McHale 991L Series User manual

McHale
Ballinrobe
Co. Mayo, Ireland
Tel: [phone]
Fax: [phone]
Email: [email protected]
Website: www.mchale.net
CLT00032_20
991L
991L Series Round Bale Wrapper
Operator Instructor Manual
Issue 15

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McHale 991L Round Bale Wrapper
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Thank you for buying this McHale machine, you have chosen wisely!
Given proper care and attention, you can expect it to provide you with
years of dependable service.
It is important to quote the machine serial number when ordering spare parts or
requesting technical assistance. Space is provided below to record machine details.
If you require further copies of this instruction manual,
please quote part number: CLT00032
This manual covers the following machine variants (Not all variants are available in all
countries):
Due to a policy of continuous product development and improvement, McHale
Engineering reserves the right to alter machine specifications without prior notice and
any obligation to make changes or additions to the equipment previously sold.
Please note that all specifications marked with an in this manual only relate to
certain models or optional equipment. Also these specifications may not be available
in all countries.
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.
Warranty/Guarantee
Attention End User!
Please ensure your machine is fully registered with McHale,
by your dealer, at the time of delivery.
Failure of the dealer to register the machine will render your warranty void!
You can check the registration of your machine by visiting www.mchale.net.
Serial number:
Year of manufacturer:
Date of delivery:
991 LB Linkage machine with manual controls
991 LBER Linkage machine using full electronic control with remote control option
991 TBER Trailed version of the 991 LBER. It gives an operator the flexibility of
being able to mount a hydraulic power pack on the front of the machine
for transportation and operation. The 991 TBER also features a trailed
drawbar and transportation wheels.

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Table of Contents
1 Introduction 6
2 Product Information 7
2.1 Designated use of the machine 7
2.2 Front view 8
2.3 General dimensions & specifications 9
2.4 Tractor attachment 9
2.5 Machine specifications 9
3 General Safety 10
3.1 Be aware of all safety information 10
3.2 Follow all safety instructions 10
3.3 Store all items carefully 11
3.4 Protective clothing 11
3.5 In case of emergencies 11
3.6 Stay clear of moving parts 11
3.7 In the event of a fire 11
3.8 General safety warnings 12
4 Specific Safety Warnings 15
4.1 Electronic safety warnings 15
4.2 Hydraulic safety warnings 15
4.3 Noise level 16
4.4 Fire precautions 16
4.5 Safety instruction decal locations 17
4.6 Safety warnings & instructions explained 18
4.7 Machine lifting guidelines 21
5 Tractor Requirements & Preparation 22
5.1 Tractor requirements 22
5.2 Hydraulic spool valve setup 23
5.3 Attaching the wrapper 24
5.4 Connecting the control box 25
6 Bale & Plastic Film Requirements 26
6.1 Bale Requirements 26
6.2 Plastic Film Requirements 26
6.3 Care of the film roll 27
7 Manual Controls 28

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8 Electronic Control System 29
8.1 Bale Wrap Computer (991 LB) 29
8.2 Electronic Control Box (991 LBER & TBER) 38
8.3 Electronic Control Box Functions 39
8.4 Available wrapping programs 40
8.5 Electronic Control Box Setup 41
8.6 Electronic Control Box Features 42
9 Wrapper Operation 50
9.1 Preparing the machine for wrapping 50
9.2 Loading plastic film 51
9.3 Wrapping at the stack with remote control 51
10 Road Traffic Safety & Operation 53
10.1 Before travelling on any public roadway 53
11 Field Operation & Wrapper Adjustments 54
11.1 Drawbar height (991 TBER) 54
11.2 Dispenser height 54
11.3 500 mm plastic film conversion kit 55
11.4 Table rollers/belts 56
11.5 Table stop position magnet (991 LBER) 56
11.6 Table load position magnet (991 LBER) 57
11.7 Table half tip magnet 58
11.8 Table drive roller shearbolt replacement 59
11.9 Gearbox cross shaft roll pin replacement 59
11.10 Cut & hold accumulator pressure 60
11.11 Chain adjustments 61
12 Accessories & Optional Equipment 63
12.1 500 mm Dispenser Kit 63
12.2 Remote Control Kit (991 LBER) 63
12.3 Dispenser Gears 64
13 Machine Maintenance 65
13.1 Maintenance intervals 65
13.2 Tightening torque values 68
14 Storage 69
14.1 End of season 69
14.2 Start of season 69
15 Trouble Shooting 70
15.1 Trouble shooting overview 70
16 Certification & Warranty 74
16.1 Declaration of Conformity 74
16.2 PDI Form 74
16.3 Change of ownership pre-checks 74
16.4 Limited Warranty 74

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1
Introduction
The McHale 991L Round Bale Wrapper is designed to wrap, with plastic stretch film,
cylindricalsectionbalesofforageforthepurposeofstorageasfodderforlivestock.The
design has been developed based on years of extensive research and development in
the field ofround balewrappers. Given proper care and attention,the McHale 991L will
provide years of reliable and dependable performance.
Pleasedonot assume that youknow how to operateandmaintain your machine before
reading this manual carefully. In order to prevent misuse, damage and accidents, it is
very important that everybody who will operate the McHale 991L be a fully trained
operator.They mustread and fullyunderstand all ofthe contents of this manual, before
operating the machine, paying particular attention to the following:
Safety instructions
Functions
Controls (hydraulic & electrical)
It is highly recommended to get acquainted with any new machinery slowly. Take time
to learn and understand all of the features of the machine. Proficiency will increase as
more experience is obtained.
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. Keep this manual safe and make sure it remains with
the machine, at all times.

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2
Product Information
The McHale 991L is protected against many dangers to itself while being operated
from the control box, in manual and fully automatic modes. However, it is of the utmost
importanceforthe safety of theoperatorandforothers,that the operator paysattention
to all warnings and instructions given in this manual. In particular all safety devices,
decals, guards and controls must be in place and in fully functioning condition. Never
try to clear any malfunction when the tractor is switched on or while the machine is
running. Keep the “Danger Zone” (An area around the machine, detailed in “Danger
Zone” on page 12) free of all persons and animals at all times, while the machine is in
operation. This manual must be read and fully understood by anyone who will operate
the machine.
2.1 Designated use of the machine
The McHale 991L is exclusively designed for normal use in agricultural applications.
The machine has been designed to wrap cylindrical bales of forage with plastic stretch
film for the purpose of storing as fodder for feeding livestock. This designation includes
the movement of the machine, between fields by track or road, incidental to the round
wrapper’s main use. The manufacturer will not be held responsible for any loss or
damage resulting from machine applications other than those specified above. Any
other use the machine may be put to, is entirely at the owners/operators risk.
The designated use of the machine includes that:
the operating, maintenance and repair instructions given by the manufacturer
will be strictly fulfilled
exclusively persons who are familiar with it and instructed about the risks are
entitled to operate, maintain and/or repair the machine
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/operators risk. In such cases, unauthorised
modifications/changes exclude any liability of the manufacturer.
WARNING: Loss of machine validity
By any alteration of safety equipment, the declaration of conformity and
the CE sign loses it’s validity for this machine.

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2.2 Front view
No. Machine Function
1Bale Support Bobbin
2Cut and Hold
3Rotating Table
4Bale Support Bobbin
5Quick Fit Dispenser
62 x Film Holders
7Shear Bolt Unit

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2.3 General dimensions & specifications
Units are given in both metric and UK imperial values, with the latter shown in brackets.
Check with national road traffic regulations in the individual country!
2.4 Tractor attachment
2.5 Machine specifications
Transport length 2.8 m (9’2”)
Transport width 1.65 m (5’ 5”)
Transport height 1.94 m (6’ 4”)
Height to top of rollers 0.83 m (2’ 9”)
Weight (unladen) 800 kg (1,764 lbs)
Tyre dimensions (991 TBER) 20.5 x 8.00 -10
Tyre pressure (991 TBER) 3.4 bar/50 psi
Maximum road speed 40 km/h (25 mph)
Attachment Pin hitch
Towing tractor requirements 45 KW
Electrics (991 LB) 12 Volt DC, 7 amp approx.
Electrics (991 LBER) 12 Volt from battery
Hydraulic systems Open centre, closed centre or load sensing
Minimum hydraulic pressure 150 bar (2,175 psi)
Minimum hydraulic flow rate 18 l/min (4 gal/min)
Maximum rotary table speed 30 rpm
Film stretch 70% (64% or 55% optional)
Film layers 2+2 system
Film width 750 mm (500 mm optional)
Maximum bale size 1.50 m (4’ 11”)
Maximum bale weight 1,000 kg (2,205 lbs)

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3
General Safety
3.1 Be aware of all safety information
Follow all safety precautions and practice safe operation of machinery, at all times.
Warning, Caution, Information & Environmental Messages:
When reading this manual, pay particular attention when you see the symbols below
i.e. Warning, Caution, Information & Environmental. They will be used at various points
in this manual and may also appear on safety decals on the machine. The purpose of
these messages are to ensure that the most important information stands out from the
rest of the text.
WARNING:This symbol indicatesa potentially hazardous situation,
thatifnotavoidedcouldresultin machinerydamage,personalinjury
or even death.
CAUTION: This symbol indicates a potentially hazardous situation,
that if not avoided could result in machinery damage or personal
injury.
INFORMATION: This symbol is used to identify special instructions
or procedures which, if not followed strictly, could result in
machinery damage.
ENVIRONMENTAL: reminds you to respect the environment in
relation to the correct disposal of waste material
3.2 Follow all safety instructions
Using this manual, read all safety instructions, messages and be
aware of the meanings of all safety decals. If safety decals are
damaged or missing due to wear and tear or component
replacement, ensure that they are replaced by genuine McHale
decals. Refer to the Decals Section in this manual (or spare parts
book provided) to see the spare part codes for the relevant decals,
which are available from your McHale dealer.

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As with all machinery, learn all operations and use controls by reading this manual
thoroughly. Do not attempt to let anyone operate this machine without being fully
instructed.
3.3 Store all items carefully
Store all attachments such as films rolls and any other stored items
in a secure and safe manner so as to prevent items from falling.
Keep storage areas clear of bystanders and children.
3.4 Protective clothing
Always wear clothing and safety equipment that is fit for the job at
hand, never wear loose clothing. In the event of loud noises, wear
suitable protective hearing devices. Use of mobile phones or radio/
music headphones are not recommended while operating
machinery as these impair the operator’s attention.
3.5 In case of emergencies
In the event of any accident, emergency equipment should be kept
close at hand. A first aid kit and fire extinguisher along with
emergency phone numbers should always be available to machine
operators.
3.6 Stay clear of moving parts
Serious injury or death can result from entanglement of clothing or body parts with
Check for smooth operation of the table and all moving parts.
Keep all guards in place at all times, only wear close fitting clothing and ensure that
tractor engine has stopped and key is removed before carrying out any adjustments,
connections or cleaning of equipment.
3.7 In the event of a fire
In the event of a fire, the following is given, only as a guideline
procedure, as it is the operator’s decision to ascertain the
seriousness and hence the solution to the situation.
1. Immediately tip the bale off the table and move the tractor and wrapper away
from the flammable material.
2. Shutdown the tractor and remove the key from the ignition.
3. Remove all hydraulic hosing and electrical looms from the machine.

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4. With all connections removed, disengage the wrapper from the tractor.
5. Drive the tractor away from the wrapper.
6. Using a suitable fire extinguisher, attempt to put out the fire.
3.8 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. The owner of this machine is obliged, by law, to ensure that
every operator understandsall of the functions,controls,working processes andsafety
warnings, before operating the machine.
Safety Devices
All safety devices such as guards, protection parts and safety controls must
be in place and in fully functioning condition. It is forbidden to operate this
machine with defective or incomplete safety devices.
Danger Zone
The ‘Danger Zone’ is the area around the rotating table (approx. 5 metres
radius from the rotating centre axis), 1 metre in front of the table and a
minimum of 10 metres at the back of the machine to allow for safe bale
discharge.
It is the operator’s responsibility to ensure that there is no person in the
‘Danger Zone’ while operating the machine, especially during start up.
Before Repair or Reassembly
Safe lifting gear of sufficient capacity must be used for machine assembly. All
chains and slings used must be in good condition.
Extreme caution is required when fitting or adjusting the mat frame or side tip
plate.
WARNING: Fire Prevention
It is recommended that the wrapper be kept reasonably clean and free
of build-ups of crop, lubricants, etc. This will help to reduce the risk of
fires.
NOTE: “Danger Zone” can vary in size
The operator must be aware of the ‘Danger Zone’ which can vary in size,
depending on operating conditions, i.e. hilly terrain.

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Before Operation
The operator must ensure that the manufacturer’s instructions for attaching
and detaching the machine are followed. This includes the electric and
hydraulic lines, in particular the lighting system.
The operator must ensure that all safety devices are in operating mode
The operator must ensure that there is no person in the “Danger Zone”
Always be familiar with the health and safety requirements that may be in
force in the country of use
During Operation
The operator must ensure that there is a minimum of 4 m clearance between
the machine and any obstacle above, in particular electrical high voltage lines.
Be careful when working with the cut & hold. Remember that the
accumulators are under pressure.
Avoid contact with the knife
Do not attempt to clamp plastic film in the cut & hold mechanism
Particular care must be taken, if the machine is left idle for any extended
period, to ensure that all sensors and safety features are working correctly.
The safety bar must always be used when working under a tipped table.
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.
Always ensure that the electronic control box or bale wrap computer and oil
supply are switched off.
Ensure lights (if fitted) are connected and working correctly.
If plastic film is to be transported on the machine it must only be done so on
the holders provided and secured, if necessary.
WARNING: Do not carry people or animals on the machine
The operator must ensure that no persons or animals are carried on the
machine at any time or are hidden under the machine (on the tractor
persons are only allowed to sit on the relevant seats)

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Performing Maintenance
Maintenance and repair work on the 991L should always be carried out in
accordance with this manual.
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
wear a necktie, necklace, scarf or loose clothing when you work near the
machine or moving parts. If these items were to get caught, severe injury
could result.
Before working on this machine, such as replacing film rolls or altering any
setting, the operator must ensure the following:
(a) The tractor has definitely stopped moving
(b) The hand brake is applied
(c) The engine is shut down
(d) The ignition key is removed
(e) Electronic power supply and control box is disconnected
(f) Hydraulic oil supply is switched off
*It is forbidden to carry out any work on the machine, unless the above specified
precautions have been carried out.
When conducting maintenance work always support the machine properly.
Where possible, lower the attachment or implement to the ground before you
work on the machine. If it is not possible to lower the machine or attachment
to the ground, always securely support the machine or attachment. Do not
work under a machine that is solely supported by a jack. Never support the
machine with props that may break or crumble under continuous load.
Never disable any electrical safety circuits, tamper with safety devices or carry
out any unauthorised modification to the machine.
Avoid heating near pressurised fluid lines, as pressurised lines can be
accidentally damaged when heat goes beyond the immediate flame area.
During inspection
If carrying out an inspection during machine operation within the “Danger
Zone” (highly dangerous and NOT recommended!), then there should be a
fully trained and competent second person operating both the tractor and
wrapper controls. If at any time the second operator loses sight of the
inspector, turn off all tractor power immediately! Such inspection should only
be carried out if all guards are fully in place, the machine is on level ground
and a safe distance is kept from any hazards on the machine.

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4
Specific Safety Warnings
4.1 Electronic safety warnings
This machine is equipped with electronic parts and components which comply
to the EMC directive 2004/108/CE but still may be influenced by
electromagnetic transmissions of other apparatus, such as welding machines,
etc.
Check electric cables regularly for signs of breakage or wear. If in doubt
always replace (faulty safety circuits will cause risks).
Do not modify any safety circuits.
4.2 Hydraulic safety warnings
The maximum pressure in the hydraulic system of this machine should not
exceed 210 bar.
Always ensure the system is not under pressure before working on the
machine. Oil under pressure can penetrate the skin and cause injury. Beware
of pipes under accumulator pressure, depressurise lines by unthreading
connections extremely slowly.
Hydraulically actuated devices, such as the table tip must be blocked
mechanically against movement, before working on the machine.
If any hoses are removed or replaced ensure they are marked and re-installed
to the correct position during re-assembly.
Check hoses regularly for signs of leakage or wear. Use a piece of card when
checking for leaks. Fine jets of hydraulic fluid can penetrate the skin. Never
use your fingers or face to check for leaks. If in doubt always replace. The
recommended maximum working time of hoses should not exceed 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.

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4.3 Noise level
The European Regulation 86/188/EEC directs employers and employees to
control the noise level at work. The noise level at field work may differ
according to the tractor, ground, crops and other environmental conditions.
In normal conditions, whilst driving the McHale 991L, 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). It
is recommended to operate this machine with closed cabin windows.
4.4 Fire precautions
Be aware that crops are easily inflammable.
Do not smoke or make use of any open fire next to the machine.
A functioning fire extinguisher should always be available on the tractor.
The machine is to be kept clear of oil, grease, crops, string, plastic or any
other flammable material at all times.
Do not continue to work with overheated parts, cables or pipes, unless you
have identified and eliminated the reason for overheating.

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4.5 Safety instruction decal locations
Figure 4.a - Decals on the 991L

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4.6 Safety warnings & instructions explained
Danger areas which cannot be protected by any devices are marked by yellow safety
decals. 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 McHale 991L are displayed with their meanings below:
Free flow return to tank
(CST00006)
Danger of rotating parts, foreign objects
Keep clear of machine while working
(CST00014)
Keep hands clear of rotation roller
(CTS00017)
Keep hands out of crush area
(CST00019)
Cable control valve controls
(CST00025

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Keep hands out of the trap area
(CST00026)
Keep clear of rotating table
(CST00028)
Max table speed 30 R.P.M.
(CST00031)
Lifting hook location
(CST00032)
Diagram of plastic film path through dispenser
(CST00049)

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Do not dismantle
High pressure always
(CST00056)
Read instruction manual
(CST00057)
Support table before working under it
Refer to the instruction manual
(CST00059)
Dispenser height setting
CST00062)
Manual control valve controls
(CST00064)