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Issue date: 01.10.2009 / V1.0

Before the initial start-up, read and keep at the machine for future use.

Operating instructions

Potting machine TM 2018

Содержание TM 2018

Страница 1: ...Issue date 01 10 2009 V1 0 Before the initial start up read and keep at the machine for future use Operating instructions Potting machine TM 2018 ...

Страница 2: ...es 2 Installing 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 ...

Страница 3: ...AYER TM 2018 potting machine 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 origin...

Страница 4: ...4 2 Structure Standard equipment basic machine Version with vibrating grid optional Soil chute for 1 workplace Soil chute for 2 workplaces Different pot sizes can be filled ...

Страница 5: ...alls into container being there by means of the soil chute A controlled conveyor belt is installed into the soil hopper which forwards the soil always towards the elevator One or several person s standing in front of the machine may plant plants into the containers Plant holding trays may be located beside the machine The filled containers are manually taken away from the machine and new empty con...

Страница 6: ...ght 480 kg Working height approx 85 cm Current consumption 16 A Control voltage 24 V DC Power connection 400V 50Hz 5 pole Power input 3 2 kW Pot size containers 25 l and larger Capacity of soil hopper 1 5 m 2 5 3 5 4 m on request Production speed depending on container size Workplace related emission value 73dB A ...

Страница 7: ...in connection with soil hopper extension Conveyor belts Roller conveyors and roller curves Towing bar Stainless steel elevator shovels Stainless steel chains Special tyres used for cars Vibrating unit Important note When placing repeat orders for accessories and spare parts make sure to have information about the machine type and number at your hand ...

Страница 8: ... 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 gua...

Страница 9: ...ion 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...

Страница 10: ...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...

Страница 11: ...ets or wristbands for operationally relevant reasons it is not possible to completely cover the compost hopper it is not allowed to reach into the compost 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 compost hopper while the machine is running ...

Страница 12: ...al 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 The floor workplaces at the machine and traffic routes must be regularly cleaned from dirt and water in order to avoid danger of slipp...

Страница 13: ...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...

Страница 14: ...he 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 during loading or unloading During transport fixings ac...

Страница 15: ...inclined plane it is necessary to completely empty the 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 ...

Страница 16: ...s which are protected by an AC DC sensitive RCCB residual current circuit breaker 0 03A 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 d In order to capacity of the machine to be used efficiently it is suggested the soil mixture seedling plants and pots to be prepared on the best place and in suffi...

Страница 17: ...a handbrake 3 Measures for the machine s stability against overturning There is no need to carry 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 ...

Страница 18: ...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...

Страница 19: ...onnected push the button Start d Care shall be taken on the following With the switch Soil means Position 1 smaller amount of soil and less speed Position 2 larger amount of soil and more speed Warning Switch position to right elevator and conveyor belt are moved in normal operational direction Switch position to left conveyor belt is moved in normal operational direction while elevator is moved i...

Страница 20: ...20 Emergency stop Switch vibrator optional Switch soil Emergency stop Controller vibrator optional Button START Button STOP ...

Страница 21: ...the machine a In normal case the machine is being controlled by means of the pedal switches The machine will stop automatically as soon as the pedal switch is being released b In emergency case by Emergency Stop switch Note See also section 6 2 Shutting down the machine ...

Страница 22: ...l mixture available in sufficient quantity Care about the following Soil transport Container preparation Use the shortest transport routes b Adjusting or shifting the pot supports The position of the two supports for the containers can be adjusted both horizontally and vertically in order to match the container size ...

Страница 23: ...lace manually by means of a shovel using a wheelbarrow using a conveyor belt using a shovel loader d The two pedal switches are placed left and right in front of the machine After switching on the main circuit breaker the machine starts when the pedal switches are beeing pressed and fills the containers with soil The soil keeps on running as long as the pedal switches are beeing pressed ...

Страница 24: ...tor and conveyor belt run into work flow direction Left switch setting means Elevator runs against work flow direction and conveyor belt runs into work flow direction II Speed of the belt may be increased or decreased by rotating the star wheel as it is marked Before setting is started clamping lever of spindle of the star wheel shall be loosened and when the required speed is set it shall be tigh...

Страница 25: ...il in the containers This depends on the strength of the vibrator Less vibration strength looser filling in the containers More vibration strength compacter filling in the containers By means of the controller Rüttler vibrator A the strength of the vibrator is being adjusted Switch B switch position 1 continuance when the pedal switches are being pressed the soil supply and vibrator are running wh...

Страница 26: ...mergency stop is eliminated the machine may be started by pressing the start switch on the switch box 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 electricity compressed air b After ...

Страница 27: ...lt 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 pedal switches the STOP button or EMERGENCY SHUT OFF depending on the situation 2 When n...

Страница 28: ...gn material causing overload Failure Malfunction Cause Trouble shooting Noise in the elevator Jammed stone or wooden piece Remove cause for malfunction Possibly by running elevator backwards turn switch left to position 1 or 2 Erratic filling of containers Matter in elevator Remove source of interference Soiled buckets Clean buckets No soil supply Soil hopper empty Fill hopper Broken return spring...

Страница 29: ...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...

Страница 30: ...may be retensioned by means of tensioning bearings located on two sides of the elevator Check regularly if the chains are tensioned properly When the chain is too loose the plates may jam with edge of the housing Overtensioned chain requires an excess of driving power and causes too quick wear When the chains are retensioned both of them shall have the same tightness With the soil hopper being com...

Страница 31: ...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 Beyond the above care shall be taken on grooves of driving and guiding drum not to be filled up with soil Regularly clean the grooves when it occurs Generally the rubber belt requires no retensioning Follow the maintenance schedule ...

Страница 32: ...32 3 Maintenance schedule Description Interval Grease elevator chain prior to a longer shutdown Grease all bearings fitted with grease nipples yearly ...

Страница 33: ...33 9 Part list ...

Страница 34: ... Spring ring 6 Topfauflage 2018 A021 00 00 1 Pot support 7 6 Kt Mutter 101 688 500 222 4 Hexagonal screw 8 U Scheibe 101 596 500 089 8 Washer 9 6 Kt Schraube 101 768 500 169 4 Hexagonal screw 10 Weiche 2018 A011 00 00 1 Soil chute 11 6 Kt Schraube 101 767 500 122 6 Hexagonal screw 12 U Scheibe 101 595 500 088 12 Washer 13 6 Kt Mutter 105 083 500 221 6 Hexagonal screw 14 Adapter für Erdrutsche 2018...

Страница 35: ...35 Pos Benennung Description Artikelnummer Part number Stück Amount 18 U Scheibe 101 597 500 090 2 Washer 19 Getriebe 108 160 500 546 1 Drive unit ...

Страница 36: ...36 ...

Страница 37: ...dblende 2018 A001 04 01 1 Soil port 3 Blech 2018 A001 02 00 1 Plate 4 6 Kt Schraube 101 768 500 169 19 Hexagonal screw 5 U Scheibe 101 596 500 089 38 Washer 6 Erdblende oben 2018 A001 17 01 1 Upper soil port 7 6 Kt Mutter 101 688 500 222 19 Hexagonal nut 8 Schalterhalter 2018 A001 18 01 2 Switch support 9 Stellring 101 544 4 Set collar 10 Rad 102 563 2 Wheel ...

Страница 38: ...38 Elevator housing ...

Страница 39: ...iche mitte I 2018 A011 04 00 1 Deflector middle I 5 Weiche mitte II 2018 A011 05 00 1 Deflector middle II 6 Weiche links 2018 A011 03 00 1 Deflector left 7 Abschlussblech 2018 A011 06 01 1 Nab 8 6 Kt Schraube 105 027 500 113 4 Hexagonal screw 9 U Scheibe 101 596 500 089 4 Washer 10 Flügelschraube 101 611 500 172 4 Butterfly nut 11 U Scheibe 101 617 500 350 4 Washer 12 Linsenflanschkopfschraube 112...

Страница 40: ...40 Deflector ...

Страница 41: ...ecting 4 Flachstahl 2018 A001 22 01 1 Flat iron 5 Halter 2018 A001 05 01 1 Holder 6 Klemmhebel 112 921 500 306 6 Clamping lever 7 Haltewinkel 2018 A001 07 00 2 Holder plate 8 Halter 2018 A001 19 00 2 Holder 9 Buschse BB345SINT 2 Bushing 10 Topfauflage 2018 A001 08 00 2 Pot support 11 U Scheibe 101 596 500 089 6 Washer 12 6 Kt Schraube 109 878 500 112 6 Hexagonal screw 13 Abschlussblech 2018 A001 1...

Страница 42: ...42 Pot support ...

Страница 43: ...1 Flange bearing 7 Federring 101 606 500 077 4 Spring ring 8 6 Kt Schraube 101 771 500 186 4 Hexagonal screw 9 6 Kt Schraube 101 661 500 164 8 Hexagonal screw 10 U Scheibe 101 597 500 090 16 Washer 11 Flanschlager 102 179 502 503 4 Flange bearing 12 6 Kt Mutter 105 079 500 223 8 Hexagonal screw 13 Umlenkrad vorne 1010 01 03 16 00 2 Deflecting wheel 14 Spann und Umlenkrad 1010 01 03 11 00 4 Tension...

Страница 44: ...ad screw 23 Schaufel 1010 01 03 36 01 8 Shovel blade 24 Schaufel 1010 01 03 35 01 9 Shovel blade 25 Förderkette rechts 1012 01 03 21 00 1 Hollow bolt chain right 26 Spindel 1010 01 03 09 02 2 Spindle 27 Tellerfeder 101 888 500 214 8 Belleville spring 28 Bundmutter 1010 01 03 09 03 2 Flange nut 29 6 Kt Mutter 107 536 2 Hexagonal nut 30 4 Kt Mutter 101 638 500 239 2 Square nut 31 Spannhülse 101 617 ...

Страница 45: ...45 Elevator soil conveyor without drive ...

Страница 46: ...Scheiben 101 596 500 089 60 Washer 7 6 Kt Schraube 105 040 500 184 8 Hexagonal screw 8 U Scheiben 101 597 500 090 16 Washer 9 Distanz 2400 B007 01 02 2 Distance 10 Rad 503 131 2 Wheel 11 Zylinder Schraube 101 721 500 259 2 Cylinder head screw 12 6 Kt Mutter 105 079 500 223 8 Hexagonal nut 13 6 Kt Mutter 101 688 500 222 27 Hexagonal nut 14 Seitenwand links 1010 B001 01 00 1 Side wall left 15 Spannp...

Страница 47: ...Spindel 1010 02 02 08 00 1 Spindle 25 Scheibe 1010 02 02 08 02 1 Disk 26 Federbolzen 1010 02 02 02 02 1 Spring bolt 27 Lasche 1010 01 12 02 01 1 Connecting plate 28 U Scheibe 101 598 500 080 2 Washer 29 6 Kt Schraube 105 042 500 181 2 Hexagonal screw 30 U Scheibe 101 619 500 348 1 Washer 31 6 Kt Schraube 105 022 500 176 1 Hexagonal screw 32 Federring 101 606 500 077 8 Spring ring 33 6 Kt Schraube ...

Страница 48: ...30 1 Threaded pin 42 Freilauf 105 425 1 Free wheel hub 43 Kreuzgriff 1010 02 02 08 03 1 Cross handle 44 Winkel 1010 B051 01 01 1 Cornel 45 Augenschraube 503 992 1 Eye screw 46 Zugfeder 1010 01 03 05 00 1 Tension spring 47 6 Kt Schraube 105 027 500 113 6 Hexagonal screw 48 Träger 1010 B051 03 00 1 Bearn 49 Sicherungsring für Welle 101 624 500 865 1 Retaining ring 50 Flanschlager 102 182 1 Flange be...

Страница 49: ...oller 56 Achse 1010 02 02 05 02 3 Axle 57 Sicherungsring für Welle 101 623 500 897 6 Retaining ring 58 Rillenkugellager 102 194 500 338 6 Ball bearing 59 Antriebsrolle 1010 02 02 01 00 1 Driving roller 60 Seitenwand rechts 1010 B001 02 00 1 Side wall right 61 Eckblech 1010 B021 01 01 2 Corner plate ...

Страница 50: ...50 Elevator soil conveyor without drive Soil hopper ...

Страница 51: ...002 02 00 2 Bracket 6 Gummi feder 505 113 4 Rubber spring 7 Federring 101 605 500 076 16 Spring ring 8 Selbsts mutter 102 972 500 232 8 Self locking nut 9 Vibromotor 505 132 1 Vibrant motor 10 6 Kt Mutter 101 688 500 222 6 Hexagonal nut 11 Blech 2018 V002 05 01 1 Plate 12 Flachrundschraube 101 686 500 108 2 Half round head screw 13 U Scheibe 101 596 500 089 2 Washer 14 6 Kt Schraube 101 663 502 48...

Страница 52: ...52 ...

Страница 53: ...53 10 Circuit diagrams for electric and pneumatic system ...

Страница 54: ...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 ...

Страница 55: ...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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