As standard, a cam operated 2.1m high-intake galvanized pick-up ensures excellent ground cleaning in all types of crop. The cam pick-up runs on a can track that is fitted with double raced cam bearings to stand up to the most testing conditions.

A 2.1m camless pick-up is available as an option on all machines in the Fusion 4 range. The camless pick-up has six bars to provide excellent ground cleaning and fast delivery of crop to the bale chamber. The camless pick-up has been designed to increase output and reduce levels of maintenance.

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 customizable on the control terminal.

Two 750 mm Dispensers

The vertical wrapping ring on the Fusion Vario Plus is fitted with two 750mm dispensers, which take 18 seconds to apply 4 layers of film and under 25 seconds to apply 6 layers of film using both dispensers. 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.

New panel lighting has been added to the McHale Fusion Vario Plus to aid the operators when changing rolls of film in the dark. These lights are neatly fitted underneath the side panels of the machines and can be switched on/off from the control terminal or the rear keypad on the machine.

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 and the wrapping film is gently supported in the cut and hold rails, once supported the cut and hold gathers the wrapping film to one point where it is cut and held. By gathering the plastic to one point, this system makes the Fusion Vario Plus' performance much more reliable, particularly in hot or wet conditions.

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.

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.

The adaptive intake plate sits higher in low volumes of crop and can adjust to a lower position for higher volumes of crop. This avoids peak loads and results in higher daily throughput regardless of working conditions.

McHale machines work in different conditions around the world. In order to optimize machine performance, a 1000 rpm gearbox is available as an option on all Variable Chamber Baler range machines. 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 1000rpm 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 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 optimize machine performance, a 1000rpm gearbox is available as an optional upgrade on all machines in the McHale integrated baler wrapper range.

The flights on the rotor are laid out in a spiral formation to achieve consistent crop flow. As crop enters the rotor, rotating flights feeds it to the bale chamber. These ensure high output, while the star layout reduces the load peaks as the machine works in heavy swaths.

• The feed rotor or chopping unit boasts a heavy-duty rotor and comb.

• The flights are welded on both sides or superior strength and on the drive side the rotor is fitted with a double row bearing with a long service life.

Fusion Vario Plus Rotors:

15 Knife Chopper Rotor (Standard)

• Rotor Formation: Spiral

• Flight Thickness: Inner - 8mm | Outer: 12mm

• Number of Knives: 15

• Selectable Knives: N/A

25 Knife Chopper Rotor

Rotor Formation: Spiral

Flight Thickness: Inner - 6mm | Outer: 12mm

Number of Knives: 25

Selectable Knives: Optional

The 15 knife chopper unit is the standard chopper unit on the McHale Fusion Vario Plus. A Bank of 15 Knives provides a chop length of approximately 65mm.

• Flight Thickness: Inner - 8mm | Outer - 12mm

• Number of Knives: 15

• Selectable Knives: N/A

The 25 Knife chopper unit is available as an option on the McHale Fusion Vario Plus. A bank of 25 knives provides a chop length of approximately 46mm.

• Flight Thickness: Inner - 6mm | Outer - 12mm

• Number of Knives: 25

• Selectable Knives: Optional

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 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, ensuring a well chopped crop and continued high output. Should different chop length be required the operator can make the adjustments by engaging or disengaging the knife bank without having to leave the tractor cab.

The McHale Fusion Vario Plus 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 be reset to its original position and bailing can resume

Automatic Unblock

A fully automated unblock sequence is available on all V6760, V8960 and Fusion Vario Plus machines. If the machine is connected via an ISOBUS tractor, the drop floor and knives will lower automatically when the software detects a blockage and the operator disengages the PTO.

A prompt is then displayed to the operator to re-engage the PTO in order to clear the blockage, after which the drop floor will automatically reset to the working position and baling can resume.

On a non-ISOBUS tractor, the operator must disengage the PTO and lower the drop floor. After the PTO is re-engaged and the blockage is fed through, the drop floor and knives will automatically raise into position.

Drop Floor Sensor

On the McHale Variable Chamber Baler Range, 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.

Automatic Knife Drop Feature

This feature can be enabled on the V6760, V8960 and the Fusion Vario Plus. 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.

Density “0” Setting

When baling hay or straw, operators have the ability to select a Density “0” setting on the control terminal. This reduces hydraulic pressure to zero and bale density is applied using springs only, which allows much lighter bales to be made.

Double Drive

In more difficult conditions, such as wet heavy grass, if the primary drive slips slightly, the double drive will engage in order to aid belt and material rotation in the chamber. This double drive helps bale formation as a constant pressure is kept on the chamber belts which results in the production of a solid and uniform bale even when dealing with a wet and heavy crop.

A cleaning auger is fitted to the double drive system in order to prevent crop build up and allow the double drive to aid bale rotation when working in wet or sugary crops.

Bale Shape Assist Indicators

All machines equipped with ISOBUS (V6750 with ISOBUS, V6760 & Fusion Vario Plus) and all machines in the V8 range are fitted with load cell bale shape assist indicators that directly measure the bale pressure inside the chamber.

By comparing the loading on each side of the chamber, the bale shape is calculated and then indicated to the operator via the control console, which side of the chamber needs to be filled.

This direct measuring of the chamber pressure allows the bale shape indicators to be extremely accurate and responsive.

Mechanical Tailgate Locking System

The tailgates on all McHale variable chamber balers are fitted with a pair of mechanical locks, which keep the bale chamber securely closed. These locks remain activated until, the progressive density system reaches the preset bale size and density and the required amount of net has been applied. This eliminates the need for the chamber door to rely on hydraulic pressure when making high density bales.

The continuous oiling system on the machine is driven off the gearbox and delivers oil to the following chains:

• Chamber Drive – Side Chains

• Rotor – Drive Chain

• Pick-Up – Drive Chains

• Pick-Up – Cam Track

• Pick-Up – Drive Gears

Greasing

All machines come fitted with a number of manual greasing points which are easily accessible throughout the baler either individually or through a centralised greasing block. 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

Automatic Greasing

Automatic greasing is standard on all McHale Fusion Vario Plus machines.The McHale Fusion Vario Plus is fittedwith 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 pressurized 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. The grease cartridge should be refilled after 1200 bales.

In the development of McHale’s film on film technology, we realised that changes in temperature and sun light could affect the chamber wrapping film; as the day got hotter or cooler the film was either being over-stretched or under-stretched, and this in turn would cause reliability problems and result in inefficient film use.

As a result, McHale developed a patented application system which adjusts the braking force on the roll of plastic in-line with working conditions. This allows for a continuously variable stretch, which can automatically adjust to changes in the day, without the operator having to adjust any settings.

The McHale patented film application system ensures consistent film stretch, reliable film application and delivers optimum bale shape and bale density. Should an operator wish to use net wrap for hay or straw, this can be done with a simple changeover.

ADVANTAGES OF FILM BINDING

CHAMBER FILM ACTS AS A WRAPPING LAYER

The plastic which is added to the barrel of the bale to keep the bale together also forms part of the wrapping process. This adds value by placing more plastic on the largest surface of the bale.

CHAMBER FILM RESULTS IN BETTER SHAPED BALES

When plastic is applied to the barrel of the bale, it can be stretched to the manufacturers recommendations, which is a higher ratio than can be achieved with net wrap or twine and as a result, the material is kept tighter, which ultimately results in better bale shape.

CHAMBER FILM DELIVERS HIGHER QUALITY SILAGE

As the plastic is being stretched during application to the barrel of the bale, it expels more air than net wrap does and as a consequence, results in better silage quality.

CHAMBER FILM MAKES RECYCLING EASIER

As plastic is used to both bind the bale in the bale chamber and to wrap the bale, on feed out, the farmer will be left with one form of waste. This reduces the time needed to feed the bale and avoids the unpleasant and time-consuming job of separating the twine or net wrap from the plastic before the plastic is recycled.

Binding Material Stretch Application

The Fusion Vario Plus can either apply net or film to the barrel of the bale. This system ensures 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 large net/film brake has been fitted to all machines in the variable chamber baler range, which provides 25% more stretch to be easily achieved. This is especially effective when operating in cold weather with film that requires a higher stretch percentage

Direct Beak Binding

The McHale Fusion Vario Plus is fitted with a new Direct Beak Binding system which maintains a permanent grip on the net or film. This system is very positive and facilitates reliable binding and cutting actions for both net and film. The new binding system features a beak which pivots upwards and away from the chamber to prevent any issues with crop accumulation during the baling process. During the binding process, it pivots downwards to actively place the net/film inside the chamber before it spreads full width for uniform coverage across the bale for consistent and accurate binding.

Net / Film Layers

The number of layers of binding material being used can be easily adjusted as the machine passes through different crop conditions. Net/film adjustment can be controlled from the control console in the tractor cab. At the touch of a button, the operator can easily adjust the stretch and the number of layers of net/film.

The operator can select bale diameter and the number of layers of net to be applied from the control console. The machine will automatically adjust the net application for different bale diameters.

Net/ Film Loading and Storage

The operator simply releases the straps on the spare roll of net/ film from its storage position on the machine and moves the roll into position. To aid the loading process for the operator, the roll of net/film can be placed in the loading cradle whilst being threaded through the binding unit. Once in position, the operator moves the tension bar to hold the roll in place. Storage for two extra rolls of net is provided on the baler platform on all V6 & V8 machines while storage on the Vario Plus is inside the panel on the side of the machine and on the front of the platform

These binding units are extremely reliable and feature:

Endless Adjustment: Endless Adjustment of tension to ensure optimum material usage and bale shape.

Up to 1300 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.

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 offers two ISO-PLAY monitor options:

Customers can purchase a McHale ISO-PLAY 10 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.

Fusion Vario Plus

Camless Pick-Up with Profi-Flo

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 range are fitted with six tine bars to provide excellent ground cleaning and fast delivery of crop to the rotor.

Rotor / Chopper Unit

The 25 knife rotor and chopper unit is available as an option on the McHale Fusion Vario Plus variable chamber machines and delivers a chop length of approximately 46mm.

Selectable Knives

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 standard V6750 & V8950 machines, knife selection is engaged from the baler, while on ISOBUS/ ISO-Play machines in the variable chamber baler range, knife selection can be decided from the tractor cab.

1000rpm Gearbox

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 baler range.

Brakes

All McHale Fusion Vario Plus machines come fitted with hydraulic brakes as standard but can be specified with air brakes as an optional extra.

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.

Bale Weighing & Moisture System

If the Fusion Vario Plus is fitted with the optional bale weighing system, the control terminal displays a bale weight icon on its main screen providing the calculated bale weight.

When fitted with the optional bale moisture recording system, a moisture icon will be shown on the main screen along with a live value showing the percentage of moisture in the crop being baled.

Tire Options

McHale offer a number of tire upgrades depending on customer preferences and ground conditions. Please see below for the tire options available to suit your machine of choice: