2 - SAFETY INFORMATION

Service steps
NOTICE: The machine has no service steps, there will
normally be no need to step onto the machine.
Should any situation require to get up to upper machine
components, use safe and stable steps or a ladder struc-
ture.

Tailgate [26071003]
Tailgate lock
DANGER
Crush hazard! The tailgate may close faster
than you can move away.
ALWAYS make sure the tailgate lockout valves
are in the OFF (locked) position before work-
ing under a raised tailgate. In the event of a
sudden loss of hydraulic pressure, the tailgate
will fall if the lockout valves are not engaged.
Stand clear of the tailgate before disengaging
the lockout valves.
Failure to comply will result in death or serious
injury.
D0002A

Engage the tailgate lock before working under or around

the tailgate in the raised position. Stand clear before un-
locking the tailgate lock.
1: Lever vertical: tailgate is unlocked.
2: Lever horizontal: tailgate is locked.

ZIL10FCRB638AAA 1

2 - 18
 3 - CONTROLS/INSTRUMENTS

3 - CONTROLS/INSTRUMENTS
Monitor Operation

Baler Operator Controls [25783688]

BSE2656A 1

Operator panel description

The Bale Command Plus™ monitor system on this machine operates as standard in the net‐plastic wrap mode. Twine
wrap is available as an accessory. If twine wrap is being installed, then activate the twine wrap mode as described in
the paragraph activating the optional twine wrap function.

General information operator that the key depression was recognized by the
operator panel.
Figure 1, shows the front view of the operator panel. The system has a permanent memory and retains all pro-
The panel display (1) contains various symbols and num- grammed wrap patterns and baling parameters, until pur-
bers that appear during operation. When the panel is posely changed by the operator.
turned off, the display is blank When switched off and back on again, the system will
Touch‐sensitive keys (3) are located on the lower and recall exactly the same programmes and parameters, as
right side of the panel. Each is marked with a symbol well as return into the same mode of operation as it was
indicating its function. in when last turned off.
Any time a key is depressed, the audible and visual
alarms (2) and (4) will pulse for 1/20 second to alert the

3-1
 3 - CONTROLS/INSTRUMENTS

Following is a description of the function of all the ele- Plus key, to increase several preset
ments on the operator panel. values, such as bale density, number
of end wraps, etc.

Power ON/OFF switch. EXTEND key, to extend the wrap

actuator.

BALES key, to display the daily and MINUS key, to decrease several
total bale count. preset values, such as bale density,
number of end wraps, etc.
CLEAR key, to stop the alarm (audible
RETRACT key, to retract the wrap
and visual).
actuator.
AUTO/MAN key, to select either
automatic or manual mode of BALE DENSITY key, to preset the
operation. desired bale density.
NET/PLASTIC/TWINE/WRAP key, to
select either net/plastic or twine wrap
Cutter ON/OFF switch.
mode of operation. (This only if the
optional TWINE wrap mode has been
activated). WRAPS key, to preset the wrap
parameters.
Cutter RETRACT key, to retract the
Cutter actuator.
Cutter EXTEND key, to extend the
WRAP key, to initiate a wrap cycle Cutter actuator.
whenever the operator desires, or
to restart a wrap cycle if, for any OPEN BOOK symbol key, to place
reason, the automatic cycle was not the controller in the "SETUP AND
completed. DIAGNOSTIC" mode.

3-2
 3 - CONTROLS/INSTRUMENTS

Liquid crystal display

The centre digits (1) in the display form the desired infor-
mation.

The two segmented vertical bargraphs (2) on the

right‐hand side of the display form the bale shape indica-
tor.

This indicator is provided to assist the operator to fill the

bale evenly.

The pointers (3) in the display indicate the status and po-
sition of various components of the baler and wrapper.
ZIL10FCRB184AAA 2
These pointers can be either continuously illuminated or
flashing intermittently. The information they provide is
very important for understanding the position and status
of the different components during the baling, wrapping
and unloading process. At the same time, they indicate
the problem area in case of a machine malfunction.

Pointer symbols
A solid "auto" pointer indicates A solid "tailgate" pointer indicates
the controller is in the automatic the tailgate is closed and latched.
mode.
A solid "twine wrap" pointer A solid "actuator" pointer
indicates the operator has indicates the wrapper actuator is
selected the twine wrap mode. in the home position.
(Accessory) A solid "cutter" pointer indicates
A solid "man" pointer indicates the Cutter is turned ON, and
the controller is in the manual the Cutter actuator is in the cut
mode. position.
The "full bale" pointer indicates A flashing "cutter" pointer
when the bale has reached the indicates the Cutter is turned ON,
preset density. but the actuator is not in the cut
A solid "net‐plastic wrap" pointer position. The actuator is then in
indicates the operator has the full extend position, home
selected the net wrap mode. position or any other position.
Standard on this machine. When the Cutter is turned OFF,
The "wrap bale" pointer indicates the "cutter" pointer is also turned
a wrap cycle is taking place. off.

The "eject bale" pointer indicates

the baling and wrapping process
has been completed and the bale
should be ejected.

NOTE: The wrap bale indicator applies to NET, PLASTIC WRAP, mode of operation only.
In general, a solid pointer (or a momentarily flashing pointer) indicates a normal operation or status of the function
selected.
Continuously flashing pointers usually indicate a machine fault condition or an operational fault condition (example in
event of error messages), or indicate that the controller is set for "SETUP AND DIAGNOSTIC" mode. The flashing
pointer points at the machine component or function concerned.

3-3
 3 - CONTROLS/INSTRUMENTS

European/American display environment

The Bale Command Plus™ monitor system provides two slightly different display modes, called the European and
American display environment. The difference just applies to the way of displaying some messages, and does not
influence the operational and/or diagnostic functions of the Bale Command Plus™ monitor system. To select either
European or American display environment.

Below and further in this manual are some examples of differences in message display, depending on the selection
made by the operator.
Error message
1. European Display
2. North American Display

ZIL10FCRB203AAA 3

Bale shape alarm ON/OFF selection (in the SETUP AND

DIAGNOSTIC mode)
1. European Display
2. North American Display

ZIL10FCRB213AAA 4

1. European Display
2. North American Display

ZIL10FCRB168AAA 5

3-4
 3 - CONTROLS/INSTRUMENTS

Key and system operation

ON/OFF Key
As a result of pressing the ON/OFF key for 2 s, all pointers
and digits will light up for 2 s.

The audible and visual alarm will sound and light up re-
spectively for 2 s. This allows the operator to see that the
operator panel is in full operating condition (panel check).

Following the operator panel check, the baler model will

appear on the display.

After model number, the display will show the actual bale
density, which is 0 (zero) for an empty bale chamber.
ZIL10FCRB044AAA 6

The "tailgate", "auto" OR "man", "actuator" and "twine

wrap" OR "net‐plastic wrap" pointer will be on solid, in-
dicating:

• The tailgate is closed and latched.

• The controller is set for automatic operation or man-
ual operation.
• The wrapper actuator is in the home position.
• The system is either in the net‐plastic wrap mode or
in the twine wrap (accessory) mode.

At this time the left and right bottom segments of the bale
shape indicator will be flashing. ZIL10FCRB003AAA 7

This is the "ready to bale" status, meaning the system is

ready to start a bale. If this status does not appear after
pressing the ON/OFF key, the machine is not in the "ready
to bale" state. Check the home position of the various
components.
Example: The tailgate is closed but not latched. This will
cause the alarm to sound and the "tailgate" pointer will be
flashing. For further details, refer to Fault Finding Section.

ZIL10FCRB004AAA 8

3-5
 3 - CONTROLS/INSTRUMENTS

AUTO/MAN key
Each time this key is pressed, the display will toggle be-
tween the automatic or the manual operating mode, illu-
minating either the "auto" pointer or the "man" pointer.

In the AUTOMATIC mode, the wrap cycle will be auto-

matically initiated and completed following a full bale sig-
nal. If equipped with the Cutter option, the cutter cycle will
be automatically initiated and completed during the bale
forming process.

ZIL10FCRB172AAA 9

In the MANUAL mode, the operator must control the ex-

tend and retract keys of the wrapper actuator and the Cut-
ter actuator.

Pressing the AUTO/MAN key during an automatic wrap

and/or cutter cycle will stop this cycle. In case of a wrap
cycle, an error message will appear on the display, the
alarm will sound and the "wrap bale" pointer and the "ac-
tuator" pointer, or the "cutter" pointer will be flashing.

For further action, refer to Fault Finding Section.

ZIL10FCRB005AAA 10

NET PLASTIC/TWINE WRAP key (net‐‐plastic

wrap standard)
Each time this key is pressed, the display will toggle
between the NET WRAP mode of operation and the
TWINE WRAP mode of operation, illuminating either the
"net wrap" pointer or the "twine wrap" pointer (if twine
wrap is installed, accessory).

ZIL10FCRB233AAA 11

3-6
 3 - CONTROLS/INSTRUMENTS

BALES key
Pressing the BALES key once will display the daily bale
count for 2 s. Pressing and holding the key will display
the daily bale count as long as the key is pressed.

ZIL10FCRB179AAA 12

Pressing the BALES key twice (within 2 s) will display the

total bale count for 2 s. Pressing and holding the key the
second time will display the total bale count as long as the
key is held pressed

ZIL10FCRB178AAA 13

To clear the daily bale count, press and hold the BALES
key, then press the CLEAR key. The total bale count can
not be reset to zero by the operator.

ZIL10FCRB180AAA 14

CLEAR key
Pressing this key clears error messages and the audible
alarm after a fault condition.

Used in conjunction with the BALES key, the daily bale

count will be cleared.

ZIL10FCRB196AAA 15

3-7
 3 - CONTROLS/INSTRUMENTS

WRAP key
Pressing and holding the WRAP key for 2 s will initiate a
wrap cycle whenever the operator desires so. When the
cycle starts, the alarm will sound for 3 s.

The key is also used to restart an interrupted wrap cycle.

NOTE: The controller must be in the AUTOMATIC mode
of operation. If not, the alarm will sound but the cycle will
not start.
For successful net wrapping, the actual bale density
should be at least 6-8, for the net to be picked up. For
twine wrapping, an actual bale density of at least 8-10 is
needed.
NOTICE: Only twine wrapping if installed (accessory) If ZIL10FCRB238AAA 16
this key is pressed during a twine wrapping cycle, the cy-
cle restarts again after retracting all wrapper components
first.

EXTEND key
This key applies both to twine and net wrap actuators. The
Cutter actuator has a separate key.

In NET WRAP mode, the duckbill moves towards the bale

to feed the net or twine (accessory).

In TWINE WRAP mode, if installed the twine arms drop

down and pull the twine tails out of the twine stop and
clamp devices.

Pressing the EXTEND key will extend the selected actu-

ator, both in AUTOMATIC and in MANUAL mode of oper-
ation.
ZIL10FCRB204AAA 17
The EXTEND key is disabled during an automatic Cutter
cycle. This means that the twine or net actuator cannot
be extended while the Cutter actuator is moving.

Pressing the EXTEND key during an automatic wrap cycle

will stop this cycle. An error message will appear on the
display, the alarm will sound and the "wrap bale" pointer
will be flashing.

ZIL10FCRB205AAA 18

3-8
 3 - CONTROLS/INSTRUMENTS

The EXTEND key is connected to possible actuator fault

condition messages:

Er 1: Actuator stalled condition

An Er 1 error code will appear on the display when the ac-
tuator stalls for 5 s and the alarm will sound. The actuator
will be locked out for 10 s to prevent overheating of the
system components.

ZIL10FCRB206AAA 19

RETRACT key
This key applies both to twine (if installed) and net‐plastic
wrap actuators. The Cutter actuator has a separate key.

In TWINE WRAP mode of operation, the twine arms move

to the home position (if twine wrap is installed) accessory.

In NET WRAP mode of operation the duckbill moves to

the home position.

Pressing the RETRACT key will retract the selected actu-

ator, both in AUTOMATIC and MANUAL mode of opera-
tion.

When the RETRACT key is pressed during an automatic

ZIL10FCRB227AAA 20
wrap cycle, this cycle will be interrupted. An error mes-
sage will appear on the display, the alarm will sound and
the "wrap bale" pointer will be flashing.

For further action, refer to Fault Finding Section.

The RETRACT key is connected to possible actuator fault
condition messages:

Er 1: Actuator stalled condition

An Er 1 error code will appear on the display when the
actuator stalls for 5 s, and the alarm will sound. The ac-
tuator will be locked out for 10 s to prevent overheating of
the system components.

For further action following these error messages, refer to

Fault Finding section.

ZIL10FCRB228AAA 21

3-9
 3 - CONTROLS/INSTRUMENTS

BALE DENSITY key

Pressing this key will display the preset full bale density
(e.g. 40 %) for 2 s or as long as the key is held pressed.

ZIL10FCRB173AAA 22

To increase the desired bale density, press and hold the

BALE DENSITY key. Then press the "+" key.

ZIL10FCRB174AAA 23

To decrease the desired bale density, press and hold the

BALE DENSITY key. Then press the "-" key.

The operator can change the full bale density in 10 %

steps, from 10 % (minimum) to 100 % (maximum) density.

ZIL10FCRB175AAA 24

WRAPS key
Relates to both TWINE if installed and NET‐PLASTIC
WRAP operations.

ZIL10FCRB245AAA 25

3 - 10
 3 - CONTROLS/INSTRUMENTS

For selected NET WRAP operation (standard):

The WRAPS key displays the preset number of wraps for

2 s, or as long as the key is held pressed.

Example:

2.25 indicates two and a quarter wraps will be put around

the bale; this is the recommended number of wraps for
average conditions.

The number of wraps can be adjusted from 1.5 to 6.0 in

quarter (0.25) wrap steps.
ZIL10FCRB246AAA 26

To increase the number of wraps, press and hold the

WRAPS key, then press the "+" key.

ZIL10FCRB241AAA 27

To decrease the number of wraps, press and hold the

WRAPS key, then press the "-" key.

ZIL10FCRB240AAA 28

For selected TWINE WRAP operation, the WRAPS key

has 2 functions (if twine wrap is installed accessory):

1. Twine wrap pattern selection.

2. Selection of the number of end wraps for each pat-
tern.
3. Twine wrap pattern selection. There are 3 fac-
tory‐pre-programmed twine wrap patterns:

• 14 wraps (7 for each twine arm)

• 18 wraps (9 for each twine arm)
• 22 wraps (11 for each twine arm)
ZIL10FCRB234AAA 29

each including 2 starting wraps and standard 2 ending

wraps (for each twine arm).

3 - 11
 3 - CONTROLS/INSTRUMENTS

There is another pattern "PAT 4" available for the operator

to programme himself his own "operator twine wrap pat-
tern".

Pressing the WRAPS key once will display the selected

twine wrap pattern for 2 s or as long as the key is held
pressed, showing the number of pre-programmed wraps
as well as the number of end wraps.

ZIL10FCRB216AAA 30

Example:
14‐2 indicates that pattern 1 is selected with 2 end wraps.

To select the next twine wrap pattern, press and hold the
WRAPS key, then press the "+" key.

ZIL10FCRB241AAA 31

To select the previous twine wrap pattern, press and hold

the WRAPS key, then press the "-" key.

ZIL10FCRB240AAA 32

2. Selection of the number of end wraps

Pressing the WRAPS key twice within 2 s will display the

selected number of end wraps (2 to 4) for 2 s or as long
as the key is held pressed (for the second time).

ZIL10FCRB244AAA 33

3 - 12
 3 - CONTROLS/INSTRUMENTS

To increase the number of end wraps, press the WRAPS

key twice and hold the key the second time, then press
the "+" key.

ZIL10FCRB243AAA 34

To decrease the number of end wraps, press the WRAPS

key twice and hold the key the second time, then press
the "-" key.
NOTE: Each time another twine wrap pattern is selected,
the number of end wraps will be reset to 2. The number
of wraps placed on the bale is based on a tractor PTO.
speed of 540 revs/min. If the PTO. speed is reduced dur-
ing wrapping, the number of wraps will also be reduced.
"PAT 4" or operator programmed twine wrap pattern:
When "PAT 4" is selected for use, but has never been
programmed before, or a programme has been cleared,
automatically the 22 wraps twine pattern will be applied.
To programme or clear "PAT 4", refer to the OPEN BOOK
ZIL10FCRB242AAA 35
key and chapter "Programming an operator twine wrap
pattern". Once programmed, "PAT 4" will automatically
wrap the bale as was programmed by the operator.

PLUS key
Is used in conjunction with the BALE DENSITY, WRAPS
or BUGLE keys to increase the preset values in memory.
The key also allows to alter the settings in the SETUP
AND DIAGNOSTIC mode.

ZIL10FCRB221AAA 36

3 - 13
 3 - CONTROLS/INSTRUMENTS

MINUS key
Is used in conjunction with the BALE DENSITY, WRAPS
or BUGLE keys to decrease the preset values in memory.
The key also allows to alter the settings in the SETUP
AND DIAGNOSTIC mode.

ZIL10FCRB212AAA 37

OPEN BOOK key

Gives access to the SETUP AND DIAGNOSTIC mode.

To enter, press and hold for 2 s.

This mode allows:

• Programming operational parameters and functions

(e.g. programming "PAT 4").
• Calibrating variable position sensors (potentiome-
ters and switches).
• Diagnosing problems (troubleshooting).

ZIL10FCRB214AAA 38

This mode contains 20 pages, each one covering the pro-

cedures of programming, calibrating and troubleshooting
a specific function and/or component of the monitor sys-
tem.

Example:
"2‐0" The flashing "2" refers to page 2, the figure (a zero or
any other figure) is the number that determines how thick
a layer of uncut crop will be placed around the bale core.
The higher the number the thicker the uncut layer.

The flashing cutter pointer indicates that the cutter is

turned on but the actuator is not in the cut position. ZIL10FCRB006AAA 39

For further details, refer to chapter cutter operation.

Successively pressing the key passes through all the

pages 1 to 21:

3 - 14
 3 - CONTROLS/INSTRUMENTS

Page and function

1. Programming "PAT 4" see Section Working Opera-
tion if twine wrap is installed (accessory).
2. Cutter machines: Uncut outer layer size (described
in this section)

ZIL10FCRB007AAA 40

Other machines: Buffer zone

3. Buffer zone
4. Bale shape alarm ON/OFF selection (described fur-
ther in this section)
5. Windrow weave frequency selection (described fur-
ther in this section)
6. European/American display environment selection
(described further in this section)
7. Model number selection (described further in this
section)
8. Buffer zone
9. Buffer zone
10. Left density sensor adjustment, calibration and trou-
ble shooting (contact your dealer)
11. Right density sensor adjustment, calibration and
troubleshooting (contact your dealer)
12. Net actuator sensor adjustment, calibration and trou-
bleshooting (contact your dealer)
13. Twine actuator sensor adjustment, calibration and
troubleshooting (contact your dealer)
14. Cutter machines: cutter actuator sensor adjustment,
calibration and troubleshooting (contact your dealer)

OR Other machines: Buffer zone

15. Cutter machines: cutter knife proximity sensor
switch adjustment and troubleshooting. Or Knife
Indicator ON/OFF selection. Or buffer zone if Knife
Indicator is turned off.
NOTE: Refer to Section Lubrication and Mainte-
nance for sensor adjustment.

3 - 15
 3 - CONTROLS/INSTRUMENTS

Other machines: Buffer zone

16. Tailgate switch adjustment and troubleshooting
(contact your dealer)
17. Net-plastic counter roll sensor adjustment and trou-
bleshooting (contact your dealer)
18. Bale shape sensitivity (contact your dealer)
19. Item number (19) not displayed: Software revision
number display (contact your dealer)
20. Item number (20) not displayed: Operator panel dis-
play and key test (contact your dealer)
21. Item number (21) not displayed: Supply voltage
check (contact your dealer)
To exit the SETUP AND DIAGNOSTIC mode, press and
hold the key for 2 s. The controller will automatically return
to the field operation mode.
NOTE: Pages 1> 7 and 15 apply to normal operation set-
tings and are described in this manual. Pages 10>14, 16>
21 apply to diagnostic and repair functions and are not
involved in normal operation. For more details on these
pages, contact your dealer.

ZIL10FCRB008AAA 41

Acoustic alarm
To adjust the volume of the acoustic signal, just turn the
knob (1).
WARNING
Entanglement hazard!
Disengage the Power Take-Off (PTO), turn off
the engine, and remove the key. Wait for all
movement to stop before leaving the operator's
position. Never adjust, lubricate, clean, or un-
plug machine with the engine running.
Failure to comply could result in death or seri-
ous injury.
W0227A

ZIL10FCRB181AAA 42
ATTENTION: When controlling the crop cutter with the
monitor, make sure nobody is working in the pickup area,
as several automatic cutter functions will make the cutter
actuator move

3 - 16
 3 - CONTROLS/INSTRUMENTS

CropCutter™ Cutter key and system opera-

tion
The cutter ON/OFF, CUTTER EXTEND and CUTTER RE-
TRACT keys will only respond if the baler is equipped with
the crop cutter system.

ZIL10FCRB009AAA 43

CropCutter™ Cutter ON/OFF key

Pressing this key turns the power to the cutter system ON
or OFF.

ZIL10FCRB010AAA 44

Turning the cutter system ON

If the controller is in automatic mode when the cutter sys-
tem is turned on, the cutter actuator will automatically ex-
tend to the full extend position and then retract to the cut
position, while the "cutter" pointer is flashing.

ZIL10FCRB009AAA 45

3 - 17
 3 - CONTROLS/INSTRUMENTS

Upon reaching the cut position, the cutter actuator will

stop and the "cutter" pointer will turn on solid. The cut-
ter knives are now cutting the incoming crop.
NOTE: The cutter cannot be turned off during the auto-
matic extend/retract cycle of the cutter actuator. However,
the automatic extend/retract cycle can be interrupted at
any time by pressing the AUTO/MAN key to switch from
automatic to manual mode.

If the controller is in manual mode when the cutter system

is turned on, the cutter actuator will remain in the same
position it was before.
ZIL10FCRB011AAA 46

Turning the cutter system OFF

If the controller is in automatic mode, turning the cutter
system off will retract the cutter actuator to the home po-
sition while the "cutter" pointer is flashing. Upon reaching
the home position, the actuator will stop retracting and the
"cutter" pointer will turn off.
NOTE: The cutter cannot be turned on again while the ac-
tuator is retracting to the home position. However, the ac-
tuator can be stopped at any time by pressing the AUTO/
MAN key to switch from automatic to manual mode.

ZIL10FCRB012AAA 47

If the controller is in manual mode of operation and the

cutter actuator is not in the home position, turning the cut-
ter system off will cause the alarm to sound. An error
message will be displayed and the cutter pointer will be
flashing.

To correct this situation, proceed as follows:

ZIL10FCRB013AAA 48

Press the CLEAR key to clear the alarm and the "cutter"
pointer will be turned off.
NOTICE: The cutter system is now turned off, but the
knives are not in the home position. Therefore, remem-
ber to correct this situation proceeding with the following
steps:

ZIL10FCRB014AAA 49

3 - 18
 3 - CONTROLS/INSTRUMENTS

Press the cutter ON/OFF key to turn the cutter power back
on.

ZIL10FCRB010AAA 50

Press and hold the CUTTER RETRACT key to retract the

cutter actuator manually to the home position.

ZIL10FCRB015AAA 51

Press the cutter ON/OFF key to turn the cutter power back
off.

ZIL10FCRB010AAA 52

CUTTER EXTENDED key

Pressing this key in manual mode will cause the cutter ac-
tuator to extend, moving the knives in to cut the incoming
crop.

The CUTTER EXTEND key is only active in manual mode,

and is inactive in automatic mode. The key is also inactive
when the cutter system is turned off.

ZIL10FCRB016AAA 53

3 - 19
 3 - CONTROLS/INSTRUMENTS

If the CUTTER EXTEND key is held pressed and the cut-

ter actuator stalls for more than 5 s, the controller will au-
tomatically turn the cutter actuator off for 10 s. The alarm
will sound, the "cutter" pointer will be flashing and the dis-
play will show an "Er 3" error message as long as the cut-
ter actuator is locked out.

For further action following this error situation, refer to

Fault Finding section.

ZIL10FCRB017AAA 54

CUTTER RETRACT key

Pressing this key in manual mode will cause the cutter ac-
tuator to retract, moving the knives to their home position.

The CUTTER RETRACT key is only active in manual

mode, and is inactive in automatic mode. The key is also
inactive when the cutter system is turned off.

ZIL10FCRB018AAA 55

If the CUTTER RETRACT key is held pressed and the

cutter actuator stalls for more than 5 s, the controller will
automatically turn the cutter actuator off for 10 s. The
alarm will sound, the "cutter" pointer will be flashing and
the display will show an "Er 3" error message as long as
the cutter actuator is locked out.

For further action following this error situation, refer to

Fault Finding section.

ZIL10FCRB019AAA 56

Knife out off cut position indicator item 15

NOTE: The knife out of cut position indicator will only func-
tion if the cutter actuator is in the cut position and the knife
indicator is turned on.

Press and hold the cutter ON/OFF" key for 2 s to select

the Knife Indicator ON or OFF. The alarm will sound for
one second when a selection is changed.

Buffer zone, if Knife Indicator is turned off. The display

should show "15" flashing at the left of the display and
three dashes on the right side of the display.

OR
ZIL10FCRB020AAA 57

3 - 20
 3 - CONTROLS/INSTRUMENTS

If the Knife Indicator is turned on the display should show

"15" flashing at the left of the display and a "Lo" or "Hi" on
the right side of the display (a "Lo" indicates the sensor is
closed and a "Hi" indicates the sensor is opened).

The "Cutter" pointer should be on solid with the display

showing a "Lo" and flashing with the display showing a
"Hi".

ZIL10FCRB021AAA 58

In normal cutter cutting operation, the cutter actuator is in

the cut (middle) position and knives are in the cut position
(a proximity sensor switch is sensing the knife control arm
cut position). The "Cutter" pointer on the display will be on
solid confirming that the cutter actuator and the knives are
in the cut position.

ZIL10FCRB022AAA 59

With the cutter actuator in the cut position and there is

a crop overload on the knives causing the knives and
the knife control arm to move out of its normal cut po-
sition. The "Cutter" pointer on the display will start flash-
ing as soon as the controller detects the knife control arm
(knives) is out of the cut position.

ZIL10FCRB023AAA 60

3 - 21
 3 - CONTROLS/INSTRUMENTS

If the knife control arm remains out of the cut position for
more than 5 s, an audible alarm will sound and an error
message will appear on the display. The "Cutter" pointer
on the display will also be flashing. Press "Clear" key to
clear the alarm and error message. The alarm and error
message will reset if the knife control arm returns to the
cut position.

If the knife control arm does not return to the cut position,
after clearing the first alarm and error message and 10 s
later there is one more audible alarm and error message
warning reminder to warn the operator that the knives are
still out of the cut position.
ZIL10FCRB024AAA 61
Again, the operator must press "Clear" key to clear the
alarm and error message.
NOTE: No more warnings will appear after this, unless
the knife control arm returns to the cut position to reset
the knife out of cut position indicator. The cutter pointer
remains flashing for as long as the knife control arm is out
of the cut position.
If the knife out of cut position alarm and error message
has not been cleared, pressing the cutter ON/OFF" key
will clear the alarm and error message and, also move the
cutter actuator to home position and turn off the cutter.

Uncut outer layer size selection

On cutter machines, it is possible to select a certain den-
sity setting for the cutter knives to retract before starting
the wrap cycle. This leaves an uncut outer layer of crop
around the cut bale core for improved bale stability and
weathering resistance.

For example:
• Leave a maximum uncut outer layer on twine
wrapped straw bales to improve bale stability and
weathering characteristics.
• On net wrapped silage bales that will be plastic
wrapped afterwards, cut the bale to its outermost
ZIL10FCRB214AAA 62
layer for maximum density and easier feed out.

To select the thickness of the uncut outer layer, proceed

as follows:

Enter the SETUP AND DIAGNOSTIC mode.

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 3 - CONTROLS/INSTRUMENTS

Press the OPEN BOOK key once more to proceed to page

2. The display will show the uncut outer layer size and the
"cutter" pointer will be flashing. The uncut outer layer size
is defined as a percent of full bale density setting.

Example:
When the uncut outer layer size is set at 6, the Cutter
knives will be withdrawn when the bale density reaches
60 % below full bale density. For a selected full bale den-
sity of 40, the knives will thus be retracted when the bale
reaches a density of 16.

The cutter actuator will remain in the home position dur- ZIL10FCRB025AAA 63
ing the wrap cycle. When the tailgate switch is opened for
bale ejection, the cutter actuator will extend to the full ex-
tend position and retract to the cut position automatically.
NOTE: On machines not equipped with the cutter option,
page 2 of the SETUP AND DIAGNOSTIC mode is empty
and the display will show three dashes.

ZIL10FCRB026AAA 64

To select the uncut outer layer size, press the "+" or the
"-" key. Uncut outer layer sizes available are from 0 to 9
in steps of 1.

ZIL10FCRB027AAA 65

The higher the number 0 to 9, the more of uncut crop will

be placed around the cut bale core.

If 0 is selected, the cutter knives will remain in the cut

position all the time to cut the bale up to its outermost
layer.

For the same uncut outer layer size setting, the real uncut
layer thickness on the ejected bale will be highly depen-
dent on crop conditions, windrow feed rate and windrow
size. Approximately, the uncut layer size can be altered
from 0 cm (uncut layer size setting 0) to 20 - 25 cm (uncut
layer size setting 9).
ZIL10FCRB028AAA 66

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 3 - CONTROLS/INSTRUMENTS

Exit the SETUP AND DIAGNOSTIC mode.

ZIL10FCRB214AAA 67

Additional automatic functions and safety

interlocks
1. If the cutter actuator is left dwelling in the full extend
position for more than 10 s, the alarm will sound, the
"cutter" pointer will be flashing and an error message
will appear on the display to warn the operator that
the cutter actuator is out of position. For further ac-
tion following this error situation, refer to Fault Find-
ing section.
2. If, in automatic mode, the cutter actuator was moved
away from the cut position (during setup, fault condi-
tion, actuator drift, etc), opening and closing the tail-
gate will cause the cutter actuator to extend to the
full extend position and then retract to the cut posi-
tion.
ZIL10FCRB029AAA 68
3. The cutter actuator will stop moving if:

• It does not extend to the full extend position in 15 s,

or
• It does not retract to the cut position in 7 s, or
• It does not retract to the home position in 10 s.
In all cases, the alarm will sound, the "cutter" pointer will
be flashing and an error message will appear on the dis-
play.

For further action following this error situation, refer to

Fault Finding section.

ZIL10FCRB048AAA 69

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 3 - CONTROLS/INSTRUMENTS

4. With the cutter power turned ON, pressing the

AUTO/MAN key to switch the controller from manual
to automatic mode will cause the cutter actuator to
extend to the full extend position and then retract to
the cut position.
5. If the tailgate is open and the cutter power is turned
on in automatic mode, the knives will not automat-
ically extend/retract to the "cut" position. To move
the cutter actuator with the tailgate open, switch to
MANUAL mode of operation and use the CUTTER
EXTEND and CUTTER RETRACT key.
NOTICE: If the tailgate is closed later on, the knives
will then insert automatically. ZIL10FCRB030AAA 70

6. If the tailgate is open and the cutter power is turned

off in automatic mode, the knives will not automat-
ically retract to the "home" position. Instead, the
alarm will sound and an error message will appear
on the display.
To correct this situation, proceed as follows:
Press the CLEAR key to clear the alarm and the "cutter"
pointer will be turned off.
NOTICE: The cutter system is now turned off, but the
knives are still not in the home position.

Therefore, remember to correct this situation proceeding

with the following steps:

ZIL10FCRB014AAA 71

Press the cutter ON/OFF key to turn the cutter power back
on.

ZIL10FCRB010AAA 72

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 3 - CONTROLS/INSTRUMENTS

Change to manual mode of operation.

ZIL10FCRB031AAA 73

Press and hold the CUTTER RETRACT key to retract the

cutter actuator manually to the home position.

ZIL10FCRB015AAA 74

Press the cutter ON/OFF key to turn the cutter power back
off.

ZIL10FCRB010AAA 75

Bale shape indicator operation

General information
The bale shape indicator on the right side of the display is
provided to assist the operator in filling the bale evenly.

It consists of two vertical bar graphs, each with nine seg-

ments. Each segment represents 10% of the selected full
bale density value. When starting to make a bale, the left
and right bottom segment of the bar graph will be flash-
ing. Once the empty bale chamber is filled up, the bale
will start exerting force on the tailgate, which will slightly
open. This is measured by the left and right‐hand side
bale density sensors.
ZIL10FCRB032AAA 76

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 3 - CONTROLS/INSTRUMENTS

As a result of this, the first, second, third, etc, segment on

the display will illuminate successively, in function of the
sensor's span. The height of the bar graphs will further
depend on windrow and crop conditions, and the opera-
tor's technique of filling both ends evenly

When baling, the objective is to keep the two bar graphs

balanced for a uniform bale. If an uneven bale shape
occurs and the difference between left and right bar graph
reaches a preset number of segments, the alarm will
sound (2 beeps) and the lower bar graph will be flashing
to alert the operator to fill the low side of the bale. If
this situation remains for more than 10 s, the alarm will
sound continuously with short beeps until the uneven ZIL10FCRB033AAA 77
bale shape condition is corrected.

Depending on windrow and crop conditions, the operator

can alter settings:

• Bale shape alarm ON or OFF: in heavy, full pickup

width windrows the operator may prefer to turn the
alarm OFF.
• Bale shape weaving frequency: this is the difference
in number of segments between left and right bar
graph it will take the bale shape alarm to come on. In
other words, it will determine the frequency of weav-
ing to fill the bale evenly.
To change these settings, enter the SETUP AND
DIAGNOSTIC mode.

Bale shape alarm ON/OFF selection

Enter the SETUP AND DIAGNOSTIC mode.

ZIL10FCRB214AAA 78

Successively press this key until page 4 appears.

The display shows the status of the bale shape alarm:

• ON or OFF in the American display environment

• 1 (for ON) or 0 (for OFF) in the European display
environment

The bottom segments of the bar graph will be flashing.

ZIL10FCRB034AAA 79

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 3 - CONTROLS/INSTRUMENTS

To toggle between alarm ON or OFF, press the "+" key.

ZIL10FCRB221AAA 80

Exit the SETUP AND DIAGNOSTIC mode.

ZIL10FCRB007AAA 81

Setting the frequency of weaving

Enter the SETUP AND DIAGNOSTIC mode.

ZIL10FCRB214AAA 82

Successively press this key until page 5 appears.

The display shows the weave frequency value.

The weave frequency value is the difference in number of

segments between left and right bar graph at which the
bale shape alarm will sound (in normal operating mode).

ZIL10FCRB035AAA 83

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 3 - CONTROLS/INSTRUMENTS

Example:
When the weave frequency value is set at 30 (in the
SETUP AND DIAGNOSTIC mode), the three left and
right bar graph segments will be flashing. This means
that, after returning to the NORMAL OPERATION mode
and starting to bale, the bale shape alarm will sound each
time the difference in bar graph segments between left
and right reaches three segments. At this time, the lower
bar graph will be flashing until the uneven bale shape
condition is corrected by the operator.

The weave frequency values available are: 20, 30, 40, 50

and 60.

ZIL10FCRB036AAA 84

Recommended: 20 for small windrows

40 for large windrows
30 for average windrows

Picture shows display in normal operation

ZIL10FCRB037AAA 85

To select the desired weave frequency value, press the

"+" or the "-" key.

ZIL10FCRB027AAA 86

Exit the SETUP AND DIAGNOSTIC mode.

ZIL10FCRB214AAA 87

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 3 - CONTROLS/INSTRUMENTS

European/American display selection

Enter the SETUP AND DIAGNOSTIC mode.

ZIL10FCRB214AAA 88

Successively press the OPEN BOOK key until page 6 ap-

pears, showing the selected display environment ("Eur"
for European, "USA" for American display).

ZIL10FCRB038AAA 89

To select the desired display environment, press the "+"

or the "-" key.

ZIL10FCRB039AAA 90

Exit the SETUP AND DIAGNOSTIC mode.

ZIL10FCRB214AAA 91

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 3 - CONTROLS/INSTRUMENTS

Model number selection

Enter the SETUP AND DIAGNOSTIC mode.

ZIL10FCRB214AAA 92

Successively press the OPEN BOOK key until page 7 ap-

pears, showing the selected model number.

ZIL10FCRB040AAA 93

To select the corresponding model number, press the "+"

or the "-" key.

ZIL10FCRB041AAA 94

Exit the SETUP AND DIAGNOSTIC mode.

ZIL10FCRB214AAA 95

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 3 - CONTROLS/INSTRUMENTS

Activating the optional twine wrap function

if the twine wrap kit is installed (accessory)
Enter the SETUP AND DIAGNOSTIC mode

The display shows a flashing "1" and three dashes.

This indicates that the controller is in the "NET‐PLASTIC

ONLY" mode.

ZIL10FCRB042AAA 96

Press and hold the NET‐PLASTIC/TWINE key for 2 s.

The alarm will sound that the twine wrapper programme

has been activated.

The display shows a flashing "1" and a number on the

right side of the display.

The twine pointer should be on and the WRAP BALE

pointer should be flashing.

All desired twine wrap programmes can be set.

ZIL10FCRB043AAA 97

Exit the SETUP AND DIAGNOSTIC mode.

ZIL10FCRB214AAA 98

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 3 - CONTROLS/INSTRUMENTS

Monitor quick view

Press the open book key to cycle to a particular mode.

Mode Function configuration Information conditions - Change adjust with Save next step with
operators display
1 Select configuration A Net A Three dashes B
wrapping B (*) Twine/net Flashing 1 and wrap
wrapping bale pointer flashing
(*) Programming PAT 4 Custom twine wrapping
patterns
2 Uncut outer layer Flashing 2 with a number
between 0 (no uncut
layer) and 9 ( 20 - 25 cm)
uncut layer
3 Buffer zone Buffer zone
4 Bale shape alarm on/off Bottom bale shape bars
flashing and 1 (alarm on)
or 0 (alarm off)
5 Frequency of weaving Flashing 5 with a number
setting between 20 (alarm
sounds with difference
of 2 segments) and 60
(difference of 6 segments)
6 Standard / metric Flashing 8 and USA
configuration (standard) or EUR (metric)
7 Model number Flashing 9 and model
configuration number
8 Buffer zone Buffer zone
9 Buffer zone Buffer zone
10/11 10 Bale density sensor A. Close tailgate fully Rotate potentiometer
left hand side. (empty position). Flashing Switch
10 with a number between between 10 and 11
15 and 40.
11 Bale density sensor left Flashing 11 with a number Rotate potentiometer
hand side. between 15 and 40.
Open tailgate and place Hydraulic control from
two 40 mm spacers on the tractor
density feeler rods. Close Switch
the tailgate until against between 10 and 11
spacers (full position).
Flashing 11 with a number
between 150 and 249.
Flashing 10 with a number
between 150 and 249.

12 Net wrap actuator Actuator fully extended Rotate potentiometer

potentiometer adjustment (insert position), flashing
and calibration 12 with a number between
20 and 30.
Retract actuator so 2 mm
between knife and knife
guide (precut position).
Flashing 12 with a number
between 76 and 85.
Actuator fully retracted
(home position), flashing
12 with a number between
160 and 249.

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 3 - CONTROLS/INSTRUMENTS

Mode Function configuration Information conditions - Change adjust with Save next step with
operators display
13 A. Twine wrap actuator Actuator fully extended Rotate potentiometer
potentiometer adjustment (insert position), flashing
and calibration. 12 with a number between
B. Buffer zone in net only 20 and 30
configuration
Actuator fully retracted
(home position), flashing
13 with a number between
160 and 249.
14 Cutter actuator Actuator fully retracted Rotate potentiometer
adjustment and calibration (home position), flashing
14 with a number between
20 and 30.
Actuator fully extended,
flashing 14 with a number
between 160 and 249.
Retract actuator so 2 mm
gap between knife break Or place cutter
away link and knife control in the desired position
arm bolt (cut position),
flashing 14 with number
between 70 and 140.
15 Knife out indication sensor A. Flashing 15 with three
dashes (knife indication)
sensor off
B. Flashing 15 with lo
(metal in front of sensor),
or hi (metal away from
sensor) Gap 3 - 7 mm.
16 Tailgate switch adjustment Flashing 16 with Lo (both Manually close one
switches closed) or Hi switch, then close both
(one switch open) switches
17 Net counter roll sensor Flashing 17 with Lo Rotate counter wheel
testing (magnet in front of sensor) (magnet) in front and
or Hi (magnet away from away from the sensor
sensor), sensor gap 1.5 face.
mm
18 Bale shape sensitivity Flashing 18 with a number
between 2 (slow) and 50
(fast)
19 Software version level O is operator's panel. C
is electronic control unit,
versions are on right of
display
20 Operator panel display Automatically test the
and key test operator's panel display
segments, then five
dashes, press all keys
then pass displayed.

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 3 - CONTROLS/INSTRUMENTS

Mode Function configuration Information conditions - Change adjust with Save next step with
operators display
21 Battery voltage test Battery supply voltage to
the electronic control Unit
on display.
Enable twine wrapper
actuator, monitor voltage.
Enable net wrapper
actuator, monitor voltage.
Enable Cutter actuator,
monitor voltage.
Lowest voltage captured
during test.
Highest voltage captured
during test

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3 - CONTROLS/INSTRUMENTS

3 - 36