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Mayer TM 2105 Operating Instructions Manual

Potting machine
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Potting machine TM 2105
Operating instructions
Issue date: 01.09.2014 / V1.4
Before the initial start-up, read and keep at the machine for future use.

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  • Page 1 Potting machine TM 2105 Operating instructions Issue date: 01.09.2014 / V1.4 Before the initial start-up, read and keep at the machine for future use.

  • 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

    1 Product description 1. Intended use The Mayer TM 2105 potting machine may be used for planting and replanting plants with a minimum of working force and of time. Other means of use of the machine, besides the ones listed here, are not permitted –...

  • Page 4: Structure

    2. Structure Plan view of potting machine TM 2105 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 moved intermittently counter clockwise.

  • Page 6: Technical Data

    Further instructions are detailed in Operation instructions of pot dispenser. 4. Technical data Make: Mayer Machine type: Potting machine Series: TM 2105 Length / width / height: 235 / 150 / 205 cm Weight: 560 kg Working height: approx. 95 cm Power connection:...

  • Page 7: Eu Declaration Of Conformity

    5. EU declaration of conformity According to Appendix IIA of the EU Machinery Directive (2006/42/EC) Mayer GmbH & Co. KG The manufacturer: Maschinenbau u. Verwaltung Poststrasse 30 89522 Heidenheim | Germany Make: Mayer hereby attests that the machine described in...

  • Page 8: General Safety Instructions

    2 General safety instructions 1. Due diligence of the operating company The Mayer TM 2105 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 9: Explanation Of The Safety Symbols Used

    Before beginning with any work on the machine, The machine may not be started if any safety • • secure its drives and accessory parts against devices are removed. being switched on unintentionally. In the working area the operator is responsible •...

  • Page 10: 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 •...

  • Page 11: Machine-Related Safety Precautions

    4. Machine-related safety precautions The workplaces are spread over various areas of It must always be possible to access the the potting machine. emergency cut-off switch. The emergency cut-off switch should always be a) Feeding pots into the rotating assembly (for a located on the relevant workplace (during normal machine without pot dispenser) or feeding pots into operation preferably on the panel, next to the right...

  • Page 12: Demands On Operating Personnel

    5. Demands on operating personnel The machine may only be operated by personnel Only trained personnel may ever operate any of the who have been trained for such, shown what is control and safety equipment. involved and are authorised to do so. These individuals have to know and act in accordance with All individuals that carry out any activities with the...

  • Page 13: 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 •...

  • Page 14: Handling

    2. Handling The potting machine is fitted with 2 rubber tyres on one axle on the front and 2 legs on the soil hopper. Due to this construction, the pot machine can be easily moved on a level surface by one person.

  • Page 15: 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. The machine must be connected to a socket which has a 0.03 amp residual current operated circuit breaker. Be sure that enough space is assured for feeding and filling pots.

  • Page 16: Installing The Machine

    2. Installing the machine A hard soil surface shall be provided under the machine to prevent the wheels and legs from sinking into the soil. 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 17: 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 •...

  • Page 18: Starting The Machine For The First Time

    1. Starting the machine for the first time After reassembly the machine shall be checked as The turntable must start turning counter-clockwise per the following: when the "Start" key on the switch cabinet is pressed. If the turntable does not start turning this way, have Be sure not foreign materials, such as tools or an electrician reverse the polarity of the connection similar, are left in the soil hopper, in the elevator or...

  • Page 19: 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 20: 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 • Use the shortest transport routes •...
  • Page 21 Place the required pot on the pot support. • Adjust the rear stop so that the pot is in the middle of the pot • support. Move the pot holding disk again to close the pot receptacle • so that there is a little space left on the sides between the pot and the clips of the pot holding disk.
  • Page 22 c) Soil feeding and emptying the machine The soil hopper contains 600 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 23 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 24 e) Adjusting the speed of operation (hourly output) In standard construction of the machine a filling capacity of 500- 2500 pots per hour may be reached by using infinitely variable drive. The infinitely variable adjustment process can only be effected when the machine is running.
  • Page 25 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. Setting the filling quantity by setting the drawer.
  • Page 26 Various designs of plates: Closed clamping Tree nursery With watering edge With soil addition plate clamping plate (optional equipment)

  • Page 27: 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 28: 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. Also read the section "General Safety Instructions".

  • Page 29: Possible Malfunctions And Trouble Shooting

    2. Possible malfunctions and trouble shooting a) Mechanical malfunctions Failure/Malfunction Cause Trouble shooting Noise in the elevator Jammed stone or wooden piece Remove cause for malfunction Rotating assembly has too much Maltese cross or carrier bolt has Replace maltese cross or carrier clearance.

  • Page 30: 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 31: 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 32: Conveyor Belt

    2.2 Conveyor belt Generally the conveyor 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 33: Maintenance Schedule

    3. Maintenance schedule Description Interval Grease maltese cross and drive chains quarterly Grease holding-down bar at drill monthly Grease elevator chain (prior to a longer shutdown) Grease all bearings fitted with grease nipples yearly Grease the guides for the drill bit slide monthly...

  • Page 34: Part List

    9 Part list...
  • Page 35 Rahmen 2110-02-01-00-00 Frame Pos. Benennung Artikelnummer Stück Description Part number Amount Blech 2104-02-01-21-00 Plate Gewindestück 1011-41-01-08-04 Threaded fitting 4-Kt-Rohr 2100-02-01-19-00 Square pipe Bohrträger 2110-02-01-03-00 Drill support Platte 2110-02-01-12-00 Plate Träger 2110-02-01-01-00 Support Halter 2110-02-01-05-00 Support 4-Kt-Rohr 2104-01-02-20-00 Square pipe Rippe 2110-02-01-10-00 Feather Platte...
  • Page 37 Antrieb 2111-02-02-00-00 Drive unit Pos. Benennung Artikelnummer Stück Description Part number Amount Zylinderkopfschraube 101 712/500 253 Cylinder-head screw U-Scheibe 101 616/500 353 Washer Steuerteil 2111-02-02-05-00 Controller Antriebsmotor 2111-02-02-21-00 Dirving motor Kegelradsatz 2110-02-02-10-01 Spannhülse 101 817 DU-Buchse 102 303 DU-Bushing Lagerbock 2110-02-02-11-01 Stange 2111-02-02-09-01...
  • Page 38 Pos. Benennung Artikelnummer Stück Description Part number Amount Rillenkugellager 500 339 Ball bearing Lagerplatte 2110-02-02-02-00 Bearing plate Kettenspanner 2110-02-02-08-01 Chain tensioning Selbstsichernde 6-Kt-Mutter 110 714/500 231 Self locking nut Kettenrad kpl. 2110-02-02-04-00 Sprocket-wheel, complete Rolle 2104-02-02-13-03 Roller Pass-Schraube Set screw Treibscheibe 2110-02-02-06-01 Kettenrad kpl.

  • Page 39: Drive Unit

    DRIVE UNIT...
  • Page 40 Drehtisch 2110-02-03-00-00 Turntable Pos. Benennung Artikelnummer Stück Description Part number Amount Klemmhebel 113 999 Cylinder-head screw U-Scheibe 101 616/500 353 Washer Topfauflage oben 2110-02-03-04-00 Upper pot support disk Topfauflage unten 2110-02-03-03-00 Lower pot support disk Gleithülse kpl. 2110-02-03-07-00 Sliding bushing, complet Topfauflage 2110-02-03-06-01 Pot holder...
  • Page 41 Pos. Benennung Artikelnummer Stück Description Part number Amount Senkschraube 101 783/500 196 Counter sunk screw U-Scheibe 101 616/500 353 Washer 6-Kt-Schraube 101 767/500 122 Hexagonal screw Anschlag 2110-02-03-05-01 Buffer Nirosta-Druckstück 112 826/501 569 Stainless pushin piece 6-Kt-Mutter 105 083/500 221 Hexagonal nut...
  • Page 42 TURNTABLE...
  • Page 43 Bohrstation 2110-02-02-00-00 Drill Pos. Benennung Artikelnummer Stück Description Part number Amount Motor 101 900 Motor 6-Kt-Schraube 109 878/500 169 Hexagonal screw 6-Kt-Mutter 101 688/500 222 Hexagonal nut Klemmstück 1010-04-01-14-04 Clamping piece Gewindestift 101 742/500 026 Threaded pin Gummipuffer 102 263 Rubber buffer Führungsrohr 1010-04-01-13-00...
  • Page 44 Pos. Benennung Artikelnummer Stück Description Part number Amount 6-Kt-Schraube 103 475/500 121 Hexagonal screw Selbstsichernde 6-Kt-Mutter 102 972/500 232 Self locking nut Bohrerschutz kpl. 2100-02-05-08-00 Drill protection, complete Führung 2104-02-05-07-01 Guide Zylinder-Schraube 101 726 Cylinder head screw 6-Kt-Mutter 105 078/500 224 Hexagonal nut Rohr 2110-02-05-06-02...
  • Page 45 Pos. Benennung Artikelnummer Stück Description Part number Amount Bolzen 2110-02-05-08-00 Linsenflachkopfschraube 112 567 Flange screw...
  • Page 46 DRILL...
  • Page 47 Übergabe 2110-02-06-00-00 Pot transfer Pos. Benennung Artikelnummer Stück Description Part number Amount Übergabehebel 2110-02-06-03-00 Transforming lever 6-Kt-Schraube 101 699/500 183 Hexagonal screw U-Scheibe 101 597/500 090 Washer Sicherungsring 101 623/500 897 Retaining ring Stützscheibe 503 457 Support disk DU-Buchse 102 879 DU-Bushing Auswerferwelle kpl.
  • Page 48 2110-02-06-00-00 POT TRANSFER...
  • Page 49 Topfführung 2110-02-07-00-00 Guide rail Pos. Benennung Artikelnummer Stück Description Part number Amount 6-Kt-Schraube 101 646/500 130 Hexagonal screw Träger 2100-02-07-01-00 Bracket Selbstsichernde 6-Kt-Mutter 1010 714/500 231 Self locking hexagonal nut 6-Kt-Schraube 105 028/500 857 Hexagonal screw Hebel II. 2105-02-07-03-00 Lever II. Hebel III.
  • Page 51 Abdeckung 2110-02-08-00-00 Cover Pos. Benennung Artikelnummer Stück Description Part number Amount Deckel 2110-02-08-02-01 Cover II. Deckel 2110-02-08-03-01 Cover III. Deckel 2110-02-08-01-01 Cover I. Abdeckung 2110-02-08-05-01 Cover IV. Deckel 2110-02-08-04-01 Cover V. U-Scheibe 101 595/500 088 Washer 6-Kt-Schraube 103 475/500 121 Hexagonal screw Linsenkopfschraube 112 576...
  • Page 53 EINREIHENMAGAZIN GEHÄUSE 1011-M001-00-00 SINGLE-ROW POT DISPENSER HOUSING Pos. Benennung Artikelnummer Stück Description Part number Amount Gestell 1011-M001-01-00 Frame Tür 1011-M001-06-01 Door Spindel 1011-M001-03-00 Shaft Scheibenhandrad 502 048 Hand wheel Speicherblock 1011-M001-02-00 Memory stack Achse 1011-M001-04-01 Shaft Verstellung 1011-M001-05-00 Adjustment Blech 1011-M050-01-01 Plate Innenmodul rechts...
  • Page 54 Pos. Benennung Artikelnummer Stück Description Part number Amount 6-Kt-Mutter 105 078/500 224 Hexagonal nut Spannhülse 101 817/500 004 Clamp sleeve Spannhülse 101 813/500 003 Clamp sleeve Klemmhebel 505 244 Clamp lever Zylinderschraube 101 721/500 259 Cylinder head screw 6-Kt-Schraube 104 029/500 129 Hexagonal screw 6-Kt-Schraube 106 208/500 111...
  • Page 56 INNENMODUL RECHTS 1011-M006-00-00 MODULE INSIDE RIGHT HAND Pos. Benennung Artikelnummer Stück Description Part number Amount Gehäuse 1011-M006-01-00 Housing Backenhalter 1011-M006-03-01 Jaw support Schwenkhalter 2601-M001-08-01 Swivelling bracket Stellstück 1011-M006-05-01 Adjuster piece Passfeder 1011-43-01-16-02 Feather key Kurvenrolle 102 549/500 323 Guide roller Steuerhebel 1011-M006-02-00 Control lever...
  • Page 57 Pos. Benennung Artikelnummer Stück Description Part number Amount Bundlager 105995 Collar bearing Passschraube 1011-43-01-06-04 Set-screw Auswerfer Gr. 1 / Ejector size 1 1011-M021-03-01 Auswerfer Gr. 2 / Ejector size 2 1011-M022-03-01 Auswerfer Gr. 3 / Ejector size 3 1011-M023-03-01 1011-43-06-14-01 Haltebacke oben Gr.
  • Page 58 Pos. Benennung Artikelnummer Stück Description Part number Amount Zugfeder 1011-40-01-07-08 Tension spring Federring 101 603/500 085 Spring ring U-Scheibe 101 595/500 088 Washer 6-Kt-Schraube 101 767/500 122 Hexagonal screw 6-Kt-Mutter 101 630/500 219 Hexagonal nut 6-Kt-Schraube 101 639/500 127 Hexagonal screw DU-Buchse 102 313/500 133 DU-bushing...
  • Page 59 1011-M006-00-00 MODULE INSIDE RIGHT HAND...
  • Page 60 MAGAZINHALTER 1011-M013-00-00 SUPPORT FOR POT DISPENSER Pos. Benennung Artikelnummer Stück Description Part number Amount Träger 1011-M013-01-00 Mounting Gleitschiene 2400-A061-05-04 Guide rail Platte 2400-M005-02-02 Plate Träger 1011-M013-02-00 Mounting Platte 1011-M013-03-01 Plate Platte 1011-M013-03-02 Plate Fuß 1011-M013-04-00 Support Spindel 2400-M007-02-00 Spindle Klemmhebel 505 244 Clamp lever 6-Kt-Mutter...
  • Page 61 Pos. Benennung Artikelnummer Stück Description Part number Amount Spannhülse 101 815/501 184 Clamp sleeve Spannhülse 101 813/500 003 Clamp sleeve Spannhülse 101 817/500 004 Clamp sleeve 6-Kt-Mutter 101 688/500 222 Hexagonal nut U-Scheibe 101 617/500 350 Washer Selbstsichernde Mutter 110 714/500 231 Self-locking nut...
  • Page 63 FUSS FÜR 1010 1011-M011-00-00 FOOT FOR 1010 Pos. Benennung Artikelnummer Stück Description Part number Amount Fuß 1011-M011-02-00 Foot Teleskop 1011-M011-01-00 Telescope Spindel 1011-M011-03-00 Spindle Scheibenhandrad 502 048 Hand wheel Abdeckkappe 504 655 Cover cap Klemmhebel 505 244 Clamp lever Spannhülse 101 813/500 003 Clamp sleeve Spannhülse...
  • Page 64 1011-M011-00-00 FOOT FOR 1010...
  • Page 65 Erdbehälter 2105-01-01-00-00 Soil hopper Pos. Benennung Artikelnummer Stück Description Part number Amount 6-Kt-Schraube 101 767/500 122 Hexagonal screw U-Scheibe 101 595/500 088 Washer 6-Kt-Mutter 105 083/500 221 Hexagonal nut Sterling 101 696 Adjusting ring 501 251 Wheel 6-Kt-Mutter 101 688/500 222 Hexagonal nut U-Scheibe 101 596/500 089...
  • Page 66 Lath Pos. Benennung Artikelnummer Stück Description Part number Amount Gummi 2104-01-01-11-00 Rubber Verbindung 2104-01-01-07-01 Connecting plate Federring 101 604/500 075 Spring ring Träger rechts 2105-01-01-06-00 Bracket right Abschlussblech 2104-01-01-08-01 Cover plate Seitenwand rechts 2105-01-01-02-01 Side wall right Versteifung rechts 2105-01-01-21-01 Brace right Flachrundschraube 101 687/500 066...
  • Page 68 Elevator 2105-01-02-00-00 Elevator Pos. Benennung Artikelnummer Stück Description Part number Amount Schutz 2105-01-02-09-00 Protection Elevator-Gehäuse 2105-01-02-10-00 Elevator housing Elevatordeckel 2105-01-02-02-00 Elevator cover U-Scheibe 101 595/500 088 Washer 6-Kt-Schraube 103 475/500 121 Hexagonal screw Deckel 2105-01-02-04-00 Cover Leitblech 2105-01-02-05-01 Guiding plate 6-Kt-Schraube 101 767/500 122 Hexagonal screw...
  • Page 70 Antrieb 2105-01-03-00-00 Drive unit Pos. Benennung Artikelnummer Stück Description Part number Amount Schaufel 2104-01-03-06-00 Shovel Förderkette links 2104-01-03-04-00 Conveyor chain left Spannwelle 2100-01-03-01-01 Tensioning shaft Spann und Umlenkrad 110 381 Tensioning and Deflecting pulley Spannlager 502 501 Tensioning bearing 4-Kt-Mutter 101 638 Square nut U-Scheibe...
  • Page 71 Pos. Benennung Artikelnummer Stück Description Part number Amount Antriebswelle 2104-01-03-02-01 Drive shaft Distanzrohr 2100-01-03-02-03 Distance 6-Kt-Mutter 105 079/500 223 Hexagonal nut Flanschlager 102 182/500 475 Flange bearing Federring 101 606/500 077 Spring ring 6-Kt-Schraube 101 671/500 182 Hexagonal screw Exzenter 1010-01-03-07-00 Excenter Distanzscheibe...
  • Page 72 Pos. Benennung Artikelnummer Stück Description Part number Amount Federbolzen 1010-02-02-02-02 Spring bolt Zugfeder 2104-01-03-15-00 Pull-spring U-Scheibe 104 043/500 082 Washer Kreuzgriff 1010-02-02-08-03 Cross handle Scheibe 1010-02-02-08-02 Disk Sterngriff 102 610 Star handle Selbstsichernde 6-Kt-Mutter 112 833 Self locking hexagonal nut U-Scheibe 101 597/500 090 Washer...
  • Page 73 Pos. Benennung Artikelnummer Stück Description Part number Amount Förderkette rechts 2104-01-03-05-00 Conveyor chain right Gewindestange 1010-02-02-08-01 Threadad bar Siederohr 2100-01-03-19-00 Distance piece Siederohr 2100-01-03-18-00 Distance piece...

  • Page 75: Circuit Diagrams For Electric And Pneumatic System

    10 Circuit diagrams for electric and pneumatic system...

  • Page 76: Guarantee

    11 Guarantee Horticultural machinery 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 – to the exclusion of all further claims – to improve or re-supply (at our discretion) free of charge any parts which have revealed themselves to be unserviceable or subject to a not inconsiderable impairment in serviceability due to faults in their...
  • Page 77 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...

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