode.
Page 145 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.9.1: Rotation, tip, bypass valve breakdown Fusion 2 12-18 McHale hydraulic systems overview section...
Page 146: Rotation, Tip, Bypass Valve Ports
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.9.2: Rotation, tip, bypass valve ports View 1 View 2 CVA00157 CVA00157 Components Ports Port Size Adopter Size Part Code Dowty Seals 1/2” 1/2"-1/2" M/M ADAPTOR CHY02013 CHY00053 3/8”...
Page 147: Wrapper During Normal Operation
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.9.3: Wrapper during normal operation Bale Wrapping Rotation Function: Normal Wrapping Feed = Return = Energised when in 50/50 mode If there is pressure Also energised on line D1 or D2 the...
Page 148: Wrapper During 50?50 Operation
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.9.4: Wrapper during 50/50 operation Bale Wrapping Rotation Function:50/50 Wrapping mode Feed = Return = Energised when in 50/50 mode If there is pressure on line D1 or D2 the...
Page 149: Wrapper Ring Reverse
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.9.5: Wrapper (ring reverse) Bale Wrapping Rotation Function: Reverse Feed = Return = Energised when in 50/50 mode If there is pressure Also energised on line D1 or D2 the...
Page 150: Cut And Hold (800 Mm Stroke) Open And Close
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.10: Cut and hold (800 mm stroke) open & close Cut & Hold To Oiler/ Function: Opening & Closing Greaser Feed = Return = Note: Cut & Holds close under...
Page 151: Cut And Hold (50 Mm Stoke) Release
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.10.1: Cut and hold (50 mm stroke) release Cut & Hold To Oiler/ Function: C&H Release Greaser Feed = Return = Note: The cut and hold release is operate when oil is...
Page 152: Tip Arm Down
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.11: Tip arm down Bale Tip & Grease Pump Function: Tip Arm Down Feed = Return = Accumulator to Protect Tip Cradle To C & H Acc CVA00157...
Page 153: Tip Arm Up/ Oiler Cycle
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.11.1: Tip arm up/ oiler cycle Bale Tip & Grease Pump Function: Tip Arm Return Feed = Return = Accumulator to Protect Tip Cradle To C & H acc.
Page 154: Lubrication System
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.12: Lubrication system Fusion 2 The Lubrication System on the is a hydraulically operated pump, where the pressure to activate the Chain oil side of the pump comes from the rear tip hydraulic cylinders and the pressure for the Grease side comes from the C &...
Page 155 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.12.1 Oiler and greaser system; components: Item Part Code Description CVA00145 OIL & GREASE PUMP CHY00201 OIL MASTER BLOCK CHY00202 OIL SECONDARY BLOCK CHY00209 GREASE MASTER BLOCK CVA00184...
Page 156 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 12-29 McHale hydraulic systems overview section...
Page 157: Oiler And Greaser System Fittings
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.12.3: Oiler and greaser system; fittings Item Description Part Code 6LL FITTING STRAIGHT CFA00549 6LL FITTING ELBOW CFA00543 6LL UNION (COMPLETE) CFA00681 COMPRESSION NUT CFA00682 6LL COUPLING NUT...
Page 158: Oiler And Greaser System; Fittings At Block
Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 12.12.4: Oiler and greaser system; fittings at blocks: CHY00201 OIL MASTER BLOCK Ports Part Code Description 1,2,4,5,6 & 8 CFA00682 COMPRESSION NUT CFA00683 BRASS OLIVE CHY00202 SECONDARY OIL BLOCK 1-5 &...
Page 159: Oiler And Greaser System Fittings At Ends
Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 12.12.5: Oiler and greaser system; fittings at ends: Fusion 2 12-32 McHale hydraulic systems overview section...
Page 160 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Item Part Code Description CFA00549 6LL FITTING STRAIGHT CFA00543 6LL FITTING ELBOW CFA00681 6LL UNION (COMPLETE) CFA00544 6LL COUPLING NUT CFA00545 STEEL OLIVE CHY02323 HOSE STUD ELBOW CHY02324...
Page 161 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual Fusion 2 12-34 McHale hydraulic systems overview section...
Page 162 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 13. Drive systems The machine is driven by a split drive gear box (Fig 1). The minimum working revs required for machine operation is 540 rpm and working revs should never exceed 610 rpm during machine operation.
Page 163 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 13.1 Gearbox; CMT00106: Fusion 2 13-2 McHale drive systems section...
Page 164 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Item Part Code Description CMT00105 Gear Case CBR00104 Bearing Housing CMH00901 Shaft CMH00902 Bevel Gear Pair CMH00903 Bush CBR00113 Ball Bearing CBR00114 Taper Roller Bearing CBR00115 Taper Roller Bearing...
Page 165 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 13.2: Chamber drive side The drive taken from the gearbox (A) to all the chamber rollers (B). Fig. 1 Fusion 2 13-4 McHale drive systems section...
Page 166 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 13.3: Chopper/pick-up drive The Rotor is driven off the Gearbox and takes the drive through its shaft to the 2 spur gears which connect to the pick-up protection slip clutch. The chain off this drives the Auger and pick up centre shaft which drives the auger on the Auger side.
Page 167 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 13.4 Chains and belts Drive side Chains—Drive Side All the chain on the drive side of the chamber are 1 –1/4 pitch. The main drive chain off the gearbox is 100H and all other chains are 20B.
Page 168 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 13.5 Roller locations There are 18 rollers in the chamber. Roller no. 1 below is the intake roller and is the only one of its kind. It is a heavy duty roller with a splined shaft.
Page 169 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 13-8 McHale drive systems section...
Page 170 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 13.5.2 Procedure for removing the sprocket from the roller shaft (short and long shaft) The sprockets are held on the roller shaft using a taper lock system To remove the sprocket Loosen the 30 mm Nut on the end of the roller shaft by 3 full turns.
Page 171 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 13.5.3 Procedure for reassembly of the sprocket on the roller shaft (short and long shaft) Place the roller in the chamber and fit the bearing complete assembly (ART00051) a break down of this can be seen in the black square above for additional information and part numbers please refer to the spare parts manual.
Page 172 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 13.5.4 Procedure for removing the sprocket off the roller ARC00030 (splined shaft) Loosen Bolt 48 and unthread Remove washers listed as 47 & 46 Remove the splined sprocket off the shaft...
Page 173 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 13.5.5 Procedure for reassembly of the sprocket on the roller ARC00030 (splined shaft) Fit the assembly as outlined in the black box above as far as part 46 Replace part 46 with a heavy 8 mm (minimum) wall spacer with the same diametre as the original part.
Page 174 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 13.6 Netter clutch unit; ACH00287: Fusion 2 13-13 McHale drive systems section...
Page 175 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual Fusion 2 13-14 McHale drive systems section...
Page 176 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 13.7 Slip clutch setting Subsequent torque adjustment of cam-type cut-out clutches K 64/1 and K 64/2 Adjust to same projection Spring pack length GKN Walterscheid GmbH sets all clutches exactly to the specified torque.
Page 177 Fusion 2 Issue 1: 0208 McHale round baler wrapper technical service manual 13.7.1 Slip clutch setting K64/22 Fusion 2 13-16 McHale drive systems section...
Page 178 Issue 1: 0208 14. Trouble Shooting 14.1 Trouble shooting 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 get to the bottom of the problem. It is important to note that it outlines the common problems and to this effect it is not exhaustive.
Page 179 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 14.4 Rotor slip clutch going off easily Reason Solution Reference Section Rotor chain loose and Tighten the rotor chain 10.6.7 slips thus causing the and check as specified...
Page 180 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 14.6 Chamber losing pressure Reason Solution Reference Section Oil Leak Find Leak and resolve Seals gone in the door Test both rams and Eliminate each ram identify leaking ram and individually.
Page 181 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 14.8 Net will not feed during an automatic cycle Reason Solution Reference Section Reason Solution Reference Section Box in manual Press net button for 3 11.6.1 Oil Leak...
Page 182 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 14.10 Net feeds in, in the middle of a bale Reason Solution Reference Section Net not cut correctly on Check knife previous bale (machine Check spring tension Spring is located on the...
Page 183 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 14.12 Safety switch error Reason Solution Reference Section Dispenser access door Close panel and secure open Wrapper roller not Manually bring up using 11.6.1 returned/ drifted down the buttons with the box...
Page 184 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 14.14 Wrapper will not start after bale transfer Reason Solution Reference Section Chamber full sensor is Check for crop build up/ 11.2.6 not closed Conduct an input output 11.8...
Page 185 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 14.16 Film break error when the film is not broken or run out Reason Solution Reference Section Magnet missing/ Remove dispenser cap, 11.2 damaged check and replace if 11.2.11...
Page 186 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 14.18 Cut and hold not going out all the way Reason Solution Reference Section Machine was Drain some of the oil Warning previously fitted to a from the accumulator...
Page 187 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 14.21 Wrapper not counting/ counting incorrectly Reason Solution Reference Section 30 mm sensor Check and replace 11.4.2 damaged sensor if necessary Dispenser position out Adjust dispenser closer of line...
Page 188 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 14.23 Dispenser moving out of position during work Reason Solution Reference Section Dispenser ring brake Re-set Brake 10.4.4 not set correctly Brake pads worn on Replace brake pads 10.4.3...
Page 189 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 14-12 McHale troubleshooting section...
Page 190 Dispenser rotary speed: Max. 30 rpm (*) May not be available in all countries, check with your McHale Importer for availability in your country. Units are given in both metric and UK imperial values, with the latter shown in brackets.
Page 191 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 15.4 Tightening torque values It is important that the correct torques for fasteners and fittings are adhered to. Below are tables of recommended torques for these. These are to be used unless torques are otherwise specified.
Page 192 170/60 – 8 (Pick-up tyre) 1.38 bar (20 P.S.I). 15.6 Declaration of conformity The McHale Fusion complies with the EU provisions as per the 98/37/EC machinery directive, the 89/336/EEC EMC directive and is manufactured to the I.S. EN ISO 9001:2000 quality standard.
Page 193 Fusion 2 McHale round baler wrapper technical service manual Issue 1: 0208 Fusion 2 15-4 McHale technical specification section...

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