Fusion 4 Integrated Baler Wrapper
THE MOST ADVANCED INTEGRATED BALER WRAPPER RANGE
The new McHale Fusion 4 range has been developed with a focus on operator comfort and machine performance, while still ensuring the renowned simplicity and reliability is maintained.
Our specialist team of engineers have maximised machine intake and output, increased bale density and reduced maintenance intervals to ensure the Fusion 4 range of machines surpasses all your baling and wrapping expectations.
These levels of comfort, when paired with proven features such as the patented bale transfer system and the vertical wrapping ring, enable the McHale Fusion 4 range of machines to offer durability, reliability and high output to the end user.
The McHale Fusion 4 is a robust, fully automatic, integrated baler wrapper recognised worldwide for its unique patented bale transfer, vertical wrapping ring and high output.
The machine is equipped with a 25-knife chopping unit, automatic progressive greasing system and a servo operated load sensing control valve, which when combined with the Expert Plus control console, makes the baling and wrapping process fully automatic. The machine is fitted with 560/60-22.5 tyres as standard.
Patented Bale Transfer
When the netting process is complete the bale chamber splits horizontally. As the top section of the bale chamber moves up, the lower section of the bale chamber simultaneously moves up and out, transferring the bale onto the wrapping platform.
Vertical Wrapping Ring
The vertical wrapping ring is fitted with two 750 mm dispensers, which take approximately 18 seconds to apply 4 layers of film and approximately 24 seconds to apply 6 layers of film in ideal working conditions. In ideal operating conditions, this means that the wrapping platform is always waiting for the next bale.
Built To Last
McHale have created their highest output pick-up for the Fusion 4 range. The new Profi-Flo pick-up has been designed to increase crop intake through more efficient crop flow and has been engineered to ensure end users are operating with a high-performance pick-up that is designed to suit various working conditions.
- The new tapered feed channel encourages the crop to flow from the pick-up and then move towards the rotor and into the bale chamber, maximising throughput.
- McHale have also moved the lateral feed augers forward and their ends are angled towards the rotor for improved crop flow.
- These changes combined offer a massive reduction in the potential for blockages to occur and in turn, increase output for the operator.
- To reduce maintenance, all Profi-Flo pick-ups are fitted with a heavier driveline which reduces chain load and increases chain life.
Over the last decade, McHale has designed and developed various types of pick-ups. After extensive testing, McHale decided it will offer customers the choice of 2 pick-up options depending on their working conditions:
Profi-Flo Cam Pick-Up
As standard, a cam operated 2.1m high-intake galvanised pick-up ensures excellent ground cleaning in all types of crop. The cam pick-up runs on a cam track that is fitted with double raced cam bearings to stand up to the most testing of conditions.
All cam pick-ups across the McHale Fusion 4 range are fitted with 5 tine bars for excellent ground cleaning, while new side bands ensure a continuous delivery of crop to the bale chamber.
A side inspection port allows the operator to quickly check and change the cam bearings if needed.
Profi-Flo Camless Pick-Up
A 2.1 m camless pick-up is available as an option on all machines in the Fusion 4 range. The camless pick-up has six tine bars to provide excellent ground cleaning and fast delivery of crop to the bale chamber. The camless pickup has been designed to increase output and reduce levels of maintenance.
Vertical Wrapping Ring
The vertical wrapping ring is fitted with two 750 mm dispensers, which take approximately 18 seconds to apply 4 layers of film and approximately 24 seconds to apply 6 layers of film. This means that the wrapping platform is always waiting for the next bale.
The dispensers are fitted with film break sensors, which notify the operator through the control console in the tractor cab if one or both dispensers run out of film. If one dispenser runs out of film, the machine will continue working by automatically slowing bale rotation, increasing the number of rotations of the wrapping ring to ensure that the bale is wrapped correctly. These sensors are fitted with removable batteries which can be easily replaced.
Heavy-Duty PROFI-FLO Pick-Up
All McHale Profi-Flo pick-ups come with a number of standard features that include:
All McHale cam pick-ups have heavy-duty formed tine supports to ensure long service life, while all camless pick-ups are fitted with a fully welded tine bars. All Profi-Flo camless pick-ups are fitted with two extra columns of tines.
Efficient Crop Flow Delivery
On the Profi-Flo pick-up, the tine bands and feed augers are positioned close to the rotor to improve crop flow from the outside of the wide pick-up. Tapering the augers with 45° ends and removing the steel hydraulic pipes above the pick-up has resulted in a massive reduction in the potential for blockages to occur due to lumps, which ensures a consistent and even crop flow for producing high density bales.
Over the course of a baling season, machines have to work with different volumes of crop. McHale have designed an adaptive intake which allows the intake area to automatically adjust for light and heavy crops to facilitate a smooth crop flow into the chamber.
Split Drive GearBox
All machines in the McHale Fusion range come fitted with a 540 rpm split drive gearbox as standard. The gearbox design ensures that power is evenly distributed to both sides of the machine.
The 1000 rpm gearbox provides the following advantages:
- The 1000 rpm gearbox results in an increase in PTO speed with a substantially reduced torque. This reduces the sharp loads on the drive line, allowing the clutch setting with 10% more capacity.
- The option to select a lower PTO speed (if available) on the tractor for easier restarts in the unlikelihood of blocking.
- Excellent fuel economy is achieved due to lower tractor engine revs, by running the machine at the nominal PTO speed of 900rpm when using a 1000 rpm box.
Optimal Power Distribution
The rollers in the bale chamber are driven from the left-hand side of the machine and the pick-up and chopper unit are driven from the right-hand side of the machine. This system ensures direct, short transfer paths, leading to optimal power distribution to provide more torque and aid in the reduction of blockages.
1000rpm Gearbox (Optional)
In order to optimise machine performance, a 1000rpm gearbox is available as an optional upgrade on all machines in the McHale integrated baler wrapper range.
We recommend you speak with your local dealer or distributor regarding which gearbox is best suited to your requirements, based on your working conditions.
Heavy Duty Feed Rotor
The star shaped feed rotor ensures a high-capacity flow of crop into the bale chamber. The flights on the rotor are laid out in a spiral formation to achieve consistent crop flow. As crop enters the rotor, rotating flights feed the crop to the bale chamber.
25 Knife Chopper Rotor (Optional)
To ensure a consistent and even chop quality, a robust and powerful 25 knife chopper unit has been developed for the McHale integrated bale wrapper range.
Selectable Knife System
All McHale Fusion machines have the option to be fitted with a selectable knife system. Various knife configurations can be chosen depending on the knife bank specification.
25 Knife Bank Options
0, 12, 13, 25 Knives
BENEFITS OF SELECTABLE KNIVES
ADJUSTABLE CHOP LENGTH
With selectable knives, the operator can vary the chop length by engaging or disengaging either knife bank. If fine chopping is required, the operator can choose to engage both knife banks. Should a longer chop length be required, the operator can disengage one bank of knives from the comfort and safety of the tractor cab.
REDUCED SHARPENING INTERVALS
When using both knife banks separately, if the first bank of knives become blunt, the operator can lower the first knife bank and raise the second bank. This reduces the downtime and allows the operator to continue working. By having consistently sharp knives, fuel consumption is reduced and the machine always delivers optimum chop.
OPERATOR COMFORT & SAFETY
A new sharp set of knives can be engaged, without the operator having to physically replace knives, nensuring a well chopped crop and continued high output. Should different chop lengths be required the operator can make the adjustments by engaging or disengaging the knife bank without having to leave the tractor cab.
Drop Floor Unblocking
For over a decade, all machines in the fixed chamber baler range are fitted with the McHale Drop Floor Unblocking System, a feature which operators have come to love for it’s simplicity of use and effective unblocking cycle.
The McHale fixed chamber baler range is fitted with a drop floor unblocking system, which means blockages can be fed through in three simple steps.
1 – Drop the Floor
Should a blockage occur, the sound of the slip clutch alerts the operator, who can hydraulically lower the floor from the tractor cab.
2 – Re-engage the PTO
This widens the feed channel and on re-engaging the PTO, the blockage can be fed through.
3 – Reset the Floor
The floor can then be reset to its original position and baling can resume
Drop Floor Features
The drop floor unblocking system has a number of novel features which aid the operator and the performance of the machine to handle uneven swaths which can lead to blockages.
When connected to an ISOBUS tractor, the drop floor will automatically lower when the software detects a blockage. Once the operator restarts the PTO and the blockage clears, the drop floor will automatically rise to its original position.
Automatic Drop Floor Reset
Automatic drop floor reset comes as standard on the McHale Fusion 4 Pro & Fusion 4 Plus. If a blockage occurs, the operator can press one button on the control terminal which lowers the floor. After the PTO is re-engaged and the blockage is fed through, the drop floor will automatically rise and the knives will reset to their original position.
Automatic Knife Drop Feature
This feature can be enabled on Fusion 4 Pro or Fusion 4 Plus machines from the control terminal in the cab. This allows the operator to chop the grass until the bale is almost complete, at which point the machine will automatically drop out the knives. Depending on the feeding method, this improves fodder distribution, keeping the bale neater when the net or film is removed.
Drop Floor Sensor
On Fusion 4 Pro and Fusion 4 Plus machines, the drop floor is equipped with a sensor to ensure the chop quality is consistent by indicating to the operator via the control terminal if the drop floor is even slightly open.
18 Roller Bale Chamber
The bale chamber on the McHale Fusion 4 range is comprised of an 18 roller bale chamber. It has a diameter of 1.23m x 1.25m (4′ ½” x 4′ 1¼”) and is formed from heavy duty rollers.
The 18 rollers are formed from high-grade tubular steel delivering maximum traction, improved bale rotation, enhanced machine performance and produces well-shaped, uniform bales. As a result, the Fusion 4 range is noted for superior performance in dry crops such as hay and straw.
Heavy Duty Chains
High quality heavy-duty chains ensure reliable operation all around the machine. The main drive chain coming off the gearbox is a high tensile, heavy duty 100H endless chain for maximum strength. All other chains on the drive side of the bale chamber are inch and a quarter (20B). The rotor chain is inch duplex (16 B2) and all pick-up chains are three quarter inch (ASA 60H). New chain tensioners are fitted on all machines in the Fusion 4 range to allow for a spring to be tensioned by simply tightening a bolt at the end which replaces the need to manually release the spring and reattach.
Single sprocket rollers on the chamber drive side are equipped with 50 mm shafts and bearings. Rollers under the most load are fitted with double row bearings. All rollers fitted with double sprockets are equipped with 55 mm shafts and double row 55 mm bearings. The non drive side of the bale chamber is also fitted with heavy duty 50 mm bearings.
Bale Density Adjustment
Bale density pressure has increased across all machines in the Fusion 4 range. On the McHale Fusion 4, the chamber pre-charge pressure can be easily adjusted by twisting the density control valve on the side of machine.
On the McHale Fusion 4 Pro and Fusion 4 Plus, the bale density can be adjusted from the tractor cab using the virtual density pressure gauge displayed on the control terminal.
Roller Design & Sealing
Bale chamber rollers are fitted with 50 mm bearings on the drive and non-drive side. Rollers fitted with double sprockets are equipped with 55 mm shafts and double row bearings. All roller ends are fitted with high performance self-cleaning seals that have a unique reverse-thread sealing system. This prevents crop from getting into the bearings; as the roller moves in one direction, the thread on the seal moves in the opposite direction, ensuring that any crop that tries to find its way into the bearing is automatically threaded out. The seals prevent the grease around the bearings from becoming contaminated by crop, resulting in increased reliability.
Greasing & Oiling
The McHale Fusion 4 range of machines are fitted with individual grease and oil pumps. The grease pump is connected to the downward movement of the bale tip, while the oil pump is connected to the upward movement of the bale tip. This ensures that grease and oil is applied evenly and continuously as the machine operates.
The McHale Fusion 4 integrated baler wrapper range is fitted with a new automatic twin pump lubrication system which has a separate pump for grease and oil. This allows the oiling rate to be adjusted independently by the operator without affecting the greasing rate.
This pressurised system delivers a measured amount of grease around the machine after every bale cycle. Automatic greasing saves time as it reduces the amount of manual greasing to be done by the operator. It also ensures all bearings are greased under high pressure. This system ensures that the grease cartridge usage is spread out evenly over the 300-bale interval to 39 individual grease points. A lube alarm sounds after 300 bales to inform the operator to refill the grease cartridge.
The following components are greased:
- Bale Chamber – Drive Side
- Bale Chamber – Non-Drive Side
- Rotor Bearings – Drive Side
- Rotor Bearings – Non-Drive Side
- Pick-Up – Drive Gears
Pressurised Oiling System
The McHale Fusion 4 integrated baler wrapper range is fitted with a pressurised oiling system. Depending on working conditions, from the in-cab control terminal,
the operator can adjust the lubrication oil flow to the following chains that are serviced by the system:
- Chamber Drive Side Chains
- Rotor Drive Chain
- Pick-Up – Drive Chains
- Pick-Up – Cam Track
High Performance Binding
Two high performance binding systems have been designed & developed to ensure optimum performance. The Fusion 4 & Fusion 4 Pro are equipped with a pivot stretch net system and the Fusion 4 Plus is fitted with an infinite stretch hydraulic binding system.
Binding Material Stretch Application
The simple yet effective binding systems can either apply net or film to the barrel of the bale depending on the model. These systems ensure efficient net or film usage and that a tight layer of net or film is evenly applied to the bale. The net or film tension can be adjusted depending on the operator’s requirements. To obtain the desired stretch, a larger net/film brake has been fitted, which allows 25% more stretch to be easily achieved. This is especially effective when operating in cold weather with film that requires a higher stretch percentage.
Net / Film Binding Control
New to the McHale Fusion 4 Plus is the ability to manually control the NRF bobbins when operating in manual mode. This feature aids the operator when binding a bale manually and has increased the feed reliability of the net/film.
The number of layers of binding material being used can be easily adjusted as the machine passes through different crop conditions. On the Fusion 4, by simply moving the net adjustment handle down, more net will be applied. Moving the handle up will result in less net being applied.
On the Fusion 4 Pro and Fusion 4 Plus, net adjustment can be controlled from the control terminal in the tractor cab. At the touch of a button, the operator can easily adjust the number of layers of net and the net stretch from the main screen or from entering the menu.
Hydraulic Net/Film Knife Reset (Optional)
After the bale is bound in the chamber, the net/film is cut before the bale is then transferred to the wrapper. Occasionally, an operator may wish to re-net/re-bind a bale, which results in the operator having to physically reset the knife on the machine. A hydraulic net/film knife reset is available as an optional extra on all Fusion 4 Plus machines. This allows the operator to reset the knife using the control terminal in the tractor cab.
Net and Film Loading and Storage (Optional)
A net or film loading device can be fitted as an optional extra to all machines in the McHale Fusion range. This device aids the operator when loading net or film onto the platform. The operator simply folds the cradle downwards and places the roll onto the cradle. It can then be pivoted up in line with the platform using gas struts. Smooth rollers ensure the net or film can be easily slid from the cradle to the platform without causing any damage.
These binding units are extremely reliable and feature:
Endless adjustment of tension to ensure optimum material usage and bale shape
Up to 1250 mm
Capacity to take rolls of net wrap up to 1300 mm in width and 4500m in length.
180-degree wrap around on the rubber feed roller, eliminating any net or film slippage while feeding
Patented High Speed Bale Transfer
The McHale Fusion 4 range is fitted with a Servo Operated Load Sensing Control Valve which, makes the baling and wrapping process fully automatic.
The advantages of the McHale patented systems
Patented High Speed Bale Transfer
• 1 Bale Binding In Chamber & Wrapped Bale Being Tipped
When the bale on the back is wrapped the machine will hold the wrapped bale and automatically tip it while the next bale in the chamber is being bound with net or film. At this point the bale on the wrapper can be set to automatically tip if preferred.
• 2 McHale Patented Bale Transfer
Once the bale is formed, net or film is automatically applied and the chamber then splits like a clamshell. The lower section of the bale chamber then transfers the bale into the high speed vertical wrapping ring.
• 3 Baling while wrapping
Once the chamber is closed the operator can continue working and the fully automatic machine will start the wrapping process. In difficult ground conditions bales can be tipped at the operator’s convenience by pressing the tip button
In normal working conditions, the ever-efficient wrapping process is always completed ahead of the baler, meaning that the wrapping platform is always ready and waiting to receive the next bale.
External Control Keypad
The McHale Fusion 4 Pro and 4 Plus come fitted as standard with an external control keypad. This keypad allows the operator to control the following functions:
• Indexing of the wrapper
• Wrapper Start / Pause
• Rear Wrapping Roller Up / Down
• Rear Work Light
• Internal Panel Lighting
There is also 2 spare buttons which are customisable on the control terminal.
Two 750 mm Dispensers
The vertical wrapping ring on the Fusion range is fitted with two 750mm dispensers. Using both dispensers, all machines in the Fusion 4 range take approximately 18 seconds to apply 4 layers of film and approximately 24 seconds to apply 6 layers of film. This means that the wrapping platform is always waiting for the next bale.
Easy Film Loading
Film can be loaded from the left hand side of the machine. After loading film on the first dispenser, the operator can push the index button and the dispensers will then rotate around and automatically stop at the loading position for the second dispenser. This allows the operator to easily load the second roll of film.
McHale have added internal panel lighting to aid the film loading process during night-time operations on all Fusion 4 Pro and Fusion 4 Plus machines.
Film Break Sensors
The dispensers are fitted with film break sensors, which notify the operator through the control console in the tractor cab if one or both dispensers run out of film. If one dispenser runs out of film, the machine will continue working by automatically slowing bale rotation, increasing the number of rotations of the wrapping ring to ensure that the bale is wrapped correctly. These sensors are now fitted with removable batteries which can be easily replaced.
Reliable Cut and Holds
On the last rotation of the wrapping cycle, the cut and hold rails extend out to be in the correct position to gather the wrapping film. The cut and hold retracts which gathers the wrapping film to one point where it is cut and held. The introduction of the new brushes on the gathering unit makes the Fusion 4’s performance even more reliable by reducing friction to eliminate plastic tearing, particularly in hot or wet conditions. The cut & holds now also feature a hydraulic tap to lock the cut and hold in the open position for the ease and safety of maintenance.
Expert Plus Control Console
The McHale Fusion 4 is fitted with an Expert Plus control console, which features a large graphic display; this allows the operator to monitor the baling process graphically from the control console. It also features:
- Automatic and Manual Operation
- Knife Control (Up / Down)
- Chamber Position Display
- Bale Only Programme
- Various Bale Transfer Options
- Knife Position Display
- Drop Floor Control (Up / Down)
- Lube Alarm
- Film Layer Adjustment
- Auto Bale Tip
- Various Bale Tip Options
- Pre-Net Bale Formation Alert
- Net Position Display
- Net Application Indicator
- Lube Count
- Various Bale Counts
McHale machines work in different conditions around the world. To optimise performance, we offer a number of options in the McHale Fusion 4 range. We recommend you speak with your local dealer/distributor as regards the best features or options to meet your requirement
Fusion 4 Options
The 2.1 m Profi-Flo camless pick-up runs smoothly, particularly in short crop, and requires less maintenance due to a reduced number of rotating parts. All camless pick-ups in the McHale Fusion 4 range are fitted with six tine bars and a double crop roller to provide excellent ground cleaning and fast delivery of crop to the rotor.
A small diameter, high throughput crop roller is available as an optional extra. This crop roller helps to level out uneven swaths and has the ability to increase baler throughput. A double crop roller is also available should it be required.
A selectable knife system consists of two knife banks which allow for various knife configurations to be chosen depending on the knife bank specification. If a machine is equipped with 25 knives, then a bank of 12 and a bank of 13 knives are available to be chosen from. If chopping is not required, then the operator can select for no knives to be engaged. On all machines in the McHale Fusion 4 range, knife selection can be controlled from the tractor cab.
McHale machines work in different conditions around the world so in order to optimise machine performance, a 1000 rpm gearbox is available as an optional upgrade on all machines in the McHale integrated baler range.
Net/ NRF Loading Device
McHale introduced this very popular option to make net or NRF loading much more user friendly. This device aids the operator when loading net or film onto the platform. The operator simply folds the cradle downwards and gently lifts the roll onto the cradle. It is then ready to be pivoted up in line with the platform. Smooth rollers ensure the net or NRF can be easily slid from the cradle to the platform without causing any damage before being placed in the binding unit or spare roll holder.
A side tip can be fitted to any machine in the Fusion 4 range to allow for bales to be placed on their ends as they are being tipped. The side tip allows the machine to turn the bale through 90 degrees to leave the bale sitting upright on its end where there is normally more plastic. This is beneficial when working in stalky crops where the customer does not want the bale to get damaged or roll.
Bale Weighing & Moisture Systems
If the machine is fitted with the optional bale weighing and moisture systems, these readings will be displayed on the control terminal. The bale weighing and moisture systems record the weight and moisture content of each bale and their average bale weight and moisture content reading for the job is displayed in the customer profile section on the control terminal.
ISO-PLAY 7 or ISO-PLAY 12
If the customer wishes to operate an ISOBUS controlled machine with a tractor that is not ISOBUS compatible, they can do so through the McHale ISO-PLAY 7 terminal, equipped with its 7” screen or the larger, 12” screen on the McHale ISO-PLAY 12 terminal which is also available as an optional extra. An additional tractor wiring loom is required to do this.
McHale offer a number of tyre upgrades depending on customer preferences and ground conditions. Please see below for the tyre options available to suit your machine of choice:
|Option 1||Option 2||Option 3|
Dimensions & Weight
|Width||2.76 / 2.94 m* (9′ – 9’8″)*|
|Length||5.8 m (19′)|
|Height||3.02 m (9’10”)|
|*Width will depend on tyre selection|
|Working Width||2100 mm (6’11”)|
|Pick Up Guide Wheels||Standard – with Fold Back|
|Pick Up Lift||Hydraulic|
Camtrack: 67mm (2 5/8”)
Camless: 55mm (2 1/8”)
||5 (Camless Option with 6)|
|Number of Knives||
|Theoretical Chop Length||(1 3/4”)|
|Unblocking System||Drop Floor|
|Knife Control||Electronic from Tractor Cab|
|Knife Protection||Hydraulic & Mechanical|
|Auto Knife Drop||Not Available|
|Width||1.23 m (4′)|
|Diameter||1.25 m (4’1”)|
|Number of Rollers||18|
|**Bearings are 55mm double raced on the main load points
Bale Chamber Wrap
|Layer Adjustment||Manual on Baler|
|Net or NRF Roll Capacity||4|
|Binding System||Pivot Stretch Netter (4 bar)|
|Control||Manual or Automatic|
|System||Vertical Wrapping Ring|
|Film Storage||10 Rolls & 2 on the Wrapper|
|Film Layers||2+2+2 System|
|Dispensers||2 x 750 mm|
|Film Stretch||70% standard (55% optional)|
|Pre & Post Roll||Not Available|
|Bale Tip Adjustment||Manual|
|Main Drive Protection||Cam Clutch
|Pick Up Protection||Slip Clutch|
|Chain Lubrication||Automatic (Standard)|
|Control System||On Baler Valve|
|Operation||Fully Automatic Electronic|
|Tyres Size||560/60R 22.5 (standard)|
|Electronics||12 Volt DC, 20 amp approx.|
|Minimum Hydraulic Flow||45 l/min @ 180 bar|
|Hydraulic System||Open, Closed or Load Sensing|
|Minimum Power Requirements