Fusion 4 Pro
Fusion 4 Pro 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.
Overview
The McHale Fusion 4 Pro is a fully automatic integrated baler wrapper which is controlled using ISOBUS. The McHale Fusion 4 Pro provides new levels of operator comfort with it’s easy-to-use control system, in-cab net & density adjustment, camera, and faster wrapping speeds along with a host of other new features.
The McHale Fusion 4 Pro uses net to bind the bale in the chamber and features the McHale patented bale transfer and vertical wrapping ring, which are noted for their reliability, speed and positive bale transfer in hilly conditions.
In-Cab Adjustment
The ISOBUS control terminal allows for bale density to be adjusted from the comfort of the tractor cab. Depending on the crop and conditions, the operator can also adjust the number of layers of net on the control terminal.
Drop Floor Unblocking
The drop floor unblocking system is fitted with an automatic unblocking function as standard. When connected to an ISOBUS tractor, the Auto Unblock feature lowers the floor when a blockage is detected. Once the operator restarts the PTO and clears the blockage, the drop floor will raise to its original position.
Control Terminals
The McHale Fusion 4 Pro is fitted with ISOBUS as standard. For customers without an ISOBUS tractor, an optional ISO-PLAY 7 or ISO-PLAY 12 terminal can be used. Through the ISOBUS tractor’s terminal or McHale’s ISO-PLAY terminals, the operator is provided with clear indicators of machine performance and allows for increased levels of monitoring, through the graphic display.
Camera Display as Standard
The McHale Fusion 4 Pro comes fitted with a camera as standard to monitor the transfer and wrapping operation at the rear of the machine. When using an ISO-PLAY terminal, this camera automatically displays on the control terminal in the tractor cab when the bale is being transferred to the wrapping table, at the beginning of the wrapping cycle and when the bale is about to be tipped.
Built To Last
Profi-Flo Pick-Up
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.
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- 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.
Pick-Up
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:
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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
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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
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Heavy-Duty Pick-Up
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.
Adaptive Intake
Split Drive GearBox
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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.
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Chopper Unit
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25 Knife Chopper Unit
- A 25 knife chopper unit comes as standard on the McHale Fusion 4 range.
- A single bank of 25 knives provides a chop length of approximately 46mm.
- Chop length can be adjusted by removing knives.
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.
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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
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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
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Auto Unblock
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
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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.
Chamber Bearings
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
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Automatic Greasing
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
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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.
Net Layer
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
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
180-degree wrap around on the rubber feed roller, eliminating any net or film slippage while feeding
Patented High Speed Bale Transfer
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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
Wrapping System
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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.
ISOBUS Integration
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The machine is connected via the tractor’s ISOBUS connector, which eliminates large cables being routed through the back window of the tractor cab. Alternatively, with an ISOBUS tractor, the operator can use a separate ISOBUS terminal.
Fully Automatic
The ISOBUS control terminals, when combined with the load sensing valve on the McHale Fusion 4 Pro and the McHale Fusion 4 Plus, is capable of making baling and wrapping fully automatic.
Bale Density & Binding Adjustment
The ISOBUS control terminals allow for the bale density to be adjusted from the comfort of the tractor cab. From the control terminal, the operator can adjust the number of layers of net or film being applied to the bale. On the McHale Fusion 4 Plus, the operator can also adjust the stretch being applied to the film in the bale chamber from the control terminal in the tractor cab.
Auto Knife Drop
This feature allows for the operator to chop the forage until the bale is almost complete, at which point the machine will automatically lower the knives. Depending on the feeding method, this can improve fodder distribution and machine intake.
McHale ISO-PLAY Control Console
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McHale offer two ISO-PLAY monitor options.
Customers can purchase a McHale ISO-PLAY 7 or ISO-PLAY 12 control terminal, which can be used to operate the functions of other ISOBUS machines. Should the customer already own an ISOBUS control terminal from another machine this then can be used to control the functionality of the McHale Fusion 4 Pro or Fusion 4 Plus. Through the ISOBUS tractor’s terminal or McHale’s ISO-PLAY terminals, the operator is provided with clear indicators of machine performance and allows for increased levels of monitoring, through the graphic display.
3D Manual Mode
When operating the machine in manual mode, a 3D image of the machine is displayed which allows the operator to select the relevant functions to control. In each function there is an information button that, when pressed, will show the current state of the function, for example:
- Netter – Net knife tripped or reset
- Chamber – Open/closed
- Chopper unit – Knives up/down
- Information Information – on/off
- Wrapping Ring – Dispenser position
- Bale Tip – Up/down
- Drop Floor- Up/down
Smart Switching Cameras
All control consoles are fitted with camera functionality as standard on the McHale Fusion 4 Pro and the Fusion 4 Plus. In manual mode, the operator can switch to camera mode to view the wrapper and rear of the machine. In automatic mode on all ISO-PLAY consoles, the camera image will appear at intelligent times on the screen during the baling cycle rather than on a time-based system, on existing machines.
The smart switching cameras can also be fully customised by the operator to suit their preferred view for when the bale is being transferred or being tipped.
If an additional camera is required on the McHale Fusion 4 Pro, the control console’s second camera input may be used. This second input is used for displaying the film binding process on the McHale Fusion 4 Plus machines.
Virtual Density Gauge
A Virtual Density Gauge is displayed on the screen of the connected ISOBUS terminal. This allows the operator to view the density of the bale being produced on screen rather than on the machine body.
During the baling process, a bale fill indicator shows the driver how the bale is forming in the chamber. When the desired density is achieved on the graph, a “Stop” warning is signalled to the driver to notify them that crop should stop being fed into the chamber.
Options
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Technical Specification
Dimensions & Weight
| Width | 2.76 / 2.94 m* (9′ – 9’8″)* |
| Length | 5.8 m (19′) |
| Weight |
5850 kgs (12,897 lbs) |
| Height | 3.02 m (9’10”) |
| *Width will depend on tyre selection | |
Pick-Up
| Working Width | 2100 mm (6’11”) |
| Pick Up Guide Wheels | Standard – with Fold Back |
| Pick Up Lift | Hydraulic |
| Tine Spacing |
Camtrack: 67mm (2 5/8”) Camless: 55mm (2 1/8”) |
| Tine Bars |
5 (Camless Option with 6) |
Chopper Unit
| Number of Knives |
25 46 mm |
| Theoretical Chop Length | (1 3/4”) |
| Unblocking System | Automatic Drop Floor |
| Knife Control | Electronic from Tractor Cab |
| Knife Protection | Hydraulic & Mechanical |
| Auto Knife Drop | Standard |
Bale Chamber
| Width | 1.23 m (4′) |
| Diameter | 1.25 m (4’1”) |
| Greasing | Progressive (Standard) |
| Bearings | 55 mm** |
| Number of Rollers | 18 |
| **Bearings are 55mm double raced on the main load points |
|
Bale Chamber Wrap
| Type | Net |
| Layer Adjustment | In Cab |
| Net or NRF Roll Capacity | 4 |
| Binding System | Pivot Stretch Netter (4 bar) |
| Control | Manual or Automatic |
Wrapping
| 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 | Standard |
| Bale Tip Adjustment | Electronic from Tractor Cab |
Drives
| Gearbox | Split Drive |
| Main Drive Protection | Cam Clutch |
| Pick Up Protection | Slip Clutch |
| Chain Lubrication | Automatic (Standard) |
Control
| Control System | ISOBUS (Optional ISO-PLAY) |
| Operation | Fully Automatic Electronic |
| Density Adjustment | In-Cab |
| Inbuilt Cameras |
1x Inbuilt Cameraa |
Other
| Axle | 8 Stud |
| Tyres Size | 560/60R 22.5 (standard) |
| Electronics | 12 Volt DC, 20 amp approx. |
| Road Lights | Standard |
Tractor
| Minimum Hydraulic Flow | 45 l/min @ 180 bar |
| Hydraulic System | Open, Closed or Load Sensing |
| Minimum Power Requirements |
85kW (115hp) |