McHale Fusion 2 Assembly instructions

Fusion 2
Fusion 2Fusion 2
Fusion 2 Baler Wrapper
Operator Instruction Manual
Issue 2
McHale Engineering Limited,
Castlebar Rd, Ballinrobe
Co. Mayo, Ireland.
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Website: www.mchale.net
ENGINEERING LTD.
ENGINEERING
Fusion 2
Fusion 2Fusion 2
Fusion 2 Baler Wrapper
Operator Instruction Manual
Issue 2
(Valid up to Serial Number 654555)
McHale Engineering,
Castlebar Rd, Ballinrobe
Co. Mayo, Ireland.
Tel: [phone]
Fax: [phone]
Email: s[email protected]t
Website: www.mchale.net

McHale Fusion 2 Introduction section 01-1
McHale Fusion 2 round baler wrapper operators instruction manual Issue 2: 0907
1. Introduction
The McHale Fusion round baler wrapper combination is a completely new
product. This product combines the baling process with the wrapping process all in
one machine. The design has been carried out on the basis of long term constant
research and development in the field of round bale wrappers and round balers.
According to consequent professional product development and proper care the
McHale Fusion will provide years of reliable and dependable performance. However
it is also important that everybody who operates this machine reads and
understands this manual before operating the machine. If any of the instructions
appear unclear do not hesitate to contact your McHale dealer. 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. These may be obtained through your McHale dealer.
Description of a fully trained operator: The McHale Fusion will require a
fully trained operator. This is someone who has read and fully understood all of the
contents of this instruction manual. They must be aware of all safety instructions, of
all functions and controls, both hydraulic and electrical. The operator is solely
responsible for safe use and maintenance of the machinery in accordance with this
manual. It is highly recommended that training be sought from your local dealer. The
operator must be constantly vigilant of their surroundings and should always think,
safety first. The machine is only to be used for it’s designated purpose as is outlined
above.
Note: The above description is a guideline only, and as a rule, it is highly
recommended to get acquainted slowly at first with any new machinery. Take the
time to both learn and understand all the features of the machine. Proficiency will
increase as more experience is obtained.
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: CLT00
Due to a policy of continuous product development and improvement, McHale Engineering Ltd.
reserves the right to alter machine specifications without prior notice. 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.
Serial number:
Year of manufacture:
Date of delivery:

McHale Fusion 2 round baler wrapper operators instruction manual Issue 2: 0907

McHale Fusion 2 round baler wrapper operators instruction manual
Issue 2: 0907
2. Contents
Section Page
1. Introduction …...………………………………………………….. 01-1
2. Contents ……………………………………………………………... 02-i
3. Getting familiar with the McHale Fusion ……………………….. 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 ……………………………... 04-1
4.4 Protective clothing ……………………………………. 04-1
4.5 In of emergencies ……………………………………. 04-2
4.6 Stay clear of rotating elements ……………………..… 04-2
4.7 Operating the McHale Fusion with safety …………... 04-2
4.8 In the event of a fire ……………………………………. 04-2
4.9 General safety warnings ……………………………... 04-3
5. Specific safety warnings
5.1 Electronic safety warnings ……………………………... 05-1
5.2 Hydraulic safety warnings ……………………………... 05-1
5.3 Noise level ………………………………………………… 05-2
5.4 Fire precautions ………………………………………….. 05-2
5.5 Special safety devices/ instructions …………………. 05-2
5.6 Safety/ instruction decal locations …………………. 05-3
5.7 Description of safety warnings and instructions …….. 05-5
5.8 Description of the serial number plate …………………. 05-9
5.9 Machine lifting eye location points …………………. 05-10
6. Tractor requirements and preparations
6.1 Tractor requirements ……………………………………. 06-1
6.2 Control box installation ……………………………... 06-1
6.3 Lighting system ………………………………………….. 06-2
6.4 Attaching the Fusion to a 540 rpm PTO…………………. 06-2
6.5 Attaching to drawbar ……………………………………. 06-2
6.6 Attaching break away brake……………………………… 06-2
6.7 What is the hydraulic system on the tractor and
how does it affect the Fusion set-up? ……………………….. 06-3
6.8 What hydraulic system does the tractor use? …….. 06-4
6.9 Hydraulic spool valve set-up ……………………….. 06-5
6.10 Attaching hydraulic hosing to tractor …………………. 06-6
6.11 Connecting the control box……………………………... 06-6
McHale Fusion 2 Contents section 02-i

McHale Fusion 2 round baler wrapper operators instruction manual Issue 2: 0907
Section Page
McHale Fusion 2 Contents section
02-ii
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 ……………………………………. 07-2
7.5 Net cutter setting………………………………………….. 07-3
7.6 Net tension bar setting……………………………………. 07-4
7.7 Chopper unit knife removal and installation …………... 07-5
7.8 Automatic lubrication system ……………………….. 07-7
7.9 Gear box oil………………………………………………… 07-8
7.10 Tyre inflation pressures ……………………………... 07-8
7.11 Drawbar and PTO shaft stand usage …………………. 07-9
7.12 Drawbar adjustment ……………………………………. 07-11
7.13 PTO shaft adjustment ……………………………... 07-11
8. Electronic control system
8.1 Control box functions ……………………………………. 08-1
8.2 Menu Structure ………………………………………….. 08-3
8.3 Control box features ……………………………………. 08-5
8.4 Error messages and their meaning …………………. 08-11
8.5 Running a simulated “bale to wrapping” cycle … …. 08-14
9. Wrapper operation
9.1 Loading plastic film ……………………………………. 09-1
9.2 Plastic film requirements ……………………………... 09-3
9.3 Wrapping process ……………………………………. 09-4
9.4 Dispenser adjustment ……………………………………. 09-4
9.5 Cut and hold system ……………………………………. 09-5
10. Road traffic safety and operation
10.1 Before travelling on any public roadway …………... 10-1
10.2 Road transportation ……………………………………. 10-2
10.3 Road transportation with side tip attached …………... 10-2
10.4 Break away brake……………………………….……….. 10-3
11. Baler field operation and adjustments
11.1 Break in period ………………………………………….. 11-1
11.2 Swath preparation ……………………………………. 11-1
11.3 Pick-up adjustment ……………………………………. 11-2
11.4 Crop guard adjustment ……………………………... 11-2
11.5 Unblocking system ……………………………………. 11-3
11.6 Chopping system ……………………………………. 11-4
11.7 Knife pressure gauge……………………………………. 11-4
11.8 Bale density gauge ……………………………………. 11-5
11.9 Setting chamber pre-charge pressure…………………. 11-5
11.10 Top and bottom door locks ……………………….. 11-6
11.11 Spare film holders and door safety latch operation…. 11-6
11.12 Adjusting pick-up float spring ……………………….. 11-7
11.13 Chain adjustments ……………………………………. 11-8
11.14 Net wrapping system ..………………………………… 11-14

McHale Fusion 2 round baler wrapper operators instruction manual
Issue 2: 0907
Section Page
McHale Fusion 2 Contents section 02-iii
12. Accessories and optional equipment
12.1 Accessory and optional equipment availability …….. 12-1
12.2 Knife blanks ………………………………………….. 12-1
12.3 Wheel Chocks ………………………………………….. 12-2
12.4 Tool box ………………………………………………… 12-2
12.5 Drawbar hitch options ……………………………... 12-2
12.6 Stand options ………………………………………….. 12-3
12.7 Brake options ………………………………………….. 12-3
12.8 Tyre options ………………………………………….. 12-3
12.9 Side tip option ………………………………………….. 12-3
12.10 Dispenser gear options ……………………………... 12-4
13. Attachments
13.1 Side tip ………………………………………………… 13-1
14. Machine maintenance
14.1 Maintenance intervals ……………………………... 14-1
14.2 Tightening torque values ……………………………... 14-3
15. Storage
15.1 End of season ………………………………………….. 15-1
15.2 Start of season ………………………………………….. 15-1
16. Technical specifications
16.1 General dimensions/ specifications …………………. 16-1
16.2 Tractor attachment ……………………………………. 16-1
16.3 Machine specifications ……………………………... 16-1
16.4 Tyre specifications ……………………………………. 16-2
16.5 Declaration of conformity ……………………………... 16-2
18. Limited warranty …………………………………………………. 18-1

McHale Fusion 2 round baler wrapper operators instruction manual
Issue 2: 0907

McHale Fusion 2 main component reference section 03-1
McHale Fusion 2 round baler wrapper operators instruction manual
Issue 2: 0907
3. Getting familiar with the McHale Fusion

McHale Fusion 2 round baler wrapper operators instruction manual
Issue 2: 0907

McHale Fusion 2 round baler wrapper operators instruction manual Issue 2: 0907
McHale Fusion 2 generic safety section 04-1
4. General Safety
4.1 Be aware of all safety information
The symbol opposite is the symbol used to alert you to safety
issues. It appears both in this manual and on some of the safety
decals. On the decals it appears on a yellow background while in
this manual it appears in black and white.
Follow all safety precautions and practice safe operation of all
machinery at all times.
When reading through this manual, pay attention to where you see the above
symbol paying extra care to where you will see the Warning and Caution pointers.
4.2 Follow all safety instructions
Using this manual, read all safety instructions, messages and be
aware of the meanings of all safety decals. Ensure, if safety decals
are damaged or missing due to wear and tear or due to component
replacement, that they be replaced. 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. Do not attempt to let anyone operate this machine without being
fully instructed.
4.3 Store all items carefully
Store all attachments such as spare net rolls, film 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.
4.4 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 radio (walkman)
headphones are not recommended while operating machinery as
this impairs operators attention.

McHale Fusion 2 round baler wrapper operators instruction manual
Issue 2: 0907
McHale Fusion 2 generic safety section
04-2
4.5 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.
4.6 Stay clear of rotating elements
Serious injury or death can result from entanglement of clothing or body parts with
PTO shafts, drivelines and other rotating and moving components.
Keep all guards in place at all times, only wear close fitting clothing and ensure
that tractor engine has stopped, key removed and that PTO has stopped turning
before carrying out any adjustments, connections or cleaning of PTO driven
equipment.
4.7 Operating the McHale Fusion safely
In order to avoid serious injury or even death by being pulled into the machine:
1. Never attempt to feed net or crop into the baling chamber or attempt to unplug
pick-up area while the baler is running.
2. Disengage PTO, shut tractor engine off and remove the key.
3. Stand well clear of baler and tractor when machine is operating.
4.8 In the event of a fire
In the event of a fire, the following is only given as a guideline procedure,
as it is the operators decision to ascertain the seriousness and hence the
solution of the situation.
1. Switch control box to manual mode (see section on Electronic control system).
Immediately tip bale off rear roller, leave roller in tipped position.
2. Eject bale from baling chamber by opening chamber doors.
3. Move tractor and baler away from the flammable material.
4. Disengage PTO, turn off tractor and remove key. Remove all hosing and elec-
trical looms from the machine.
5. With all connections removed, disengage drawbar from tractor. Drive tractor
away from baler.
6. Using a suitable fire extinguisher put out all fires.
Note: It is recommended that the baler be kept reasonably clean and free of
build-ups of grass, lubricants etc., this will help to reduce the risk of fires.

McHale Fusion 2 round baler wrapper operators instruction manual Issue 2: 0907
McHale Fusion 2 generic safety section 04-3
4.9 General safety warnings
¾Read 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.
¾Only 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 must understand all the functions, controls,
working processes and safety warnings before operating the machine.
¾All 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 (never disable or defeat
any electrical safety circuits).
¾All safety decals on the machine must be kept in good legible condition. If
they are not they must be replaced by genuine McHale decals from your
McHale dealer (part numbers are available in this manual).
¾Before operating this machine the operator must ensure that all covers are
closed and all safety devices are in operating mode.
¾Before operating this machine the operator must ensure that the
manufacturer’s instructions for attaching and detaching the machine are
followed. This includes besides the drawbar attachment, the electric and
hydraulic lines, in particular the lighting and brake system.

McHale Fusion 2 round baler wrapper operators instruction manual
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McHale Fusion 2 generic safety section
04-4
¾Before operating this machine the operator must ensure that no persons or
animals are carried on the machine or are hidden under the machine (on the
tractor persons are only allowed to sit on the relevant seats).
¾Before operating this machine the operator must ensure that there is no
person in the “danger zone” (in front of tractor, between tractor and round
baler wrapper combination, and a minimum of 5 m behind the machine).
Note: It is the operator’s responsibility to keep all people out of this area!
In this area a person is subject to a risk to his/her own health or safety!”
¾While operating this machine on hilly or sloping ground the operator must
take extra precautions, in particular the “danger zone” is increased in such
conditions as bales are more likely to roll away causing a potential risk.
¾While operating this machine 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.
¾Before working on this machine, such as replacing net or film rolls, clearing
forage away from any part of the machine or altering any setting, the operator
must ensure that the tractor has definitely stopped moving, handbrake is
applied, engine has stopped and ignition key is removed, PTO shaft is
removed from pto stub and electric power supply is disconnected. It is
forbidden to open any safety guards or to carry out any work on the machine
unless the above-specified precautions have been carried out.
¾Warning! If carrying out inspection during machine operation within the danger
zone (highly dangerous and not recommended!), then there should be a
trained and fully competent second person operating both the tractor and baler
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, machine on level ground and a safe distance from the
machine maintained from any hazards on the machine e.g. pick-up region.
¾Maintenance and repair work on this machine should always be carried out
in accordance with this manual.
¾Maintenance and repair work exceeding the content of this manual should
only be carried out by qualified persons or your McHale dealer.
¾Before 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 (see section 10).
¾Ensure that no bale is carried on the rear table section, while travelling on
public roads.
¾When parking both wheels of this machine have to be blocked using wheel
chocks according to the road traffic regulations relating to the country of use.

McHale Fusion 2 specific section 05-1
McHale Fusion 2 round baler wrapper operators instruction manual Issue 2: 0907
5. Specific safety warnings
5.1 Electronic safety warnings
¾This machine is equipped with electronic parts and components which comply
to the EMC directive 89/336/EEC but still may be influenced by
electromagnetic transmissions of other apparatus, such as welding machines,
etc.
¾Check electric cables regularly for signs of breakage or wear. If in doubt
always replace (faulty safety circuits will cause risks).
¾Do not modify any safety circuits.
5.2 Hydraulic safety warnings
¾The maximum pressure in the hydraulic system of this machine should not
exceed 210 bar.
¾Always ensure 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.
¾Hydraulically actuated devices, such as pick-up, cutting device and wrapping
ring, must be blocked mechanically against movement, before working on the
machine.
¾If any hoses are removed or replaced ensure they are marked and re-installed
to the correct position during re-assembly.
¾Check hoses regularly for signs of leakage or wear. 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.
¾Do 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.

McHale Fusion 2 specific section
05-2
McHale Fusion 2 round baler wrapper operators instruction manual
Issue 2: 0907
5.3 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, 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 round baler wrapper combination does not exceed 70 dB (A) with open rear
screen of the tractor cabin. 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.
5.4 Fire precautions
¾Be aware that crops are easily inflammable.
¾Do not smoke or make use of any open fire next to the machine.
¾A functioning fire extinguisher should always be available on the tractor.
¾The machine is to be kept cleared of oil, grease, crops or any other flammable
material at all times.
¾Do not continue work with overheated parts, cables or pipes unless you have
identified and eliminated the reason for overheating.
5.5 Special safety devices / instructions
¾According to the European safety regulations the covers of this machine are
designed to be opened only by the aid of a special tool and to be closed
without a tool. For unlocking the covers the locks should be turned slightly
anti-clockwise with a 13-mm-spanner; for locking the covers push cover
towards the chassis until the fasteners lock into place. It is forbidden to operate
the machine without, or with open covers. The owner of this machine is obliged
by law to ensure that all covers are installed on the machine and are in good
functioning condition.
¾When maintenance or repair work has to be carried out at the open bale
chamber the additional upper chamber lever valve must be in the locked
position. Before the upper chamber can be closed it has to be unlocked again.
¾Before replacing the knives of the chopping system make sure that all knives
are in the upper position. Always use protective gloves when working at the
chopping system.
¾Avoid contact with the plastic film cutting knives.

McHale Fusion 2 specific section 05-3
McHale Fusion 2 round baler wrapper operators instruction manual Issue 2: 0907
1
2
3
4
5
6
7
8
9
10
11
CST00136

McHale Fusion 2 specific section
05-4
McHale Fusion 2 round baler wrapper operators instruction manual
Issue 2: 0907

McHale Fusion 2 specific section 05-5
McHale Fusion 2 round baler wrapper operators instruction manual Issue 2: 0907
5.7 Description of safety warnings and instructions
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 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.
The accurate meanings are explained as follows:
Machine chassis plate.
Read instruction manual before use.
(CST00110)
Turn off and remove key from tractor, read
and understand manual before working on,
or performing maintenance on the machine.
(CST00113)
Close protective covers before
operating the machine.
(CST00114)
Beware of high-pressure hoses, even when
machine is switched off. Also read and
understand manual before working on any part of
the hydraulic system.
(CST00111)
Keep clear of pickup area as long as the
engine is running and the PTO shaft is
connected to the tractor.
(CST00108)

McHale Fusion 2 specific section
05-6
McHale Fusion 2 round baler wrapper operators instruction manual
Issue 2: 0907
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.
(CST00107)
Keep hands out of crush area
between roller & chassis rail.
(CST00120)
Hydraulic accumulator is under high pressure.
Slowly release hydraulic pressure before carrying
out any maintenance.
(CST00115)
Knives of the cutting device should only be
removed with an appropriate tool and protective
gloves.
(CST00112)
Keep hands out of crush area.
(CST00019)