McHale Fusion 3 User manual

McHale
Ballinrobe
Co. Mayo, Ireland
Tel: [phone]
Fax: [phone]
Email: [email protected]
Website: www.mchale.net
CLT00485_1
Fusion 3 Baler & Wrapper
Operator Instructor Manual
Issue 1

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McHale Fusion 3 Baler & 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.
See “Description of the serial number plate” on page 30.
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 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:

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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 dimensions & specifications 12
2.5 Tractor attachment 12
2.6 Machine specifications 13
2.7 Tyre specifications 13
3 General Safety 14
3.1 Be aware of all safety information 14
3.2 Follow all safety instructions 14
3.3 Store all items carefully 15
3.4 Protective clothing 15
3.5 In case of emergencies 15
3.6 Stay clear of rotating elements 15
3.7 Operating the McHale Fusion 3 15
3.8 In the event of a fire 16
3.9 General safety warnings 16
4 Specific Safety Warnings 20
4.1 Electronic safety warnings 20
4.2 Hydraulic safety warnings 20
4.3 Noise level 21
4.4 Fire precautions 21
4.5 Special safety devices/instructions 21
4.6 Safety instruction decal locations 22
4.7 Safety warnings & instructions explained 23
4.8 Description of the serial number plate 30
4.9 Machine lifting guidelines 31
5 Tractor Requirements & Preparation 32
5.1 Tractor requirements 32
5.2 Control box installation 33
5.3 Attaching to drawbar 33
5.4 Attaching ‘break-away’ brake 33
5.5 Attaching the Fusion 3 to a 540 rpm PTO 34
5.6 Lighting system 34
5.7 Fusion 3 set-up & tractor hydraulic system 34
5.8 Which hydraulic system is used? 36
5.9 Hydraulic spool valve setup 36
5.10 Attaching hydraulic hosing to the tractor 37
5.11 Connecting the control box 38

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6 Baler Requirements & Preparation 39
6.1 Net requirements 39
6.2 Care of the net roll 39
6.3 Care of the net wrapping system 40
6.4 Loading & operating the netter system 40
6.5 Net cutter setting 41
6.6 Net tension bar setting 43
6.7 Chopper unit knife removal & installation 43
6.8 Automatic lubrication system 48
6.9 Gear box oil 51
6.10 Tyre inflation pressures 51
6.11 Wheel chocks 52
6.12 Drawbar and PTO shaft stand usage 52
6.13 Drawbar adjustment 54
6.14 PTO Shaft adjustment & maintenance 55
7 Electronic Control System 58
7.1 Control box functions 59
7.2 Control box features 60
7.3 Menu Structure 65
7.4 Warning messages 70
7.5 Simulating a “bale to wrapping” cycle 74
8 Wrapper Operation 75
8.1 Loading plastic film 75
8.2 Plastic film requirements 77
8.3 Wrapping process 78
8.4 Dispenser adjustment 79
8.5 Cut and hold system 79
9 Road Traffic Safety & Operation 82
9.1 Before travelling on any public roadway 82
9.2 Road transportation 83
9.3 Road transportation with side tip attached 83
9.4 ‘Break-away’ brake 84
10 Field Operation & Baler Adjustments 85
10.1 Break-in period 85
10.2 Swath preparation 85
10.3 Pick-up reel height adjustment 86
10.4 Crop guard adjustment 87
10.5 Unblocking system 87
10.6 Chopping system 88
10.7 Selectable knives 88
10.8 Bale density gauge 89
10.9 Setting chamber pre-charge pressure 89
10.10 Chamber door lock 91
10.11 Spare film holders & door latch safety 91
10.12 Adjusting pick-up float springs 92
10.13 Chain adjustments 93

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11 Accessories & Optional Equipment 98
11.1 Drawbar hitch options 98
11.2 Stand options 98
11.3 Brake options 99
11.4 Tyre options 99
11.5 Side tip option 99
11.6 Selectable Knives 100
11.7 Crop Roller 100
11.8 Dispenser gear options 101
12 Attachments 102
12.1 Side tip 102
13 Machine Maintenance 105
13.1 Maintenance intervals 105
13.2 Tightening torque values 108
14 Storage 109
14.1 End of season 109
14.2 Start of season 109
15 Trouble Shooting 111
15.1 Trouble shooting overview 111
16 Certification & Warranty 116
16.1 Declaration of Conformity 116
16.2 PDI Form 116
16.3 Change of ownership pre-checks 116
16.4 Limited Warranty 116

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1
Introduction
The McHale Fusion 3 Baler & Wrapper is a completely new product. This product
combines the baling process with the wrapping process, in one machine. The design
hasbeendevelopedbasedonyearsofextensiveresearchanddevelopmentinthefield
of round bale wrappers and balers. Given proper care and attention, the McHale
Fusion 3 will provide years of reliable and dependable performance.
Pleasedo not assumethat youknow howtooperate andmaintain yourmachinebefore
reading this manual carefully. In order to prevent misuse, damage and accidents, it is
very important that everybody who will operate the McHale Fusion 3 be a fully trained
operator.They must readand fullyunderstand 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.

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2
Product Information
The McHale Fusion 3 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
importancefor the safetyof the operatorand for others, thatthe 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 16) 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 Fusion 3 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 round baler/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
1Netter unit
2Net tension bars
3Hydraulic section (Inside cover)
4Chamber door pressure clock
5Crop guard
6Pick-up reel
7Chopper unit
8Wheel chocks & knife blanks (Inside cover)

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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
7Table roller
8Cut & hold unit
9Dispenser access door
10 Drive side

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2.4 General dimensions & specifications
Check with national road traffic regulations in the individual country!
2.5 Tractor attachment
(*) May not be available in all countries, check with your McHale dealer for availability
in your country.
Units are given in both metric and UK imperial values, with the latter shown in brackets.
Transport length 5.8 m (19’ 1”)
Transport width 2.76 m (9’ 1”)
Transport height 3.02 m (9’ 11”)
Transport weight 5700 kg (12,566 lbs)
Tyre dimensions 560/60 R22.5
Tyre pressure 1.65 bar/24 P.S.I.
Tyre dimensions (Pick-up reel) 170/60 - 8
Tyre pressure (Pick-up reel) 2.07 bar (30 P.S.I.)
Maximum road speed 40 km/h (25 mph)
Brake system Hydraulic brakes (Cemagref approved)
Air brakes* (TUV approved)
Drawbar Low drawbar
High drawbar *
PTO speed 540 rpm
Lighting 12 V / 7 pin socket
Electrics 12 V / 20 Amp euro socket
Hydraulic systems Load sensing, open centre, closed centre
Minimum pressure 180 bar (2610 P.S.I.)
Minimum flow rate 45 l/min (9.9 gal/min) @ 180 bar
(2610 P.S.I.)

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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 2.00 m (78”)
Net tying Net width Max. 1.26 m (49.5”)
Net length 2000 m / Max 4000 m
(2187 yd / Max 4374 yd)
Plastic film
Film width 750 mm (29½”)
Film stretch 70% (55% optional)
Film layers 2+2; 2+2+2; etc.
Film storage 8 Rolls (+ 2 Rolls on
dispenser)
Dispenser rotary speed Max. 30 rpm
Tyre type Pressure
560/60 R22.5 1.65 bar (24 P.S.I.)
650/50 R22.5 (Optional Specification) 1.65 bar (24 P.S.I.)
170/60 - 8 (Pick-up tyre) 2.07 bar (30 P.S.I.)

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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 is to ensure that the most important information stands out from the
rest of the text.
WARNING:This symbolindicates a potentially hazardous situation,
thatifnotavoidedcouldresultinmachinerydamage,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: 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. If safety decals are
damaged or missing due to wear and tear or component
replacement, ensure that they are replaced. Refer to section 4.7 in
this manual (or spare parts book provided) to see the spare part
codesfortherelevantdecals, whichareavailablefromyour 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 spare net rolls, 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 operators 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
Seriousinjury ordeath canresult fromentanglement ofclothing 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.
3.7 Operating the McHale Fusion 3
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.
Disengage the PTO, apply handbrake, shut the tractor engine off and remove
the key from the ignition.
Stand well clear of the baler and tractor when the machine is operating.

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3.8 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. Switch control box to manual mode (See “Electronic Control System” on
page 58). Immediately tip bale off rear roller and leave roller in tipped position.
2. Eject the bale from the baling chamber by opening the chamber doors.
3. Move the tractor and baler 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.
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.
3.9 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 thefunctions, 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.
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.
WARNING: Fire prevention
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.
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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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
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.
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 as bales are more likely to roll away, causing a potential risk.
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 dispenser safety arms damaged or missing.
Be careful when working with the cut and hold. Remember that the
accumulators are under pressure.
Avoid contact with the knife.
Do not attempt to clamp plastic film in the cut and 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.
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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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 dispenser safety chain.
When parking, both wheels of this machine have to be blocked using the
wheel chocks and hand brake (if fitted) should be applied according to the
road traffic regulations, relating to the country of use.
Performing maintenance
Maintenance and repair work on the Fusion 3 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 net/film rolls, clearing
forage away from any part of the machine, 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) PTO shaft is removed from PTO stub
(f) Electronic power supply and control box is disconnected
(g) Hydraulic oil supply is switched off
*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.
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.

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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
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, the machine is on level ground and a safe
distance is kept from any hazards on the machine i.e. pick-up region.

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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 pick-up, cutting device and wrapping
ring, 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. 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.