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Summary of Contents for Mayer TM 2400DR
- Page 1 Potting machine TM 2400DR Operating instructions Issue date: 01.08.2020 / V1.7 Before the initial start-up, read and keep at the machine for future use.
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Page 2: Table Of Contents
List of Contents 1 Product description 5 Initial start-up 1. Intended use 1. Check prior to first start 2. Structure 2. Starting the machine for the first time 3. Functional description 3. Stopping the machine 4. Technical Data 5. EU Declaration of conformity 6 Operation 2 General safety instructions 1. -
Page 3: Product Description
Other means of use of the machine, besides the ones listed here, are not permitted – and they are not the usage for intended purpose. If the MAYER TM 2400DR potting machine is not used in accordance with the regulations, the safe operation of the machine is not guaranteed. -
Page 4: Structure
2. Structure Plan view of potting machine 2400DR back left right front... -
Page 5: Functional Description
3. Functional description a) Working without automatic pot dispenser When there is no pot dispenser installed then empty pots are loaded by one person on the turntable located on the right side of the machine when it is viewed from front side. The turntable is driven by a worm drive mechanism and is moved intermittently in counter clockwise. -
Page 6: Technical Data
When there is an automatic pot dispenser installed then feeding by hand is not necessary and one person may be saved. Further instructions are detailed in Operation instructions of pot dispenser. 4. Technical data Make: Mayer Machine type: Potting machine Series: 2400DR Length / width / height:... - Page 7 Available accessories (for an additional charge) • Drill sleeve 100 mm • Standard drills from 3.5 – 13 cm • Special drills from 3.5 – 16 cm • Container drill from 11 – 16 cm • Plate from 4.0 – 14 cm •...
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Page 8: Eu Declaration Of Conformity
5. EU declaration of conformity According to Appendix IIA of the EU Machinery Directive (2006/42/EC) Mayer Ipari és Kereskedelmi BT. The manufacturer: Georg Mayer út 1. 9341 Kisfalud / Magyarország Mayer GmbH & Co. KG Maschinenbau u. Verwaltung Poststrasse 30... - Page 9 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, 01.08.2020........Geschäftsführer | Managing Director...
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Page 10: General Safety Instructions
2 General safety instructions 1. Due diligence of the operating company The MAYER TM 2400DR potting machine was designed and built taking a danger analysis into consideration and after careful selection of the harmonised standards to be complied with as well as other specifications. -
Page 11: Explanation Of The Safety Symbols Used
• • Before beginning with any work on the The machine may not be started if any safety machine, secure its drives and accessory parts devices are removed. • against being switched on unintentionally. In the working area the operator is responsible •... -
Page 12: Basic Safety Precautions
Be sure to also note that a safety symbol can never replace the text of safety instructions—the text of safety instructions must therefore always be read completely. 3. Basic safety precautions Always be sure that: • … tight-fitting working clothes are worn at all the workplaces. -
Page 13: Machine-Related Safety Precautions
4. Machine-related safety precautions The workplaces are spread over various areas of In case of malfunctions during the work flow it is the potting machine. forbidden to touch the running machine in order to resolve the malfunction. a) Feeding pots into the rotating assembly (for a It must always be possible to access the machine without pot dispenser) or feeding pots into emergency cut-off switch. -
Page 14: Demands On Operating Personnel
Frequency converters can cause fault currents that are not detected by means of a standard soil leakage circuit breaker. So the machine may be operated with an AC/DC sensitive RCCB (residual-current circuit-breaker) only. Frequency converters have built-in capacitors that discharge after switching off the machine. -
Page 15: Transport
3 Transport To prevent damage to the machine as well as When transporting the machine, the following injuries while transporting the machine, it is special dangers must be expected: absolutely necessary to comply with the • following points: Suspended loads can drop, which would be a lethal danger –... -
Page 16: Handling
2. Handling The potting machine is fitted with 2 pneumatic tyres on one axle on the front and 2 castors with handbrake on the soil hopper. The weight of the empty machine is balanced on the axle. The machine can be pushed and pulled. On request, a trailer coupling can also be attached for an extra charge. -
Page 17: Installation
4 Installation 1. General notes To protect the machine against weather caused damages it is suggested to use and store it inside. Electrical connection: 400V/50Hz. Connection is permitted only to socket-outlets which are protected by an AC/DC sensitive RCCB (residual-current circuit- breaker). -
Page 18: Installing The Machine
2. Installing the machine A hard soil surface shall be provided under the machine to prevent the wheels and lags from sinking into the soil. In order to ease the pneumatic tyres, prop up the machine using the pedestals. 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. -
Page 19: Initial Start-Up
5 Initial start-up It is absolutely necessary to comply with the following safety instructions for the initial start-up of the machine. This will prevent injury to individuals, damage to machinery and other property damage. • The initial start-up may only be carried out by qualified individuals, complying with the safety instructions. -
Page 20: Starting The Machine For The First Time
2. Starting the machine for the first time Care shall be taken on the following: After reassembly the machine shall be checked as With the potentiometer, “Soil” means: per the following: • turn to the right > larger amount of soil and more speed •... - Page 21 1 Main switch 2 Soil 3 Rotating assembly 4 Drill 5 Scraper brush (option) 6 Socket-outlet belt storage Socket-outlet belt connection Emergency stop Flexible start/stop with emergency cut-out...
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Page 22: Stopping The Machine
3. Stopping the machine There are two ways provided to switch off the machine. In normal case by switch „Stop” mounted on the swinging cable. In emergency case by „Emergency Stop” switch. Note: See also section "6.2 – Shutting down the machine"... -
Page 23: Operation
6 Operation 1. Normal operation a) Before starting operation the following shall be checked: • Are pots, plants and soil mixture available in sufficient quantity? Care about the following • Soil transport • Plant feeding and unloading • Pot preparation •... - Page 24 • By means of the reversible ratchet, tighten the adjustable pot holder until the clamps slightly grip the pots. • Adjust pot scraper in such a way that excessive soil is scraped from the pot. • Shifting of the scraper takes place via the hand wheel from outside: - clockwise >...
- Page 25 c) Soil feeding and emptying the machine The soil hopper contains 1,500 litres and can be fed in various ways without the work flow at the machine being disturbed or interrupted. Feeding can take place: • manually by means of a shovel •...
- Page 26 • Set the drilling slide to lower position • Apply a suitable spindle on the drill and slide them on shaft of the motor then fix them by means of a threaded pin • Set roughly the required drilling depth by using an empty pot •...
- Page 27 e) Adjusting the speed of operation (hourly output) Infinitely variable adjustment can be carried out only if the machine is running by turning the potentiometer on a scale of 1 to 10 to run faster or slower. For initial work with the potting machine we recommend to start with a low hourly output until all workers have complete command of individual work steps.
- Page 28 Thus you save the elevator and it results in longer lifetime. g) Setting compactness of the soil (in the pot) Special feature of MAYER potting machines is to set compactness of the soil in the pot. This depends on: 1. Drilling in or out the soil mixture.
- Page 29 Comment to 2: Filled in quantity may be set by drawer with adjustable height. Larger quantity of soil results in more compact filling while soil filling drawn down at edge of the pot results in loose filling. Comment to 3: Function of the pressing plate is to hold the pot and to keep rest of the soil during drilling.
- Page 30 h) Soil chute • Adjustment of height • Adjustment of inclination i) Rotating brush with motor (option) • Adjustment from outside...
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Page 31: Shutting Down The Machine
2. Shutting down the machine There are two ways provided to switch off the machine. In normal case by pressing switch „Stop” mounted on the swinging cable. In this case the machine may be restarted by pressing switch „Start”. In emergency case by „Emergency Stop” switch. When push button „Emergency Stop”... -
Page 32: Malfunctions
7 Malfunctions To prevent damage to the machine as well as injuries while remedying malfunctions at the machine, it is absolutely necessary to comply with the following points: • Only eliminate a malfunction if you have the qualification specified to do so. •... -
Page 33: Possible Malfunctions And Trouble Shooting
2. Possible malfunctions and trouble shooting a) Mechanical malfunctions Failure/Malfunction Cause Trouble shooting Noise in the elevator Foreign matter got stuck Remove cause for malfunction. Possibly by running elevator backwards for a short time. Rotating assembly has too much Worn shifting roll or carrier bolt Replace shifting roll or carrier bolt. -
Page 34: Maintenance
• Release pressure of every 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. -
Page 35: General Notes
Spare parts have to meet the technical requirements of the machine's manufacturer. This is guaranteed with original spare parts from MAYER. 2. Inspection and preventative maintenance 2.1 Elevator chains Chains may be retensioned by means of tensioning bearings located on two sides of the elevator. -
Page 36: Rubber Conveyor Belt
2.2 Rubber conveyor belt Generally the rubber belt requires no retensioning. However if the belt should be readjusted caused for example by remedy works carried out on the machine, follow the process described below: Tensioning of the belt may be adjusted by means of tensioning nuts located at end of soil hopper. -
Page 37: Maintenance Schedule
3. Maintenance schedule Description Interval Check function of safety devices daily Using compressed air, clean guide rods of drilling unit daily Check safety instructions for sound condition weekly Check tension of elevator chain weekly Clean chains and buckets weekly Check and retighten, if necessary, drive chain of drilling monthly stand Grease shifting roll’s groove and drive chains... - Page 38 Grease holding-down bar at drill yearly Grease all bearings fitted with grease nipples yearly Retighten rubber conveyor belt (soil hopper) after repair works...
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Page 39: Part List
9 Part list... -
Page 40: Guarantee
10 Guarantee Horticultural machinery and special machinery We will accept liability for faults in the supplied goods and for any failure to provide features for the existence of which an express assurance had been given. In such a case we undertake –... - Page 41 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 Your MAYER-TEAM...
- Page 42 Two side pot dispenser type MDR single and double Brief instruction Before the initial start-up, read and keep at the machine for future use.
- Page 43 List of Contents 1 Product description 1. Intended use 2. Functional description 3. Technical Data 2 Initial Start-up 1. General notes 2. Starting the pot dispenser 3. Stopping the pot dispenser 3 Operation 1. Normal operation 2. Measures prior to and after a longer shutdown 4 Malfunctions 1.
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Page 44: Product Description
1 Product description 1. Intended use It is possible to use the two side pot dispenser type The usage for intended purpose involves the MDR (pneumatic drive) for loading the potting reading of the operating instructions, and the machine with pots suitable for dispensing. Round compliance of the regulations, especially safety pots with an external diameter of 8–13 cm (double regulations... -
Page 45: Functional Description
2. Functional description... -
Page 46: Technical Data
Pneumatic using compressed air cylinders (pressure min. 8 bar) Round pots 8 – 13 cm external diameter Pot size: Available accessories (for an additional charge) • Mayer compressed air ejector • Sets of jaws: clamping for large pots • Storage belt Important note! -
Page 47: Initial Start-Up
3 Initial start-up It is absolutely necessary to comply with the following safety instructions for the initial start-up of the pot dispenser. This will prevent injury to individuals, damage to machinery and other property damage. • The initial start-up may only be carried out by qualified individuals, complying with the safety instructions. -
Page 48: Starting The Pot Dispenser
2. Starting the pot dispenser When the machine is connected to compressed air supply, the pot dispenser will start to operate automatically as soon as the turntable of the potting machine begins to run. 3. Stopping the pot dispenser The pot dispenser stops as soon as the potting machine's turntable comes to a standstill (if the cylinder has already begun to move, it will stop as has soon as it has reached its final position). -
Page 49: Operation
3 Operation To prevent damage to the pot dispenser as well as When operating the pot dispenser, the following injuries while operating the pot dispenser, it is special dangers must be expected: absolutely necessary to comply with the following • Usage not for the intended purpose can points: result in personal injury or damages of the... -
Page 50: Normal Operation
1. Normal operation Adjusting the pot dispenser Set the pot pick-ups and the pot supports of the turntable to the size of the pots to be used if it is necessary to make an adjustment or conversion to another pot size (see the operating instructions for the potting machine). - Page 51 Adjust the height of the top holding jaw so that it securely holds the second-to-last pot at the top edge of the pot. Adjust double pot receptacles 2-3 mm below the upper pot’s edge. Adjust the height of the pot dispenser. The bottom edge of the last pot in the dispenser should be 10 –...
- Page 52 Push the storage belt (optional) towards the pot dispenser as near as 2-3 mm. Run the dispenser and potting machine at a low potting speed and watch how the pots are fed in. Stop the machine before making any corrections to the setting if any are necessary. Set the potting machine to the required working speed if the pots are being fed in correctly.
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Page 53: Measures Prior To And After A Longer Shutdown
Measures prior to and after a longer shutdown a) Before a long shutdown • Clean carefully the pot dispenser. • Grease and oil certain parts according to maintenance plan. • Protect against dirt and moisture (to be covered) b) After a long shutdown •... -
Page 54: Malfunctions
4 Malfunctions To prevent damage to the pot dispenser as well as injuries while remedying malfunctions at the pot dispenser, it is absolutely necessary to comply with the following points: • Only eliminate a malfunction if you have the qualification specified to do so. -
Page 55: Possible Malfunctions And Trouble Shooting
2. Possible malfunctions and trouble shooting Failure/Malfunction Cause Trouble shooting Pots do not drop Static charge build-up in the pots Fit a compressed air ejector (mutual attraction) Either no pots or several pots at Incorrect dispenser setting Correct the setting once fall into the pot receptacle Recycled pots do not run well on Incorrect bottom holding jaw... -
Page 56: Maintenance
• Release pressure of every unit that is under crushing. pressure. • Only Mayer GmbH & Co. KG may ever manipulate dispenser's control programme. • All un-recycled operational materials, lubricants and supplies must be disposed of in an environmentally friendly manner. -
Page 57: General Notes
For service or repair work, order our customer service at one of our service workshops. Spare parts have to meet the technical requirements of the machine's manufacturer. This is guaranteed with original spare parts from MAYER. 2. Inspection and preventative maintenance Grease and clean machine regularly. -
Page 58: Part List
6 Part list... - Page 59 Pos. Description Part number Remark Amount 1 upper fastening plate DV6.0.01.001/1 2 upright fastening plate DV5.0.01.002/1 3 upright guiding block DV5.0.01.003/0 4 central fastening block DV5.0.01.004/1 5 connecting plate for sliding rail DV5.0.01.005/1 6 block with control curve DV5.0.01.006/1 7 fastening plate for guides DV5.0.01.007/1 8 guide pin for adjustment DV5.0.01.008/1...
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