Mayer EM 6012 Operating Instructions Manual Download Page 7

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5. EU declaration of conformity

According to Appendix IIA of the EU Machinery Directive (2006/42/EC)

The manufacturer:

Mayer GmbH & Co. KG
Maschinenbau u. Verwaltung
Poststrasse 30
89522 Heidenheim | Germany

hereby attests that the machine described in
the following:

Make:

Mayer

Model:

Soil mixer

Series:

6012

Year constructed: From 2011

fulfils the safety and health requirements of the
following EU Machinery Directive:

2006/42/EC

Harmonised standards applied:

Part 1 EN ISO 12100-1

Part 2 EN ISO 12100-2

EN ISO 13857

ISO 13854

EN ISO 13849-1

EN ISO 14121

ISO 14119

ISO 13850

IEC 60204-1

Safety of machinery, basic terminology, general guiding
principles for organisation

Part 1: Basic terminology, methodology

Part 2: Guiding technical principles and specifications

Safety distances to keep the upper limbs from reaching
danger points

Safety of machines, minimum distances to avoid any
crushing of body parts

Safety-related parts of control systems
Part 1: General principles for design

Principles for risk assessment

Interlocking devices associated with guards

EMERGENCY SHUT-OFF systems

Electrical equipping of industrial machines
Part 1: General requirements

Any design alterations that effect the technical specifications given in the Operating Instructions or
the intended use, i.e. change the machine substantially, will invalidate this EU Declaration of
Conformity.

Heidenheim, 01 March 2014

......................................

Dipl.-Ing. (TU)

Arpad G. Meszaros

Head of Development and Design

Graduate engineer (from a technical university)

Summary of Contents for EM 6012

Page 1: ...Issue date 01 03 2014 V1 3 Before the initial start up read and keep at the machine for future use Operating instructions Soil mixer EM 6012 ...

Page 2: ...nstalling the machine 3 Measures for the machine s stability against overturning 4 Disassembly and disposal of the machine 5 Initial start up 1 Check prior to first start 2 Starting the machine for the first time 3 Stopping the machine 6 Operation 1 Normal operation 2 Shutting down the machine 3 Measures prior to and after a longer shutdown 7 Malfunctions 1 Behaviour in case of malfunctions 2 Poss...

Page 3: ...f the MAYER Soil mixer EM 6012 is not used in accordance with the regulations the safe operation of the machine is not guaranteed The usage for intended purpose involves the reading of the operating instructions and the compliance of the regulations specially safety regulations stated in it Furthermore every inspection and maintenance should be performed in specified time For damages that are orig...

Page 4: ...4 2 Structure Plan view of soil mixer EM 6012 back right left front ...

Page 5: ...inuously thereby mixing the soil The mixing time can be selected as required After the mixing time has elapsed the elevator swivels forward into the unloading position The soil is now transported out of the soil mixer into a waiting container or the soil hopper of the potting machine It is also possible to select the discharging time A moistening system is available as an accessory It can be insta...

Page 6: ... m Workplace related emission value 70dB A Available accessories for an additional charge watering device with ball tap watering device with magnetic valve heavy duty execution for extreme soils with heavy duty motor towing bar emptying control Laser light sensor emptying by means of pedal switch Important note When placing repeat orders for accessories and spare parts make sure to have informatio...

Page 7: ...for organisation Part 1 Basic terminology methodology Part 2 Guiding technical principles and specifications Safety distances to keep the upper limbs from reaching danger points Safety of machines minimum distances to avoid any crushing of body parts Safety related parts of control systems Part 1 General principles for design Principles for risk assessment Interlocking devices associated with guar...

Page 8: ... section the machine is only operated when in flawless working order and especially that the working order of the safety equipment is regularly checked the Operating Instructions are always available in legible condition and complete at the location where the machine is used only sufficiently qualified and authorised personnel operate service and repair the machine these personnel are regularly in...

Page 9: ...ist when dealing with this machine These residual hazards relate to People The machine Other things and objects The environment The following safety symbols are used in these Operating Instructions This symbol indicates that there are dangers to the machine things and the environment but that no dangers to people are to be expected If these instructions are not followed it might result in malfunct...

Page 10: ...acelets or wristbands for operationally relevant reasons it is not possible to completely cover the soil hopper it is not allowed to reach into the soil hopper to push in more soil for example because when doing so there would be a danger of getting caught by the scraping chain it is not allowed to get into the soil hopper while the machine is running ...

Page 11: ...ible to access the emergency cut off switch The emergency cut off switch should always be located on the relevant workplace during normal operation preferably on the panel next to the right of the worker It is forbidden to climb onto the running machine The machine must be set up on even and solid surface so that it stands securely in place There is danger of life in case of a machine falling over...

Page 12: ...to this special qualifications are required for the following activities Operation personnel being trained may at first only work with the machine under the supervision of an experienced individual It should be confirmed in writing that the training has been successfully completed Only trained personnel may ever operate any of the control and safety equipment All individuals that carry out any act...

Page 13: ...eneral Safety Instructions section When transporting the machine the following special dangers must be expected Suspended loads can drop which would be a lethal danger never go under suspended loads If load lifting equipment other than that specified here severe damage to the machine may result 1 Transport When the machine is transported special care shall be taken to avoid damage of the machine d...

Page 14: ...soil hopper to make sufficient safety precautions in order to prevent the machine from accidentally rolling away Such precautions may include enough personnel to secure the wheels using a wedge and so on 3 Storage When the machine or its parts are not reassembled right after transport then they shall be carefully stored on a protected area It shall regularly be covered and protected against dust a...

Page 15: ... c Be sure that enough space is assured for feeding and filling pots Same care shall be taken in case of machines connected in front of or behind it 2 Installing the machine a A hard soil surface shall be provided under the machine to prevent the wheels and feet from sinking into the soil b Make sure the individual components of the soil to be mixed and the finished soil after mixing only need to ...

Page 16: ...ry out other activity for erecting the machine than it is described in section 4 2 4 Disassembly and disposal of the machine After completion of its full time of operation the machine must be duly separated from energy supply systems and disposed of according to valid legal regulations ...

Page 17: ...n it have been removed from the machine Before the first start up check the electrical connections Activate all the safety equipment and EMERGENCY SHUT OFF switches before the initial start up Also read the section General Safety Instructions 1 Check prior to first start Prior to starting up the machine the following must be checked are all safety devices available was the machine damaged during t...

Page 18: ...oil hopper is removed before the machine is taken into operation c Put main switch of the machine to OFF Null position before plug of the connection cable would be connected to the socket d The MAYER soil mixer is fitted with a phase sequence watchdog which ensures it always moves in the same working direction If the Control on check lamp on the control cabinet does not light up after the start ke...

Page 19: ...ging switch to Continuous Set the master switch to 1 ON The mixing cycle is started by pressing the Start key Control on comes on The machine operates for the preset mixing time The elevator automatically swings forward into the discharging position after the mixing time has elapsed Interrupt the discharging cycle by setting the Discharging switch to 0 Press the stop key f In case of there were no...

Page 20: ... machine There are two ways provided to switch off the machine a In normal case by switch Stop mounted on the switch board b In emergency case by Emergency Stop switch Note See also section 6 2 Shutting down the machine ...

Page 21: ...ic Time set on time delay relay K7 elapses Elevator swivels forward into discharging position Mixing time can be set from 1 5 30 min Mixer stops Comes on when master switch is on and start key is pressed Motor protection fault Mixing or discharging cycle commences EMERGENCY STTOP Main switch On Off Control Fault Elevator on motor protection forward Start Stop Mixing time Discharching Reverse 1 Rev...

Page 22: ... the mixing position with its scoops running The elevator automatically swivels into the discharging position after the mixing time has elapsed It then conveys the soil into waiting containers or the soil hopper of the potting machine It is possible to interrupt the mixing process using the Elevator forward key if you have selected too long a mixing time The elevator then swivels into the initial ...

Page 23: ...g cycle with moistening has finished Leave the setting on the straight way valve unchanged in order to have the same level of moisture in the next batch We recommend you mix the moistened soil again before discharging it To discharge the soil turn the Discharging switch to Time The soil hopper is now discharged under the control of the automatic timer e Mixing and automatic moistening It is possib...

Page 24: ...OIL MIXER has been loaded The elevator swivels forward and remains in that position after the mixing time has elapsed Now remove the back plate in the soil hopper Set the moving direction of the elevator from Forward to Reverse and the Discharging switch to Continuous This means the soil is not discharged via the elevator but instead out of the back of the soil hopper by the reversing conveyor bel...

Page 25: ...een interrupted by pressing the Stop key or the Emergency stop The machine has to be restarted and another mixing cycle initiated 3 Measures prior to and after a longer shutdown a Before a long shutdown Clean carefully the machine Grease and oil certain parts of the machine according to maintenance plan Protect against dirt and moisture to be covered Disconnect the machine from power lines electri...

Page 26: ... can result in injuries to people as well as damage to the machine In case of unprotected manual operation there is an increased risk of injuries through bruising 1 Behaviour in case of malfunctions If any malfunctions should occur while the machine is in operation proceed as follows 1 Stop the machine either using the STOP button or EMERGENCY SHUT OFF depending on the situation 2 When necessary f...

Page 27: ...e or reversing rollers and the conveyor belt Failure Malfunction Cause Trouble shooting Roller chains of the mixer drive are jumping Chains are too loose Tighten the chains Roller chains of the mixer drive are worn Chains are not greased Grease the chains fit new chains if necessary Elevator chains climbing onto the chain sprockets Transport chains on the elevator are too loose Tighten the chains ...

Page 28: ...y unit that is under pressure Only Mayer GmbH Co KG may ever manipulate the machine s control programme All un recycled operational materials lubricants and supplies must be disposed of in an environmentally friendly manner Also read the section General Safety Instructions When carrying out maintenance on the machine the following special dangers have to be expected Installing incorrect spare part...

Page 29: ...ce The extent of maintenance work has been reduced to a minimum thanks to the installation of zero maintenance machine elements The following parts should be greased with standard machinery grease 1 Mixer and transport chain 2 Swivel drive with spindle and spindle nut 3 Swivel guide with ball bearing 4 Roller chains on the mixer drive 2 1 Elevator chains The oil in the elevator drive gearbox shoul...

Page 30: ... tension on the transport and mixer chains The tension is sufficient if it is possible to press in the chain by 1 1 5 cm in the middle of the elevator The transport chain can be tightened using the two tightening bearings at the top of the elevator The tension of the chains on the mixer drive must also be checked regularly The chains can be tightened using the housing if they are too loose Grease ...

Page 31: ...ension Tensioning of the belt may be adjusted by means of tensioning nuts located at end of soil hopper It is important that both sides of the belt are tensioned by the same force 2 2 V belt The V belt for the swivel drive can be tightened using the mount for the electric motor Follow the maintenance schedule ...

Page 32: ...32 3 Maintenance schedule Description Interval Grease elevator chain prior to a longer shutdown Grease the shaft for the swivel drive quarterly Grease the mountings of the swivel drive quarterly ...

Page 33: ...33 9 Part list ...

Page 34: ... 6 Leiste 6002 01 02 02 02 4 Lath 7 Platte 6002 01 02 04 02 1 Plate 8 Scheibe 101 604 500 075 12 Washer 9 6 Kt Schraube 101 767 500 122 60 Hexagonal screw 10 Erdrutsche 6012 A031 01 00 1 Soil chute 11 Kopfblech 2400 A011 01 03 1 Headplate 12 Trichter 6012 A001 02 00 1 Cone 13 Scheibe 101 595 500 088 28 Washer 14 Spannrolle 6012 A011 02 00 1 Tensioning piece 15 Schaufel 5 Kratzer 6012 A021 02 00 10...

Page 35: ... 6002 01 03 04 1 Distance 25 Sicherungsring 101 624 500 865 2 Seeger ring 26 U Scheibe 101 606 500 077 4 Washer 27 6 Kt Schraube 105 040 500 184 4 Hexagonal screw 28 Passfeder 101 851 500 057 1 Latch 29 Antriebswelle 6012 A011 01 01 1 Shaft 30 Passfeder 101 849 500 055 2 Latch 31 Passfeder 505 557 1 Latch 32 Schaufel 6 Kratzer 6012 A021 01 00 10 Shovel blade 33 U Scheiben 101 618 500 349 2 Washer ...

Page 36: ...A001 01 00 1 Elevator housing 43 Abstreifer 2400 A062 00 00 1 Pull of 44 Halter für Abstreifer 2400 A061 00 00 1 Support for Pull of 45 Deckblech 2400 A001 02 01 1 Cover plate 46 Abdeckplatte 2 Cover plate 47 Klemmleiste 16 Connecting lath 48 Profil 2400 A001 04 01 2 Profile 49 6 Kt Mutter 101 614 500 230 2 Hexagonal nut 50 Spannhülse 101 817 500 004 2 Clamping sleeve 51 4 Kt Mutter 101 638 500 23...

Page 37: ...37 ...

Page 38: ... Back plate 6 Befestigung 6012 B001 03 00 1 Bracing 7 Austräger 6012 B001 02 00 1 Frame 8 U Scheiben 101 617 500 350 32 Washer 9 6 Kt Schraube 105 023 500 112 4 Hexagonal screw 10 6 Kt Schraube 105 025 500 173 4 Hexagonal screw 11 U Scheiben 101 606 500 077 12 Washer 12 Fuss 6012 B031 01 00 1 Foot 13 6 Kt Mutter 105 078 500 224 8 Hexagonal nut 14 Keilriemenscheibe 6002 01 04 03 17 1 V belt pulley ...

Page 39: ...01 08 02 2 Defector rubber 25 6 Kt Schraube 101 768 500 169 5 Hexagonal screw 26 Spannrolle 2601 B011 01 00 1 Tensioning roller 27 Tragrolle 2601 B011 03 00 6 Long cylinder 28 Antriebsrolle 2601 B011 02 00 1 Driving roller 29 Lager 500 476 2 Bearing 30 U Scheiben 101 598 500 081 4 Washer 31 6 Kt Mutter 105 079 500 223 8 Hexagonal nut 32 Kettenrad 6012 A011 05 03 2 Sprocket 33 Gewindestift 101 746 ...

Page 40: ... 8 Hexagonal screw 45 Hülse 6002 01 04 03 05 2 Money box 46 U Scheiben 101 597 500 090 8 Washer 47 Führung 6002 01 04 02 01 1 Gate leaf 48 Rahmen 6012 B021 01 00 1 Frame 49 Stellring 101 696 4 Ring 50 Stahlscheibenrad 102 598 500 409 2 Solid wheel 51 Band 6012 B011 02 00 1 Band 52 6 Kt Schraube 105 033 500 170 4 Hexagonal screw 53 U Scheiben 501 530 4 Washer 54 Lager 502 502 2 Bearing 55 Spindelmu...

Page 41: ...41 SOIL HOPPER ...

Page 42: ...42 10 Circuit diagrams for electric and pneumatic system ...

Page 43: ...r parts which we do not manufacture ourselves e g motors we can only accept liability for the same scope and length of time which the subcontractor has accorded to us Any replaced parts shall become our own property No warranty claims can be accepted if the fault occurs as a result of the customer having mistreated or neglected the products delivered by us made modifications or undertaken repairs ...

Page 44: ...c during the delivery period provided that the purchased object is not thereby significantly altered rendered less effective or reduced in value and the customer can reasonably be expected to accept the modifications You have chosen to purchase a product of true quality We wish you every success with your product We would be most grateful if you would recommend our products to others Thank you You...

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