Page 1 ZR51200 self-propelled baler Operator’s and maintenance manual EN_o-m1_07_original instructions Serial No. 101 - Order No. 105400FA6 Cabled Assembly Order No. 510542686...
Page 2: Notice To Owner
This manual explains the proper operation of your machine. Study and understand these instructions thoroughly before operating or maintaining the machine. Failure to do so could result in personal injury or equipment damage. Consult your Vermeer dealer if you do not understand the instructions in this manual, or need additional information.
Page 3 Orientation: Right and left sides of the machine are determined by facing in the direction of forward travel. RADEMARKS VERMEER, VERMEER Logo, and EQUIPPED TO DO MORE are trademarks of Vermeer Manufacturing Company. ZR51200 self-propelled baler operator’s and maintenance manual...
Page 4 WARRANTY TERMS: During the Limited Warranty period specified above, any defect in material or workmanship in any warranted item of Vermeer Agricultural Equipment not excluded below shall be repaired or replaced at Vermeer’s option without charge by any authorized independent Vermeer dealer.
Page 5 The warranties contained herein shall NOT APPLY TO: Any defect which was caused (in Vermeer’s sole judgment) by other than normal use and service of the Agricultural Equipment, or by any of the following: (i) accident; (ii) misuse or negligence; (iii) overloading; (iv) lack of reasonable and proper maintenance;...
Page 6 In no event shall Vermeer’s liability exceed the purchase price of the product. (10) Vermeer shall not be liable to any person under any circumstances for any incidental or consequential damages (including but not limited to, loss of profits, out of service time) occurring for any reason at any time.
Page 7 NO DEALER WARRANTY. The selling dealer makes no warranty of its own and the dealer has no authority to make any representation or promise on behalf of Vermeer or to modify the terms or limitations of this warranty in any way.
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Page 9: Receiving And Delivery Report
Engine and drivetrain ___ Check engine oil level. ___ Check battery electrolyte level and battery charge. ___ Check radiator coolant level. ___ Check air cleaner element condition. ___ Check belt tension. ___ Check engine operation. ZR51200 self-propelled baler operator’s and maintenance manual...
Page 10: Hydraulics
Front: 135 ft-lb (183 Nm) Rear: 630 ft-lb +/- 50 ft-lb (854 Nm +/- 68 Nm) ___ Check for signs of leakage and oil level in gearbox. ___ Inspect tires and rims for damage. ZR51200 self-propelled baler operator’s and maintenance manual...
Page 11 ___ Inspect bale chamber-mounted controller sensors. Ensure they are intact, properly adjusted, and operating correctly. • Tailgate Lock Sensor • Bale Size Sensor • Netwrap Feed Sensor • Bale Shape Sensor • Bale Moisture Sensors ZR51200 self-propelled baler operator’s and maintenance manual...
Page 12: Delivery
___ Check netwrap system operation and adjust if needed. ___ Review netwrap settings on controller. ___ Explain operation. ___ Manually extend and retract to show start, feed, and home positions. ___ Load netwrap and explain proper netwrap routing. ZR51200 self-propelled baler operator’s and maintenance manual...
Page 13: Review Of Operation
___ Check all chains for proper adjustment. ___ Check hydraulic density system function. ___ Run baler; check all phases of operation. Warranty registration ___ Check that warranty registration information has been filled out and returned to Vermeer Corporation. ZR51200 self-propelled baler operator’s and maintenance manual...
Page 14: Dealer/Owner Information
Dealer/Owner information dealer owner address address city city state / province state / province zip / postal code zip / postal code country country phone number phone number email address email address ZR51200 self-propelled baler operator’s and maintenance manual...
Page 15: Identification Numbers - Record
Serial number tag located under right hand side of cab Model number ______________________________________________________________ Serial number ______________________________________________________________ Bale chamber Serial number tag located on left side of bale chamber Model number ______________________________________________________________ Serial number ______________________________________________________________ Engine Model number ______________________________________________________________ Serial number ______________________________________________________________ ZR51200 self-propelled baler operator’s and maintenance manual...
Page 16: Display Unit
Display unit Controller part number ___________________________________________________ Controller software/revision number_______________________________________ Electronic control unit Controller part number ____________________________________________________ Controller software/revision number _______________________________________ viii ZR51200 self-propelled baler operator’s and maintenance manual...
Page 17: Table Of Contents
DEF (diesel exhaust fluid) ......12-2 Electronic control system - protection and care ..21-2 ZR51200 Self-Propelled Baler Table of Contents ix...
Page 18 Driving the machine ......30-3 Vermeer TempSense operation ....21-16 Trailering the machine .
Page 19 Bale carriers ........51-1 ZR51200 Self-Propelled Baler...
Page 20 Wheel bearings - check ......60-18 Maintenance - as required ......60-20 xii Table of Contents ZR51200 Self-Propelled Baler...
Page 21: Safety Messages
This symbol indicates that at least one part of the machine is not operating correctly. Shutting down the machine may not be necessary, but some maintenance may be required. ZR51200 self-propelled baler operator’s and maintenance manual Safety messages 10-1...
Page 22 WARNING: Engine exhaust can asphyxiate or poison resulting in death or serious injury. Operate machine outdoors. If it is necessary to operate engine in an enclosed area, properly vent exhaust gases. 10-2 Safety messages ZR51200 self-propelled baler operator’s and maintenance manual...
Page 23 Fluid injected under the skin must be removed immediately by a surgeon familiar with this type of injury. WARNING: Fuel and fumes can explode and burn. Shut off engine before refueling. No flame. No smoking. ZR51200 self-propelled baler operator’s and maintenance manual Safety messages 10-3...
Page 24 Maintain a 3-point hand/foot contact with the access system (one hand and two feet, or two hands and one foot). Keep all handrails in place. 10-4 Safety messages ZR51200 self-propelled baler operator’s and maintenance manual...
Page 25 Riders are not allowed on the machine. Do not climb. If access is needed, use suitable height stepladder. WARNING: Belts, rollers, and chains can cut off hand or arm. Keep all shields in place when operating. ZR51200 self-propelled baler operator’s and maintenance manual Safety messages 10-5...
Page 26 50-24. ALWAYS disengage baler ground drive, shut off engine, engage park brake, and remove key before manually unplugging or servicing. WARNING: Rolling bale can crush. Do not eject downhill. 10-6 Safety messages ZR51200 self-propelled baler operator’s and maintenance manual...
Page 27 WARNING: Failure to follow any of the preceding safety instructions or those that follow within this manual, could result in death or serious injury. This machine is to be used only for those purposes for which it was intended as explained in this Operator’s Manual. ZR51200 self-propelled baler operator’s and maintenance manual Safety messages 10-7...
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Page 29: Diesel Fuel And Def Requirements
15 ppm (15 mg/kg). Use of fuels other than what is specified in the engine manual will impact engine performance, damage engine emissions systems and may result in engine and exhaust system warranty being voided. 15 mg/kg ZR51200 self-propelled baler operator’s and maintenance manual Diesel fuel and DEF requirements 12-1...
Page 30: Def (Diesel Exhaust Fluid)
Consistent Shelf life temperature °F (°C) (approximate months) ≤ 50 (10) ≤ 77 (25) ≤ 86 (30) ≤ 95 (35) > 95 (35) Test prior to use. 12-2 Diesel fuel and DEF requirements ZR51200 self-propelled baler operator’s and maintenance manual...
Page 31: Intended Use
Section 15: Intended use The ZR51200 is a self-propelled round baler, designed solely for use in baling agricultural crop material. Always use the machine in accordance with the instructions contained in this operators and maintenance manual, safety signs on the machine, and other material provided by Vermeer Corporation.
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Page 33: Emissions Quick Reference Guide
• Before disconnecting battery, verify that DEF system purge is complete. Refer to “Battery disconnect procedure,” page 60-2. Refer to engine operator’s manual for more information. failure to follow instructions may void engine warranty. ZR51200 self-propelled baler operator’s and maintenance manual Emissions quick reference guide 18-1...
Page 34 Operator should ensure exhaust pipe outlet is not directed toward any flammable or High exhaust system combustible surfaces. temp (HEST) lamp • Will illuminate during manual exhaust system cleaning. 18-2 Emissions quick reference guide ZR51200 self-propelled baler operator’s and maintenance manual...
Page 35 Engine exhaust regen menu (located in advanced engine menu) ZR51200 self-propelled baler operator’s and maintenance manual Emissions quick reference guide 18-3...
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Page 37: Machine Controls
LOCKED position (B). This prevents unexpected tailgate movement. Rotate tailgate cylinder lock valve handle (1) up (clockwise) to place tailgate lock valve in UNLOCKED position (A). ZR51200 self-propelled baler operator’s and maintenance manual Machine controls 20-1...
Page 38: Engine Controls
Rotate left......... .low idle 20-2 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 39: Ground Drive Controls
....disengage park brake Ground drive is not allowed when manual park brake is engaged. ZR51200 self-propelled baler operator’s and maintenance manual Machine controls 20-3...
Page 40 Press to activate maximum speed limiter (forward speed only). Rotate to adjust maximum speed limit. Set speed limit is shown on display. Return Ground Drive Speed Control Lever to neutral, then press to deactivate. 20-4 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 41 Press........to cancel Auto mode ZR51200 self-propelled baler operator’s and maintenance manual...
Page 42 Rotate center knob a quarter turn to the left and push or pull steering wheel to the desired position. Rotate center knob a quarter turn to the right to lock steering wheel position. 20-6 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 43 Turn to position ....... . . HIGH speed ZR51200 self-propelled baler operator’s and maintenance manual...
Page 44 Push down ........left turn signal 20-8 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 45: Baler Controls
Push button ........lower pickup ZR51200 self-propelled baler operator’s and maintenance manual...
Page 46 Push top ........no function 20-10 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 47: Diesel Particulate Filter Controls
Touch softkey....... . Auto Regen off NOTICE: Auto DPF regen should not be turned off unless high exhaust temperature presents an immediate hazard. To cancel DPF Inhibit, turn Ignition Switch off. ZR51200 self-propelled baler operator’s and maintenance manual Machine controls 20-11...
Page 48: Accessory Controls
Push again..........off 20-12 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 49 Work light switch Rotate to 1, upper work lights on Rotate to 2, upper work lights on Rotate to 3rd position, upper work lights on Rotate to O, all work lights off ZR51200 self-propelled baler operator’s and maintenance manual Machine controls 20-13...
Page 50 LED (C) is illuminated when function is on. (14) Outside air temperature softkey Touch softkey to turn Outside Temperature function on and off. LED (D) is illuminated when function is on. Outside temperature is shown on display. 20-14 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 51 (15) 12-volt accessory outlet ZR51200 self-propelled baler operator’s and maintenance manual Machine controls 20-15...
Page 52: Cab Access Steps
Cab access steps Use steps (1) and handholds (2) to enter and exit cab. 20-16 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 53: Cab Door
Pull lever ........opens door ZR51200 self-propelled baler operator’s and maintenance manual...
Page 54: Emergency Exit
Pull handle and swing up ....... release emergency exit Push handle forward, then push pane out ....fully open emergency exit 20-18 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 55: Front Sunscreen
(1) Sunscreen Pull the center of the roll-up sunscreen down to desired level. (2) Release cord Pull release cord to raise roll-up sunscreen. Hold center of sunscreen to control retraction speed. ZR51200 self-propelled baler operator’s and maintenance manual Machine controls 20-19...
Page 56: Seat Belts And Seat Controls
The seat is equipped with an operator presence switch. The operator must be seated to operate multiple machine functions. Instructional seat with seat belt Use only temporarily for instructing new operator or diagnosing the machine. Not a passenger seat. 20-20 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 57: Operator Presence System
(netwrap will not stop). Controls must then be reset to neutral or off before resuming work. The Operator Presence system must be maintained in good functional condition. Contact your Vermeer dealer if it does not function correctly.
Page 58: Access Panels And Doors
Access panels and doors Fuel and DEF fill locations (1) Fuel fill (2) DEF fill Hydraulic fluid fill (3) Hydraulic fluid fill (4) Hydraulic fluid level gauge 20-22 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 59 (5) Left side access door Turn handle (A) counterclockwise and pull to open. (6) Right side access door Turn handle (B) counterclockwise and pull to open. ZR51200 self-propelled baler operator’s and maintenance manual Machine controls 20-23...
Page 60: Fire Extinguisher Mounting Location
Two fire extinguishers are available with the machine. An ABC fire extinguisher (1) is mounted on the right side of machine by the DEF tank. A water fire extinguisher (2) is mounted outside the left side cab door. 20-24 Machine controls ZR51200 self-propelled baler operator’s and maintenance manual...
Page 61: Electronic Controller
• fault and alarm information • field statistics display • tailgate status indication (open or closed) • bale shape indication • starts and monitors netwrap operation • crop moisture display ZR51200 self-propelled baler operator’s and maintenance manual Electronic controller 21-1...
Page 62: Electronic Control System - Protection And Care
NOTICE: The monitor is not waterproof or dust proof and can be damaged by moisture and excess dust. Clean the monitor with a moist, fuzz free, cotton cloth. If necessary, a mild cleaning agent can be used. Do not use acid or abrasive cleaning agents. 21-2 Electronic controller ZR51200 self-propelled baler operator’s and maintenance manual...
Page 63: Monitor Face And Control Functions
If no faults are detected, default “Home” screen (3) then appears after 10–15 seconds and machine is ready for baling. Use Expand Softkey (4) to switch between default “Home” screen and alternate “Home” screen (5). ZR51200 self-propelled baler operator’s and maintenance manual Electronic controller 21-3...
Page 64: Monitor Functions And Screen Symbols
Netwrap roll diameter monitor (6) Monitor shows amount of remaining netwrap roll to inform operator when netwrap roll needs to be replaced. 21-4 Electronic controller ZR51200 self-propelled baler operator’s and maintenance manual...
Page 65: Navigation Softkeys
Use this selector softkey to navigate between default Home screen and alternate Home screen. Settings softkey (4) Touch softkey to access settings menu screen. Field control softkey (5) Touch softkey to access field control screen. ZR51200 self-propelled baler operator’s and maintenance manual Electronic controller 21-5...
Page 66 Pickup and Tailgate Camera mode. Pickup camera selection softkey (8) Touch softkey to enter Pickup Camera mode. Tailgate camera selection softkey (9) Touch softkey to enter Tailgate Camera mode. 21-6 Electronic controller ZR51200 self-propelled baler operator’s and maintenance manual...
Page 67: Bale Size Screen Symbols
7" (18 cm) below full bale size. When set to 0 yellow bar will not appear with no sound. To change near full alert setting contact your Vermeer dealer. ZR51200 self-propelled baler operator’s and maintenance manual Electronic controller 21-7...
Page 68 When bar fills beyond the line which represents a full bale, an overfill alarm is displayed and logged when sensed bale size is at least 55" (140 cm) (8) and signal from overfill sensor is received. 21-8 Electronic controller ZR51200 self-propelled baler operator’s and maintenance manual...
Page 69: Bale Shape And Information Boxes
(7) to calibrate bale shape bar display. Field information data (2) Information shows different field information. Touch Field Control softkey (3) to switch between field information. ZR51200 self-propelled baler operator’s and maintenance manual Electronic controller 21-9...
Page 70: Bale Weight
Weight display (1) Provides real-time bale weight data in pounds while baling. Zero scale Touch Settings softkey (2), Calibration softkey (3), Scales softkey (4), then follow on-screen directions (5) to zero scale. 21-10 Electronic controller ZR51200 self-propelled baler operator’s and maintenance manual...
Page 71: Bale Chamber Tailgate Screen Symbols
A short signal also sounds to indicate that the tailgate is closed completely. Bale wrap complete (2) When symbol is present, bale wrap is complete, open tailgate. Tailgate unlocked and open (3) When symbol is present, tailgate is unlocked and open. ZR51200 self-propelled baler operator’s and maintenance manual Electronic controller 21-11...
Page 72: Fault Screen Symbols
Text describes the current fault displayed. OK softkey (6) Touch Green Check softkey to acknowledge notification of fault and return to previous screen or menu. When a fault occurs, follow on-screen instructions. 21-12 Electronic controller ZR51200 self-propelled baler operator’s and maintenance manual...
Page 73: Programming And Configuration Functions
To resume normal operation touch Home softkey to return to the “Home” screen. Depending on software revision, the ECU may have additional settings not explained in this manual. These additional settings should remain at factory-set values to ensure proper operation. ZR51200 self-propelled baler operator’s and maintenance manual Electronic controller 21-13...
Page 74: Bale Chamber Setup Screen
Touch Settings softkey (1) to access “Baler Setup” screen (2). Step 2: Menu items appear for changing parameters: “Bale Size” (3) “Net Wraps” (4) Step 3: Touch Home softkey (5) to return to “Home” screen. 21-14 Electronic controller ZR51200 self-propelled baler operator’s and maintenance manual...
Page 75 Recalibrate bale size to confirm actual bale size matches current bale size with wrapped bale in chamber. Step 2: Touch Home softkey (5) to save settings and return to the “Home” screen. ZR51200 self-propelled baler operator’s and maintenance manual Electronic controller 21-15...
Page 76: Vermeer Tempsense Operation
(3). Left and right bearing statuses are represented using a single-colored dot (4) on the overview screen. More detailed information can be viewed on the bearing temperature screen. 21-16 Electronic controller ZR51200 self-propelled baler operator’s and maintenance manual...
Page 77 If a bearing icon is colored in gray (indicating sensor is disconnected or offline), no temperature will be provided in list (7). Step 3: Touch Home softkey (8) to return to the “Home” screen. ZR51200 self-propelled baler operator’s and maintenance manual Electronic controller 21-17...
Page 78: Vermeer Tempsense Regulatory Notice
: (1) l'appareil ne doit pas produire de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d'en compromettre le fonctionnement. 21-18 Electronic controller ZR51200 self-propelled baler operator’s and maintenance manual...
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Page 80: Starting Procedure
Section 22: Starting procedure WARNING: Read operator’s and maintenance manual and safety signs before operating machine. Starting the engine Complete daily maintenance before starting engine. Refer to Maintenance, page 60-1. ZR51200 self-propelled baler operator’s and maintenance manual Starting procedure 22-1...
Page 81 Operator ........must be in seat Step 2: Sound horn (4) to signal engine starting. 22-2 Starting procedure ZR51200 self-propelled baler operator’s and maintenance manual...
Page 82: Extended Idle Periods
If extended idle is necessary for any reason, consult the engine operation manual for allowable idle RPM and time periods. Prolonged idle at slow speeds can allow engine to cool and damage engine components. ZR51200 self-propelled baler operator’s and maintenance manual Starting procedure 22-3...
Page 83: Cold Weather Starting
NOTICE: Handheld aerosol starting aid use can cause explosion. Engine damage is possible. Do not use handheld aerosol. For frequent starts below 10°F (-12°C), consult your Vermeer dealer. Refer to the engine operation manual for additional information. Engine can be forced to derate if DEF is not completely thawed out within 30 minutes of startup.
Page 84: Jump-Starting (12-Volt System)
External: Flush with plenty of water. If eyes have been exposed, flush with water for 15 minutes and get prompt medical attention. Internal: Drink large quantities of water or milk, follow with milk of magnesia, beaten egg, or vegetable oil. Call a physician immediately. ZR51200 self-propelled baler operator’s and maintenance manual Starting procedure 22-5...
Page 85: Jump-Starting Procedure
Black (B) to discharged machine frame (4), away from discharged battery. Step 3: Start engine. Step 4: Remove cables in reverse order and install red cover over positive battery cable clamp. BOOSTER BATTERY 22-6 Starting procedure ZR51200 self-propelled baler operator’s and maintenance manual...
Page 86: Shutdown Procedure
If working in bale chamber, move tailgate cylinder lock valve handle (1) down to locked position (A) to prevent unexpected tailgate movement. A variation of the above procedure may be used if so instructed within this manual or if Locked an emergency requires it. ZR51200 self-propelled baler operator’s and maintenance manual Shutdown procedure 23-1...
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Page 88: Preparing The Equipment
Initial training should be conducted at a site free of obstacles and review the following: • all sections of this manual • processes and procedures used to form and wrap a bale • transporting machine • setup of the machine ZR51200 self-propelled baler operator’s and maintenance manua Preparing the equipment 25-1...
Page 89: Operator Presence System
(netwrap will not stop). Controls must then be reset to NEUTRAL or OFF before resuming work. The Operator Presence system must be maintained in good functional condition. Contact your Vermeer dealer if it does not function correctly.
Page 90: Seat Belt Use
Ensure there are no twists in seat belt webbing. Step 4: Allow retractor to take up any slack in webbing. Step 5: Pull sharply on webbing to ensure retractor is locked. ZR51200 self-propelled baler operator’s and maintenance manua Preparing the equipment 25-3...
Page 91: Prestarting Inspection
Ensure you are familiar with the location and function of each machine control before operating the machine. Refer to “Machine controls,” page 20-1. 25-4 Preparing the equipment ZR51200 self-propelled baler operator’s and maintenance manua...
Page 92 Rear Tires at 29 psi (200 kPa) ___ Torque wheel lug nuts to: Front wheels – 135 ft-lb (185 Nm) Rear wheels – 630 ft-lb +/- 50 ft-lb (854 Nm +/- 68 Nm) ZR51200 self-propelled baler operator’s and maintenance manua Preparing the equipment 25-5...
Page 93: Netwrap - Prestarting Inspection
Section 40 for Netwrap operating instructions. SMV sign - position Ensure slow-moving vehicle (SMV) sign (1) is properly installed on rear of machine as shown and in good condition. 25-6 Preparing the equipment ZR51200 self-propelled baler operator’s and maintenance manua...
Page 94: Transporting The Machine
(one hand and two feet, or two hands and one foot). Keep all handrails in place. • Do not use any controls as handholds when climbing on or off the machine. • Never jump off the machine. ZR51200 self-propelled baler operator’s and maintenance manual Transporting the machine 30-1...
Page 95: Machine - Clean
Always wear seat belt when machine is being driven. The instructional seat is provided for training or diagnosing purposes only and is not intended for children or other passengers. 30-2 Transporting the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 96: Driving The Machine
WARNING: Machine can strike or run over a person resulting in death or serious injury. Before steering or driving machine, clear area and sound horn to warn others to stay away. ZR51200 self-propelled baler operator’s and maintenance manual Transporting the machine 30-3...
Page 97 Contact utility company to shut off electrical power. • Do not allow anyone to approach the machine or any connected equipment. • Do not resume operation until utility company declares area safe. 30-4 Transporting the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 98 Press Maximum Speed Limiter Rotary Switch (4) to activate. Turn rotary switch to adjust and set maximum speed limit (forward speed only). Return Ground Drive Speed Control Lever to NEUTRAL, then press to deactivate. Approximate maximum speed (5) is shown on display. ZR51200 self-propelled baler operator’s and maintenance manual Transporting the machine 30-5...
Page 99: Trailering The Machine
Verify pickup is fully raised before loading or unloading. • Slowly drive machine on and off trailer squarely to minimize steering. • Position machine at location for tie-downs and weight distribution as recommended by trailer manufacturer. 30-6 Transporting the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 100: Loading
Uncover or install slow-moving vehicle sign on machine. Step 3: Remove chains and load binders. Step 4: Start engine. Refer to Starting procedure, page 22-1. Step 5: Slowly drive machine squarely off trailer. Rear ZR51200 self-propelled baler operator’s and maintenance manual Transporting the machine 30-7...
Page 101: Towing/Retrieval
• Never try to jerk the disabled machine in order to get the machine to move. Sudden cable overload may cause cable Rear to fail. 30-8 Transporting the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 102 There are two valves per pump, four valves total. Step 4: Locate ball valve (2) under left side of cab, then remove nylon tie and close valve. ZR51200 self-propelled baler operator’s and maintenance manual Transporting the machine 30-9...
Page 103 Open ball valve and install new nylon tie. Step 10: Install retained bolts and nuts on pump prevention plate. Step 11: Tighten high pressure relief valves and torque to 52 ft-lb (70 Nm). 30-10 Transporting the machine ZR51200 self-propelled baler operator’s and maintenance manual...
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Page 105: Preparing The Crop To Bale
Crop that is too wet will result in operating difficulties and spoilage during storage. • Crop that is too dry will result in excessive leaf loss and poorly packed bales. ZR51200 self-propelled baler operator’s and maintenance manual Preparing the crop to bale 35-1...
Page 106: Windrow Preparation
NOTICE: Never make windrows wider than the width of the bale chamber 47" (119 cm). Difficulty in core starting may result. Windrows other than 24 or 47" (61 or 119 cm) wide will cause poorly shaped bales. 35-2 Preparing the crop to bale ZR51200 self-propelled baler operator’s and maintenance manual...
Page 107: Netwrap Operation
The netting contains the round bale, ensuring it cannot come apart, while shedding water to reduce spoilage. WARNING: Netwrap can move suddenly. Crushing injury possible. Keep hands away from moving parts. Shut off machine. Read manual before servicing. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-1...
Page 108 WARNING: Sharp knife can cut. Keep hands away from knife. Wear heavy gloves when working around knife. 40-2 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 109: Netwrap Components
Knife (5) - A vertical steel knife is used to cut the netwrap at the end of a wrapping cycle. Brake (6) - A mechanical friction pad against a drum is used to provide tension to the netwrap while it is feeding. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-3...
Page 110 Actuator stops between these two positions while net is applied. It also controls brake release weldment (7) on right hand side. 40-4 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 111: Netwrap Components - Operating Positions
Net load - When loading a new roll of netwrap, the operator must open the shear bar to feed the netwrap through. To do this the system must be moved from its typical “Home” position into the Net Load position. Refer page 40-24. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-5...
Page 112: Net Storage Location
40-36. • Adjust net guide weldment. Refer to “Netwrap brake spring (tension) - initial adjustment,” page 40-36. • Adjust netwrap knife. Refer to “Netwrap knife - adjust,” page 60-25. 40-6 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 113: Netwrap - Controller Setup Instructions
On Settings screen touch the Minus (3) or Plus (4) to adjust “Number of Wraps” setting (5) to desired value. Step 3: Touch Home softkey (6) to save settings and return to the Home screen. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-7...
Page 114 Value shows time in milliseconds from when actuator moves net into belts to when brake is applied adding tension to netwrap. Step 8: Touch Home softkey (6) to save settings and return to the Home screen. 40-8 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 115 Neither field nor total bale counts will increase unless netwrap cycle is completed and bale size drops below 25% of target full bale size. This prevents bale counts from increasing if multiple netwrap cycles are performed. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-9...
Page 116: Start Softkey - Manual Netwrap Cycle
Shear bar moves away from netwrap, allowing it to be pulled from roll. • When netwrap cycle is complete, open tailgate symbol (4) appears indicating cycle is done and bale should be ejected. 40-10 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 117 When tailgate is closed, bale size indicator (7) goes to gray, showing no bale in chamber, bale size goes to 0 (8), bale shape indicator bars (9) minimize, and bale count should increase by 1 (10). ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-11...
Page 118: Pause Softkey - Netwrap Cycle
Step 3: Touch and release Pause softkey (1) or Start softkey (3) to resume normal netwrap application operation. NOTICE: If net is feeding, it will continue to feed in paused mode. 40-12 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 119: Manual Control Softkeys - Netwrap
Touch and hold Cut softkey (6) to manually extend netwrap mechanism toward cut position. Releasing the softkey will stop mechanism movement. Step 5: Touch Home softkey (7) to save settings and return to the Home screen. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-13...
Page 120: Netwrap - Apply To Bale
NEVER try to unplug the baler while it is running. Refer to “Unplugging the Baler,” page 50- ALWAYS disengage baler ground drive, shut off engine, engage park brake, and remove key before manually unplugging or servicing. 40-14 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 121: Netwrap System - Automatic Cycle Start
Engage baler drive, then touch and release Pause softkey or Start softkey (3) to begin or complete a wrap cycle. • If the bale has already been tied off, eject bale and resume normal operation. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-15...
Page 122: Netwrap - Normal Operation
Bale size indicator (5) color will change to red for full bale. • Audible alert will sound a 3-second long beep. • Machine ground drive will come to a stop unless Pause softkey (6) is pressed. 40-16 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 123 Brake pad-to-wheel clearance is set at 1/16" (1.6 mm). Refer to page 40-32 for instructions. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-17...
Page 124 Netwrap mechanism will remain in this position until next bale is finished. Step 7: When tie cycle is complete, audible device sounds 1 beep, indicating application is finished, and arrow icon (13) flashes. 40-18 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 125 (16), bale shape indicator bars (17) minimize, and bale count should increase by 1 (18). Step 12: Inspect bale to ensure required number of wraps have been applied. If not, refer to page 40-7 to make adjustments. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-19...
Page 126: Netwrap - Manual Start
Stop forward motion. Step 2: Touch and release Start softkey (1) to manually start wrapping the bale. Step 3: Follow Steps 4–12 on previous pages to finish wrapping and ejecting bale. 40-20 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 127: Failed And Misfed Netwrap
Keep hands away from moving parts. Shut off machine. Read manual before servicing. WARNING: Sharp knife can cut. Keep hands away from knife. Wear heavy gloves when working around knife. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-21...
Page 128: Netwrap Misfeed - Check For And Remove
Start engine and engage baler drive. • Increase engine to full idle. • Press and release Start Key to rewrap bale. This will ensure bale is sufficiently covered with netwrap prior to ejection. 40-22 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 129: Netwrap - Loading And Storage
Netwrap - loading and storage WARNING: Sharp knife can cut. Keep hands away from knife. Wear heavy gloves when working around knife. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-23...
Page 130: Net Loading Operation
Load menu screen (A) will display showing netwrap routing diagram. Step 3: Continue with Step 4 on the following page to load netwrap roll. After netwrap roll is correctly installed, press and hold Home softkey (2). 40-24 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 131 Step 7: Inspect netwrap contact surfaces for debris. Surfaces must be kept clean and smooth for proper operation. Step 8: Push tensioning roller (8) toward front of baler until it latches. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-25...
Page 132 Slide roll of netwrap (9) onto spindle (5) on right side with the netwrap coming off the bottom (10) of the roll. Step 10: Swing spindle support (7) into opposite end of netwrap roll and secure with linchpin (6). 40-26 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 133 Pull netwrap through so it hangs 4" (10 cm) below front of feed pan (13). Spread netwrap so it is at least 1/2 the width of the pan. View from left-hand side, netwrap mechanism in “Net Load” position 4" (10 cm) ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-27...
Page 134 Step 17: Ensure net roll is still centered after tightening brake wheel. If T-handle is not sufficiently tight, NO NET FEED error may come up and net may not cut well. 40-28 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 135 Step 20: Display will return to Home screen (15), baler is now ready to continue baling. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-29...
Page 136: Netwrap - Adjustments And Maintenance
After new roll is installed, weight of roll on brake wheel may affect clearance between brake wheel and sensor. • To check sensor and circuit, rotate wheel out of cycle. Feeding code should be displayed. 40-30 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 137: Netwrap System - Optimize Performance
Maximizing netwrap tension can help optimize bale appearance, increase the number of bales wrapped per roll of netwrap, and ensure netwrap cuts properly at end of wrap cycle. Refer to page 40-36. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-31...
Page 138: Netwrap Brake Pad-To-Wheel Clearance - Adjust
Netwrap brake pad-to-wheel clearance - adjust Step 1: Press Start softkey (1) to fully extend feed pan (2) against belts (3). 40-32 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 139 In (forward) - To move brake pad (5) further from brake wheel (4). Tighten lock nut (6) to secure. Step 4: Repeat previous steps as needed to verify proper adjustment. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-33...
Page 140: Netwrap Shear Bar Clearance - Adjust
Touch and release Netwrap softkey (3) on Manual Control screen (C), then touch and hold Cut softkey (4) and/or Apply (5) softkeys as needed to position top edge of shear bar (6) in center of timing hole (7). Front 40-34 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 141 If mark (9) is to the front of mark (8), decrease “Net Fine Tune” setting. Setting can be adjusted between 1.5 and 8, because this is a time setting. Refer to page 40-9. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-35...
Page 142: Netwrap Brake Spring (Tension) - Initial Adjustment
Spring length (3) is 4.8" (12 cm) from end of spring coil to inside end of spring hook as shown. Step 5: Tighten jam nut (2) to secure. 40-36 Netwrap operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 143 (2) to secure. This is the optimal netwrap tension. Step 10: Ensure wrap cycle operates properly with new roll of netwrap installed. ZR51200 self-propelled baler operator’s and maintenance manual Netwrap operation 40-37...
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Page 145: Auto Lube Operation
See instructions on the following pages to manually operate auto grease pump and purge air out of the system. Grease is pumping if current is 2.5 amps. Step 7: After auto grease pump cycles one time, tighten canister (3). ZR51200 self-propelled baler operator’s and maintenance manual Auto lube operation 44-1...
Page 146: Auto Lube - Setup Procedure
Step 6: Touch Home softkey (8) to save settings and return to the “Home” screen. Step 7: Touch Back softkey (9) to save settings and return to the previous screen. 44-2 Auto lube operation ZR51200 self-propelled baler operator’s and maintenance manual...
Page 147: Manual Lube - Setup Procedure
When the softkey is held for 15 seconds (maximum), the manual greaser function can be used to: • purge air from grease lines • perform special maintenance If necessary, release softkey and touch and hold softkey again to continue to purge grease lines. ZR51200 self-propelled baler operator’s and maintenance manual Auto lube operation 44-3...
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Page 149: Moisture Sensing
Use of crop preservative agent could increase the moisture reading by up to 4%. • Percentage of grass in crop – sensors are initially set for 100% alfalfa, more grass in the crop may result in higher readings. ZR51200 self-propelled baler operator’s and maintenance manual Moisture sensing 45-1...
Page 150 (1) will read “WET.” As such, display will not provide an accurate moisture reading in silage crop conditions. When operating at moisture levels less than 7%, moisture display will read “DRY.” Accuracy rating is +/- Number displayed reflects percent of moisture content in crop material. 45-2 Moisture sensing ZR51200 self-propelled baler operator’s and maintenance manual...
Page 151: Moisture Display - Calibrate
Put a 10 fl-oz (300 ml) covered glass of water in the corner of a microwave oven. This will help prevent damage to oven by capturing unabsorbed microwaves as the crop sample dries. ZR51200 self-propelled baler operator’s and maintenance manual Moisture sensing 45-3...
Page 152 Step 15: If “Moisture” content (Step 2) is different from moisture content measured in Steps 3–14, follow the moisture offset procedure. 45-4 Moisture sensing ZR51200 self-propelled baler operator’s and maintenance manual...
Page 153: Moisture Offset - Settings
Touch Settings softkey (1) to open selections menu. Step 2: Touch Calibration softkey (2) to advance to Calibrate screen (3). Step 3: Touch Moisture softkey (4) to open Moisture Offset screen (5), shown on the following page. ZR51200 self-propelled baler operator’s and maintenance manual Moisture sensing 45-5...
Page 154 Step 5: Touch Back softkey (9) to save settings and return to previous screen or menu, or touch Home softkey (10) to save settings and return to the “HOME” screen. 45-6 Moisture sensing ZR51200 self-propelled baler operator’s and maintenance manual...
Page 155: Operating The Machine
Become familiar with the controls, operation, and use of the machine under the supervision of a trained and experienced operator. Operator must be familiar with the workplace’s safety rules and regulations, and must be mentally and physically capable of operating machine safely. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-1...
Page 156: Personal Protection
Be sure you are familiar with location and function of each baler control before operating baler. Refer to “Machine controls,” page 20-1. Keeps doors and windows closed while operating machine. 50-2 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 157 WARNING: Falling from baler can result in serious injury. Riders are not allowed on the baler. Do not climb. If access is needed, use suitable height stepladder. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-3...
Page 158: Fire Prevention
Do not allow foreign material to build up under shields or near potentially hot areas of the baler such as roller bearings. Remove any buildup as part of the regular maintenance operations. 50-4 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 159: Fire - Extinguish
Press and hold bale chamber unload switch to fully extend arms until bale chamber is on ground. Refer to page 50-28. Step 6: Drive power unit away from bale chamber and shut off engine. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-5...
Page 160 Spray water from fire extinguisher at the base of the flame to extinguish it and cool surrounding parts. Refill fire extinguisher, if possible, and continue to extinguish the fire as needed. 50-6 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 161: Preparing For Operation
These include surface moisture, bale density, crop variety, temperature of the hay, overall climatic conditions and the use of a crop preservative. Use meter readings as guides, not absolute moisture values. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-7...
Page 162: Diesel Particulate Filter (Dpf) Safety
Use proper engine oil. Refer to “Specifications,” page 65-1. • Use only ultra low sulfur diesel fuel. NOTICE: Prolonged inhibiting of DPF regeneration can cause damage to engines and aftertreatment system. 50-8 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 163: Dpf Alert Indicators
This may result in premature failure of exhaust system components and an engine service technician will be required to perform a service regeneration. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-9...
Page 164: Arriving At The Field
Contact utility company to shut off electrical power. • Do not allow anyone to approach the machine or any connected equipment. • Do not resume operation until utility company declares area safe. 50-10 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 165: Crop Feed Direction
WARNING: Contact with machine or bales can result in death or serious injury. Survey area around baler for persons or obstacles before moving the machine. Keep all spectators and other workers away from machine and work area while in operation. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-11...
Page 166: Prepare Baler
After core of bale is formed, decreasing baler drive speed may be advisable under the following conditions: • When baling very dry or short-stemmed crops • When baling crops in small windrows Step 6: Align machine with center of windrow. 50-12 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 167: Bale Formation
Current bale size as indicated by the bar graph (2) just before bale ejection should match actual size of ejected bale. Belt length may change over time. As belt length changes, actual bale size will become larger or smaller than current bale size (3). ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-13...
Page 168: Baling Speed
Generally, the smallest desirable bale is 46" (117 cm) in diameter. Maximum bale size is 72" (183 cm). • Do not leave a partially formed bale in the chamber. Ensure bale chamber is empty before shutting down baler. 50-14 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 169: Bale Shape
Sensors help to achieve a high material intake and well-shaped round bales. The bale chamber must be evenly supplied with material over the entire width of the machine by an appropriate driving style. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-15...
Page 170 Currently too little material in the right part of the bale chamber. Steer machine a bit to the left and let the right part of the pickup collect more material, until the right sensor bar is of equal height again. 50-16 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 171: Baling
After core of bale is formed, decreasing baler drive speed may be advisable under the following conditions: • When baling very dry or short-stemmed crops • When baling crops in small windrows ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-17...
Page 172 Drive, without weaving, until bale reaches full size. The full width windrow eliminates the need for weaving. • Follow Step 11 to finish bale. No action required if Auto mode direction is selected. 50-18 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 173: Wrapping The Bale
When wrapping cycle is finished, audible device sounds, 1 beep, and tailgate can be opened to eject bale. If an auto mode direction is selected, tailgate will automatically open when wrapping cycle is finished. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-19...
Page 174: Wrapping The Bale Sequence - Netwrap
Netwrap cuts as it pulls across netwrap knife. • Amount of netwrap applied to bale is adjustable by pressing and holding Net Density Key while pressing and releasing Up/Down Arrow Keys. 50-20 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 175: Ejecting The Bale
WARNING: Contact with baler or bales can result in death or serious injury. Survey area around baler for persons or obstacles before moving the machine. Keep all spectators and other workers away from baler and work area while in operation. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-21...
Page 176 (2) appears indicating tailgate has closed and latched. Audible device sounds 1 beep, indicating tailgate is closed and machine is now ready to continue baling. If an auto direction is selected, tailgate automatically closes. 50-22 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 177: Unplugging The Baler
WARNING: Opening tailgate can crush, resulting in death or serious injury. Stay away from rear of baler. Warn others to stay away before opening tailgate. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-23...
Page 178: Plugged Pickup Area
Pull crop material through bale chamber to clear the throat. Step 9: Move tailgate cylinder lock valve to unlocked position. Step 10: Close and latch tailgate. Step 11: Repeat Steps 4–10 as required. 50-24 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 179: Flipped Belt - Reposition
Move tailgate cylinder lock to unlocked position. Step 10: Start machine and open tailgate fully. Step 11: Shut off machine, remove key, and remove cylinder stop on density cylinder. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-25...
Page 180: Unloading And Loading Bale Chamber
Park machine on a hard level surface. Step 2: Follow shutdown procedure. Refer to “Shutdown procedure,” page 23-1. Step 3: Turn handle (1) counterclockwise and pull left side access door (2) open. 50-26 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 181 Disconnect electrical connector (6). Step 6: Support hydraulic lines (5) and electrical connector (6) by hanging them on hook (7). Step 7: Disconnect electrical connector caps (8). Hydraulic hoses hung on hook ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-27...
Page 182 Drive power unit away from bale chamber. If an emergency requires it, follow ONLY steps 10 and 11 to unload the bale chamber and drive the power unit away. NOTE: Machine damage could result. 50-28 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 183 Back power unit up to bale chamber until arms (10) are in correct position. Step 2: Press and hold bale chamber loading switch (11) until bale chamber is fully loaded onto power unit. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-29...
Page 184 Connect hydraulic lines (5) and pull lever (4) toward rear of machine to lock lines in place. Step 6: Connect electrical connector (6). Step 7: Connect caps (8) together. Step 8: Close left side access door. 50-30 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
Page 185: Operational Messages
High priority alert, audio device will sound with 12 intermittent tones. Medium priority alert, audio device will sound with six intermittent tones. ZR51200 self-propelled baler operator’s and maintenance manual Operating the machine 50-31...
Page 186: Tailgate Open Alert
Display indicates an open tailgate message (2). • Close tailgate using the machine's hydraulic control. • Alert screen (1) disappears. • Home screen appears and display indicates a closed tailgate (3) for normal operation. 50-32 Operating the machine ZR51200 self-propelled baler operator’s and maintenance manual...
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Page 188: Handling Round Bales
- moving very slowly and smoothly. • Front-mounted bale handler must be equipped with a grapple or similar restraint device to prevent bale from rolling down loader arms onto tractor operator. ZR51200 self-propelled baler operator’s and maintenance manua Handling round bales 51-1...
Page 189: Storing Bales
Place on solid, high ground. CORRECT Align single rows (1) at least 1 ft (30 cm) apart. Rows should follow slope of ground. SLOPE 1 ft (30 cm) 1 ft (30 cm) 51-2 Handling round bales ZR51200 self-propelled baler operator’s and maintenance manua...
Page 190: Incorrect Bale Storage
Water will collect between stacked bales (2), causing spoilage. Stacks can be used if covered under plastic. Bales stored on end (3) cannot shed water and will spoil rapidly. INCORRECT INCORRECT ZR51200 self-propelled baler operator’s and maintenance manua Handling round bales 51-3...
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Page 192: Maintenance
23-1, for instructions. Visually inspect machine daily before starting the machine. Make no modifications to your equipment unless specifically recommended or requested by Vermeer Corporation. Safety signs Safety signs located on your machine contain important and useful information that will help you operate your equipment safely. Refer...
Page 193: Welding Alert - Electronic Components
Allow engine control module (ECM) enough time (up to 15 minutes) after machine shut down to properly power down. Step 2: Verify that DEF system purge is complete. Step 3: Disconnect negative battery cable then disconnect positve battery cable. Step 4: Unplug all controllers. 60-2 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 194: Engine Maintenance Intervals
Verify all fittings and grease applicator nozzle are clean before applying grease. If any grease fittings are missing, replace them immediately. Recommended fluids Use specified lubricants. Refer to Engine Operation and Maintenance Manual, supplied with each machine, for details on lubricant specifications. ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-3...
Page 195: Maintenance Intervals
Rear wheels – 630 ft-lb +/- 50 ft-lb (854 Nm +/- 68 Nm)  Wheel bearings - grease  Belt lacing and pins - inspect  Overall machine - check  Backup alarm - check 60-4 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 196 Wheel bearings - check and repack if necessary  Pickup teeth - replace  Chains - inspect/remove/install  Lights - replace  Tailgate latches - adjust  Netwrap knife - adjust ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-5...
Page 197: Maintenance - 10 Hours
Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin must be removed immediately by a surgeon familiar with this type of injury. Inspect for leaks, wear, and damage. Repair components as needed. 60-6 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 198 Step 5: Follow Shutdown procedure, page 23-1. Suspension accumulator pressurizes when engine is started. Steps 1–5 must be repeated to release pressure if engine is started before work can be completed. ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-7...
Page 199: Misfed Netwrap - Check For And Remove
Insert a suitable knife between stripper bands to cut netwrap away from pickup reel. Step 6: If netwrap wraps around rollers or pickup reel again within 10 service hours or a day of operation, recalibrate bale size. 60-8 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 200: After Each Use
Ensure all fittings and nozzle of grease applicator are clean before applying grease. If any grease fittings are missing, replace them immediately. ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-9...
Page 201: Maintenance - Every 50 Hours
Step 2: Unlock and remove filters. Step 3: Vacuum clean or knock off dirt on surface of filter. Step 4: Replace any damaged filters. Step 5: Insert filters. Step 6: Close cover. 60-10 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 202: Tires And Rims - Check
Check lug nuts; torque to (check after first 10 hours of operation, then at 50-hour intervals): Front wheels – 135 ft-lb (183 Nm) Rear wheels – 630 ft-lb +/- 50 ft-lb (854 Nm +/- 68 Nm) ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-11...
Page 203: Grease Points
........one fitting each wheel 60-12 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 204: Belt Lacing And Pins - Inspect
Move tailgate lock valve to LOCKED position before working under tailgate. WARNING: Falling from baler can result in serious injury. Riders are not allowed on the baler. Do not climb. If access is needed, use suitable height stepladder. ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-13...
Page 205 Pins (2) and (4) are new. Pin (3) is severely worn. When pins develop this “segmented” appearance, they should be replaced immediately. 60-14 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 206: Maintenance - Every 100 Hours
Slip-resistant material - Check for worn or missing slip-resistant strips. Replace at once if damaged. Refer to parts manual replacement parts. Levers, switches, buttons - check Check levers, lever switches and buttons, and console switches and buttons for freedom of movement. Refer to “Machine controls,” page 20-1. ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-15...
Page 207: Backup Alarm - Check
Step 3: Attempt to start engine. Machine must not start if ground drive control is out of neutral. Contact your Vermeer dealer if machine does start when ground drive control is out of neutral. Operator presence system - check Operator presence system must work for safety.
Page 208: Hydraulic System - Check
When a hose with a protective sleeve is replaced, always install a new protective sleeve over the new hose. • Check hydraulic cylinders for leaks and damage. Repair or replace as required. • Check density system for correct pressure. ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-17...
Page 209: Maintenance - 250 Hours
Remove seal (2) and inspect for damage. Replace if damaged. Step 11: Remove inner bearing (3). Step 12: Wash bearings (3) and (8), bearing races (5) and (7), and inside of hub (6) with solvent and wipe clean. 60-18 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 210 Mount tire and rim assembly; Torque lug nuts (10) to 135 ft-lb (183 Nm). Re-torque after 10 and 50 hours of operation. Step 25: Remove blocks and lower jack. Repeat procedure for the other wheel. Grease ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-19...
Page 211: Maintenance - As Required
Reinstall stripper band (1) using top bolts (4). Leave bolts (4) loose. Step 6: Install bottom bolts (4) and torque to 19 ft-lb (26 Nm), then torque top bolts (4) to 19 ft-lb (26 Nm). 60-20 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 212: Chains - Inspect/Remove/Install
Install chain onto sprockets in the same orientation from which it was removed. Step 3: Pull ends of chain together and install new master link (2), retainer (3), and secure with cotter pins (4). ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-21...
Page 213 Loosen chain, remove two cotter pins (4), coverside (3), two O-rings (6), and master link (2). Do not reuse connecting link components when installing chain. Step 2: Remove chain from baler and lay the chain on a flat surface. 60-22 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 214 Follow instructions in connecting link kit to install connecting link pin (2), O-rings (6), coverside (3), and cotter pins (4). Step 4: After chain is installed follow chain adjustment procedures for each separate chain. Refer to the following page. ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-23...
Page 215: Tailgate Latches - Adjust
Step 6: Repeat Steps 1–2. Step 7: On both sides of baler, move latch plate (1) rearward 1/16–1/8" (1.5–3 mm) and tighten bolts (2) to secure. 1/16–1/8" .400" (1.6–3 mm) (10.16 mm) 60-24 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 216: Netwrap Knife - Adjust
WARNING: Netwrap can move suddenly. Crushing injury possible. Keep hands away from moving parts. Shut off tractor. Read manual before servicing. WARNING: Sharp knife can cut. Keep hands away from knife. Wear heavy gloves when working around knife. ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-25...
Page 217 Netwrap Roll side of baler and remove pan (1). Belts Step 5: Remove bolts (4) from each side of baler to remove netwrap knife assembly (3). Feed Pan Shear Bar Netwrap Knife 60-26 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 218 Secure knife (6) to knife mount (9) using three 5/16 x 1" carriage bolts (8) and lock nuts (one bolt in middle and one bolt at each end of knife mount). Front ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-27...
Page 219 (6) from one end to the other. Install and tighten all bolts (8) at locations (A). FRONT Step 12: Follow Steps 4–5 in reverse order to reinstall netwrap knife assembly in baler. Step 13: Close tailgate and move netwrap mechanism back to home/cut position. 60-28 Maintenance ZR51200 self-propelled baler operator’s and maintenance manua...
Page 220: Tailgate Camera - Clean
Tailgate camera - clean Use an appropriate ladder to access tailgate camera (1) attached on top of right rear light mount. Clean lens cover of dirt and debris. ZR51200 self-propelled baler operator’s and maintenance manua Maintenance 60-29...
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Page 222: Specifications
Hydraulic fluid Vermeer HyPower Hydraulic Fluid Tank: 25 gal (94.6 L) ISO 68 Oil (Vermeer HyPower 68): -4–104°F (-20–40°C) ISO 68 oils are recommended and (Below +23°F or -5°C refer to “Cold weather starting,” page 22-4) should be used for most applications.
Page 223: Machine Specifications
NOTICE: Engine operating angles do not indicate safe machine operating angles. Group size: 8D (8D-MHD) 12-volt negative ground (12-volt system) Battery (1) 1400 cold cranking amps, 30 seconds, 0°F (-18°C) Reserve capacity: 450 min @ 25 amp output at 80°F (27°C) 65-2 Specifications ZR51200 self-propelled baler operator’s and maintenance manua...
Page 224 Front: 21.5L-16 FRM HWY Service – 20 psi (140 kPa) Tire pressure Rear: 480/80R38 (18.4R38) – 29 psi (200 kPa) Front: 135 ft-lb (183 Nm) Lug nut torque (tires) Rear: 630 ft-lb +/- 50 ft-lb (854 Nm +/- 68 Nm) ZR51200 self-propelled baler operator’s and maintenance manua Specifications 65-3...
Page 225 NOTICE: Air conditioner service must be performed by a certified technician. • Follow OEM instructions when replacing a compressor. • Other system components may require replacement at the same time a compressor is replaced or the compressor warranty may be voided. 65-4 Specifications ZR51200 self-propelled baler operator’s and maintenance manua...
Page 226 Baling speed, 50-14 Display unit, viii Baling, 50-17 DPF alert indicators, 50-9 Battery burns - avoid, 22-5 Driving the machine, 30-3 Battery disconnect procedure, 60-2 Battery explosion - avoid, 22-5 Before each use, 60-6 Ejecting the Bale, 50-21 ZR51200 Self-Propelled Baler Index...
Page 227 Maintenance - every 100 hours, 60-15 Greasing the machine, 60-3 Maintenance - every 50 hours, 60-10 Ground drive controls, 20-3 Maintenance Intervals, 60-4 Manual control softkeys - netwrap, 40-13 Hydraulic fluid fill, 20-22 Manual lube - setup procedure, 44-3 Index ZR51200 Self-Propelled Baler...
Page 228 Preparing for Operation, 50-7 Netwrap components - operating positions, 40-5 Prestarting inspection, 25-4 Netwrap components, 40-3 Programming and Configuration Functions, 21-13 Netwrap feed sensing, 40-30 Netwrap knife - adjust, 60-25 Netwrap misfeed - check for and remove, 40-22 ZR51200 Self-Propelled Baler Index...
Page 229 Unloading and Loading Bale Chamber, 50-26 Receiving, i Unloading, 30-7 Recommended fluids, 60-3 Unplugging the Baler, 50-23 Review of operation, v VERMEER NEW AGRICULTURAL EQUIPMENT LIMITED Safe operating practices, 50-2 WARRANTY, 1-4 Safety signs, 60-1 Vermeer TempSense operation, 21-16 Safety symbol explanation, 10-1...
Page 230: Revision History
Updated warranty information and added maximum speed limiter o-m1_03 01/21 Introduction, Section 20, 30 rotary switch information. o-m1_04 10/21 Section 50 Added bale chamber removal. o-m1_05 12/21 Section 2, 25, 60, 65 Updated rear wheel lug torque specification. ZR51200 self-propelled baler operator’s and maintenance manual Revision history...
Page 231: Proposition 65 Warning
State of California to cause cancer, State of California to cause cancer birth defects, and other reproductive harm. and reproductive harm. Wash hands after handling. Copyright 2021. All rights reserved. Vermeer Corporation 1210 Vermeer Road East, P.O. Box 200 Pella, Iowa 50219-0200...