McHale Fusion 3 Assembly instructions

McHale
Ballinrobe
Co. Mayo
F31 K138 Ireland
Tel: [phone]
Email: [email protected]
Website: www.mchale.net
CLT00485_4.02
55
I.S. EN ISO 9001:2015
Fusion 3
Baler & Wrapper
Operator Instruction Manual
Issue 3

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Think before printing documents! Is a PDF on a laptop or tablet
sufficient? If a printed copy is required, always select ‘Print on both sides
of paper’ and always try to limit the number of printed pages by selecting
a specific page range or just select ‘Current page’ if that is sufficient.
This is the original operator manual with ‘Original Instructions’. The English
language version of the operator manual is the source document for all
translations.
If there is any conflict as to the accuracy or content, of any translation, the English
source manual remains the authorised document.
No part of this manual may be reproduced, distributed or translated, in any form or
by any means, without prior written permission by McHale.

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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.
(See ‘Description of the serial number plate’)
If you require further copies of this instruction manual,
please quote part number: CLT00485
Due to a policy of continuous product development and improvement, McHale
Engineering reserves the right to alter machine specifications, including the contents of
this manual, without prior notice or any obligation to make changes or additions to the
equipment previously sold. Images and screenshots used in this manual may differ in
appearance from the actual product.
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.
Throughout this manual there are links to other relevant sections of the manual, to
guide the reader to additional information to convey the complete message. These
links are in (grey italic font). See the example above i.e. the link to the description of
the serial number plate. When you click on the link in the PDF document, the page will
jump automatically to the linked section. With Adobe Reader, you can go back to the
page on which you clicked the link, by clicking on the ‘Previous view’ button (or by
holding ‘Alt’ and pressing the ‘left arrow’).
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 manufacture:
Date of delivery:

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Table of contents
1 Introduction 8
2 Product information 9
2.1 Designated use of the machine 9
2.2 Front view 10
2.3 Rear view 11
2.4 General specifications 12
2.5 Tractor specifications 12
2.6 Machine specifications 13
2.7 Tyre specifications 13
2.8 Optional equipment* 14
3 General safety 15
3.1 Be aware of all safety information 15
3.2 Follow all safety instructions 15
3.3 Store all items carefully 16
3.4 Personal protective equipment (PPE) 16
3.5 In case of emergencies 16
3.6 Stay clear of rotating elements 16
3.7 Trained operator criteria 17
3.8 Operating the machine 17
3.9 In the event of a fire 17
3.10 General safety warnings 18
4 Specific safety warnings 24
4.1 Electronic safety warnings 24
4.2 Hydraulic safety warnings 24
4.3 Noise level 24
4.4 Fire precautions 25
4.5 Special safety devices/instructions 25
4.6 Safety instruction decal locations 26
4.7 Safety warnings & instructions explained 27
4.8 Hydraulic control valve decal 34
4.9 Description of the serial number plate 35
4.10 Machine lifting guidelines 36
4.11 Jacking guidelines 37
5 Tractor requirements & preparation 38
5.1 Tractor requirements 38
5.2 Control box installation 38
5.3 Attaching to drawbar 39
5.4 Attaching ‘break-away’ brake 40
5.5 Attaching the PTO shaft 40
5.6 Machine set-up & the tractor hydraulic system 41
5.7 Which hydraulic system is used? 42

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5.8 Hydraulic spool valve setup 42
5.9 Making connections to the tractor 43
5.10 Connecting the control box 44
5.11 Lighting system 44
6 Machine requirements & preparation 45
6.1 Net requirements 45
6.2 Care of the net roll 45
6.3 Care of the net wrapping system 46
6.4 Loading & operating the netter system 46
6.5 Net layer adjustment setting 49
6.6 Net tension bar setting 51
6.7 Chopper unit knife removal & installation 51
6.8 Automatic lubrication system 56
6.9 Gearbox oil 58
6.10 Tyre inflation pressures 59
6.11 Wheel chocks 60
6.12 Drawbar & PTO shaft stand usage 60
6.13 Drawbar adjustment 63
6.14 PTO shaft adjustment & maintenance 64
7 Electronic control system 68
7.1 Control box functions 69
7.2 Control box features 70
7.3 Menu structure 75
7.4 Warning messages 81
7.5 Simulating a ‘bale to wrapping’ cycle 85
7.6 Knife selection system 86
8 Wrapper operation 89
8.1 Loading dispenser film 89
8.2 Plastic film requirements 92
8.3 Wrapping process 94
8.4 Dispenser gear options 95
8.5 Cut and hold system 96
9 Road traffic safety & operation 100
9.1 Before travelling on any public roadway 100
9.2 Road transportation with side-tip attached 101
9.3 ‘Break-away’ brake 102
10 Field operation & machine adjustments 103
10.1 Break-in period 103
10.2 Swath preparation 103
10.3 Pick-up reel height adjustment 104
10.4 Crop guard adjustment 105
10.5 Crop roller adjustment 105
10.6 Unblocking system 106
10.7 Chopping system 107
10.8 Selectable knives 107
10.9 Bale density gauge 108

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10.10 Setting chamber pre-charge pressure 108
10.11 Chamber door lock 109
10.12 Spare film holders & door latch safety 110
10.13 Brake overview 111
10.14 Adjusting pick-up float springs 116
10.15 Chain adjustments 118
11 Attachments 122
11.1 Side-tip 122
12 Machine maintenance 127
12.1 Maintenance intervals 127
12.2 Tightening torque values 130
13 Storage 131
13.1 End of season 131
13.2 Start of season 132
14 Troubleshooting 133
14.1 Troubleshooting overview 133
15 Certification & Warranty 137
15.1 Declaration of Conformity 137
15.2 PDI form 137
15.3 Change of ownership pre-checks 137
15.4 Limited Warranty 137
16 Appendix 142
16.1 Adjusting the PTO shaft to the tractor 142
16.2 Unit conversion tables 143

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1
Introduction
This product combines the baling process with the wrapping process, in one machine.
The design has been developed based on years of extensive research and
development in the field of round bale wrappers and balers. Given proper care and
attention, the machine will provide years of reliable and dependable performance.
Please do not assume that you know how to operate and maintain 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 machine is a fully trained operator.
(See ‘Trained operator criteria’). They must read and fully understand all of the
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.
ENVIRONMENT: Reduce paper consumption
Think before printing documents! Is a PDF on a laptop or tablet
sufficient? If a printed copy is required, always select ‘Print on both sides
of paper’ and always try to limit the number of printed pages by selecting
a specific page range or just select ‘Current page’ if that is sufficient.

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2
Product information
The machine is protected against many dangers to itself while being operated from the
control box in both manual and automatic cycles. However, it is of the utmost
importance for the safety of the operator and for others, that the operator pays attention
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) free of all persons and
animals at all times, while the machine is in operation (See ‘Danger Zone’). This
manual must be read and fully understood by anyone who will operate the machine.
2.1 Designated use of the machine
The machine is exclusively designed for normal use in agricultural applications. The
machine has been designed to pick up and compact stalks from the ground, to produce
cylindrical bales of forage, which are in turn wrapped 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 machine’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 owner/operator’s 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/operator’s risk. In such cases, unauthorised
modifications/changes exclude any liability of the manufacturer.
NOTE: Loss of machine validity
By any alteration of safety equipment, the declaration of conformity and
the CE sign loses its validity for this machine.

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2.2 Front view
No. Machine function
1Netter unit
2Net tension bars
3Hydraulic section (inside cover)
4Chamber door pressure clock
5Drawbar & stand
6Crop guard or crop roller
7Platform
8Pick-up reel
9Chopper unit
10 Wheel chocks & knife blanks (inside cover)
11 Spare film section (inside cover)
4
2
3
1
67 89
510 11

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2.3 Rear view
No. Machine function
1Hose carrier
2Netter unit
3Top chamber door
4Spare film section (inside cover)
5Dispenser ring
6Dispenser
7Tip arm roller
8Cut & hold unit
9Dispenser access door
10 Drive side
3
1
245
678910

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2.4 General specifications
Units are given in both metric and UK imperial values, with the latter shown in brackets.
*May not be available in all countries, check with your McHale dealer for availability in
your country.
2.5 Tractor specifications
*Please note that some specifications may only relate to certain models or optional
equipment and may not be available in all countries.
Transport length 5.8 m (228”)
Transport width 2.76 m (109”)
Transport height 3.02 m (119”)
Transport weight (unladen) 6,325 kg (13,945 lbs)
Axle weight (unladen) 5,325 kg (11,740 lbs)
Maximum road speed 40 km/h (25 mph)
Brake system Air brakes
Hydraulic brakes*
Tractor capacity (min) 85 kW (115 HP)
Hitch type Low drawbar
High drawbar*
PTO speed 540 rpm (1,000 rpm optional)
Lighting 12 V / 7-pin socket
Electrics 12 V, 20 A euro socket
Hydraulic systems Open-centre, closed-centre, load-sensing
Minimum pressure 180 bar (2,610 psi)
Minimum flow rate 45 l/min (9.9 gal/min) @ 180 bar (2,610 psi)

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2.6 Machine specifications
2.7 Tyre specifications
Bale chamber diameter 1.25 m (49”)
Bale chamber width 1.23 m (48”)
Pick-up width 2.10 m (83”)
Net wrap
Net width Max. 1.26 m (49.6”)
Max. roll weight 40 kg (See warning below)
Dispenser film
Film width 750 mm (29.5”)
Film stretch 70% (64% optional)
Film layers 2+2; 2+2+2; etc.
Film storage 10 rolls (+ 2 rolls on dispensers)
Dispenser rotary speed Max. 30 rpm
CAUTION: Heavy net rolls should be handled by two people
Pay attention to the heavy weight of the net roll. It is recommended that
full net rolls should be handled by two people.
Details Type Field
pressure
Road
pressure Part No.
560/60R22.5 155 D (Vredestein) Flo-Pro 1.65 bar 3.2 bar CWH00053
560/60R22.5 161 D (BKT) FL-630 1.65 bar 4 bar CWH00068
650/50R22.5 157 D (Vredestein) Flo-Pro 1.65 bar 3.2 bar CWH00054
650/55R22.5 167 D (BKT) FL-635 1.65 bar 4 bar CWH00088
650/55R22.5 163 D (Alliance) A-885 1.65 bar 4 bar CWH00290
680/50R22.5 157 D (Vredestein) Flo-Trac 1.65 bar 2.8 bar CWH00281
710/45R22.5 165 D (Vredestein) Flo-Trac 1.65 bar 4 bar CWH00271
170/60-8 71 A8 (Vredestein) Pick-up 2.07 bar 2.07 bar CWH00037

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2.8 Optional equipment*
*May not be available in all countries, check with your McHale dealer for availability in
your country.
Side-tip option
The side-tip option is used for knocking the bale onto its side and is very useful for
coarse ground with strong stubble (which may have a tendency to puncture the film),
as it allows the bale to land on its edge, which has a much higher degree of film
coverage. It is also very useful on hilly/sloping ground as it can prevent bales from
rolling, when they land on their side. The side-tip is attached to the rear wrapping
cradle.
Drawbar hitch High/Low drawbar
Drawbar stand Stand type A/B/C
Brakes Hydraulic/Air brakes
Side-tip Trailed fold up side-tip

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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, note & environment messages:
When reading this manual, pay particular attention when you see the symbols below
i.e. warning, caution, note and environment. 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 is to ensure that the most important information stands out from the rest of
the text.
WARNING: This symbol indicates a potentially hazardous situation,
that if not avoided could result in machinery damage, personal injury
or even death.
CAUTION: This symbol indicates a potentially hazardous situation,
that if not avoided could result in machinery damage or personal
injury.
NOTE: This symbol is used to identify special instructions or
procedures which, if not followed strictly, could result in machinery
damage.
ENVIRONMENT: This symbol 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 and messages, and
be aware of the meanings of all safety decals. (See ‘Safety warnings
& instructions explained’). The spare part codes for each decal are
also listed, which are available from your McHale dealer. If safety
decals are damaged or missing due to wear and tear or component
replacement, ensure that they are replaced. As with all machinery,
learn all operations and use controls by reading this manual
thoroughly. Do not attempt to let anyone operate this machine
without being fully instructed.

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3.3 Store all items carefully
Store all attachments in a secure and safe manner so as to prevent
items from falling. Keep storage areas clear of bystanders and
children.
3.4 Personal protective equipment (PPE)
The following PPE should be worn, at all times, when carrying out
maintenance work on this machine, to help prevent health and
safety hazards:
Safety glasses
Ear muffs
Safety boots
Gloves
Tight fitting clothing
Use of mobile phones or radio/music headphones are strictly forbidden while operating
machinery and driving, 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 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 the
tractor engine has stopped, the key has been removed and that the PTO has stopped
turning before carrying out any adjustments, connections or cleaning of PTO driven
equipment.

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3.7 Trained operator criteria
3.8 Operating the machine
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
the pick-up area while the baler is running.
Disengage the PTO, apply the hand brake, shut the tractor engine off and
remove the key from the ignition.
3.9 In the event of a fire
In the event of a fire, it is the operator’s decision to determine the
seriousness and hence the solution to the situation. The following is
given only as a guideline procedure:
Age related requirements General requirements
18 +
The operator needs to be fully
trained in the use of this machine
and have a valid tractor driver’s
licence.
The operator must be in full
control of his/her senses and
must not be under the influence
of any alcohol or drugs,
prescribed or otherwise.
The operator must have read
and understood all aspects of the
operator manual in order to
operate, maintain and clean the
machine. Ideally, they should
also receive training from their
McHale Dealer.
It is only acceptable to have
more than one person in the
tractor cab, if it has a second
seat.
16 - 18
An operator between the age of 16
and 18 years old must have a
provisional licence and must be
accompanied by an experienced
driver/operator, at all times, even
during maintenance and cleaning!
< 16
Persons younger than 16 years of
age are not allowed to operate,
clean or carry out maintenance on
this machine, under any
circumstances!
WARNING : Never clear a blockage while the machine is in operation!
Never attempt to clear a blockage while the machine is in operation. You
could be severely injured or pulled in by the rotating tines!
WARNING : Stand well clear of the machine while it is in operation!
Stand well clear of the machine and tractor when the machine is
operating. Objects such as loose tines, stones and other debris may be
discharged from the machine.

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1. Switch control box to manual mode. (See ‘Electronic control system’).
Immediately tip the bale off rear roller and leave the roller in a tipped position.
2. Eject the bale from the baling chamber by opening the chamber door.
3. Move the tractor and machine away from the flammable material.
4. Disengage the PTO, turn off the tractor and remove the key from the ignition.
5. Remove all hosing and electrical looms from the machine, assuming it is safe
to do so.
6. With all connections removed, disengage the drawbar from the tractor.
7. Drive the tractor away from the baler.
8. Using a suitable fire extinguisher, put out all the fires or call the fire brigade.
3.10 General safety warnings
It is important to be aware of the potential hazards associated with the operation of farm
machinery. Numerous research studies have shown that the majority of machinery-
related accidents occur as the result of human negligence, including taking shortcuts
to save time, lack of or improper maintenance, ignoring warnings, failing to read the
operator's manual, lack of or improper instruction and failure to follow safety rules.
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. (See ‘Trained operator criteria’). The owner of this machine is
obliged, by law, to ensure that every operator understands all of the functions, controls,
working processes and safety 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.
WARNING: Fire prevention
It is recommended that the machine be kept reasonably clean and free
of build-ups of crop, lubricants, etc. This will help to reduce the risk of
fires.

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Danger Zone
The ‘Danger Zone’ is the area around the rotating dispensers (approx.
2 metres radius from the rotating centre axis) & (a minimum of 5 metres) at
the back of the machine to allow for safe bale discharge.
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.
Before operation
Never operate farm machinery while under the influence of drugs or alcohol.
The physiological effects of drugs and alcohol impair performance and can
lead to operators taking risks or putting others at risk. This includes over-the-
counter cold/flu and allergy medications or prescription drugs that are not
recommended to be taken whilst driving a car or operating machinery.
The operator must ensure that the manufacturer’s instructions for attaching
and detaching the machine are followed. This includes the drawbar
attachment, the electric and hydraulic lines, in particular the lighting and brake
system.
The operator must ensure that all covers are closed and all safety devices are
in operating mode.
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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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
While operating this machine on hilly or sloping ground the operator must take
extra precautions, in particular the ‘Danger Zone’ is increased in such
conditions.
Precaution must be taken when travelling over sloping or rough ground due to
the risk of overturning. Always travel at a speed suitable for the ground
conditions.
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.
Never operate the machine with guards or safety devices damaged or
missing.
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.
Before travelling on public roads
The owner of this machine is obliged by law to ensure that every operator has
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 and oil supply are switched off.
Always attach the break-away rope. (See ‘Attaching ‘break-away’ brake’)
When parking, both wheels of this machine have to be blocked using the
wheel chocks and hand brake should be applied according to the road traffic
regulations, relating to the country of use.
Ensure lights are connected and working correctly. Ensure that the work lamp
is switched off.
The machine is not suitable for towing at speeds above 40 km/h.
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).