Mayer 6160 Big Bale Breaker User manual

The 6160 Big Bale Breaker
Issue date: 13.07.2022 / V1.7
Before the initial start-up, read and keep at the machine for future use.
Operating Instructions

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Table of Contents
1 Product description
1. Intended use
2. Structure
3. Functional description
4. Technical specifications
5. EU declaration of conformity
2 General safety instructions
1. The operating organisation's duty to take due
care
2. Explanation of the safety symbols used
3. Basic safety measures
4. Requirements upon the operating personnel
3 Transport
1. Dimensions and weight
2. Transport equipment allowed
3. Transport to and at the set-up location
4 How to set up
1. Ambient requirements for setting up
2. Stability
3. Setting up / Alignment
5 Initial start-up
1. Check before the first start-up
2. Starting the machine for the first time
3. Check after the first start-up
6 Operation
1. The workplace for the operating personnel
2. Description of the control elements
2.1 EMERGENCY SHUT-OFF elements
2.2 Control cabinet
2.3 Control levers
3. How to operate
3.1 How to adjust
3.2 Positioning
3.3 How to fill
3.4 Tipping
3.5 Scraping chain / Break-up system
3.6 Watering system (accessory)
7 Malfunctions
1. What to do when there is a malfunction
2. Possible malfunctions and how to correct them
8 Maintenance
1. General information
2. Inspection and preventative maintenance
3. Cleaning
4. Maintenance schedule
9 Shutting down operation
1. Shutting down operation temporarily
2. Measures before and after long shutdowns
3. Final shutting down of operation / Disposal
10 Part list
11 Guarantee

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1 Product description
1. Intended use
The MAYER 6160 Big Bale Breaker is only
intended to gently break up commercially available,
compacted substrate bales (big bales) with
maximum dimensions of L/W/H = 1.20/1.20/2.25 m,
and supplying such to a subsequent machine (such
as the 1010 Potting Machine.
This machine is not intended for any other (as such
would be considered as inappropriate use) than the
types of use listed here.
If the MAYER 6160 Big Bale Breaker is not used
in accordance with this intention, then no safe
operation of the machine will be guaranteed.
2. Structure
Use as intended also includes reading these
Operating Instructions and complying with all the
instructions contained in them, especially the safety
instructions. It also includes all the inspection and
maintenance work being carried out at the
prescribed time intervals.
Not the manufacturer, but rather the operating
organisation of the MAYER 6160 Big Bale Breaker
shall be responsible for any injuries or damage
arising from use not complying with its intended
use.

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3. Functional description
•Loading is carried out by forklifts or lift trucks
•The soil hopper tips hydraulically into the operating
position.
•The substrate is taken off gently in layers by means of a
scraping chain and conveyed upward into the break-up
system.
•Here the substrate is put back into its original loose
condition and ejected downwards.
4. Technical specifications
Make:
Mayer
Machinery model:
Big Bale Breaker
Series:
6160
Length / Width / Height
330 / 169 / 220 cm
Weight:
1,100 kg
Working height
120 cm
Power connector
400V/50Hz, 5-pin
Power consumption
4.5 kW
Oil volume, hydraulic system
4 litres
Size of Big Bale L/W/H
120 / 120 / 225 m
Emission figure relating to the
workplace
70 dB (A)
Capacity of the soil hopper
4 m³
Filling weight
1,400 kg
Max. specific gravity
650 kg/ m³
Capacity
0 –750 litres/min

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5. EU declaration of conformity
According to Appendix IIA of the EU Machinery Directive (2006/42/EC)
The manufacturer:
Mayer Ipari és Kereskedelmi BT.
9341 Kisfalud, Georg Mayer út. 1.
Mayer GmbH & Co. KG
Maschinenbau u. Verwaltung
Poststrasse 30
89522 Heidenheim | Germany
hereby attests that the machine described in
the following:
Make: Mayer
Model: Big bale breaker
Series: 6160
Year constructed: From 2014
fulfils the safety and health requirements of the
following EU Machinery Directive:
2006/42/EC
Harmonised standards applied:
EN ISO 12100:2011
Safety of machinery - General principles for design -
Risk assessment and risk reduction
EN ISO 60204-1:2019
Safety of machinery - Electrical equipment of machines -
Part 1: General requirements
EN ISO 13849-1:2016
Safety of machinery - Safety-related parts of control
systems - Part 1: General principles for design
EN ISO 13850:2016
Safety of machinery - Emergency stop function -
Principles for design
EN ISO 13855:2010
Safety of machinery - Positioning of safeguards with
respect to the approach speeds of parts of the human
body
EN ISO 13857:2008
Safety of machinery - Safety distances to prevent hazard
zones being reached by upper and lower limbs
EN ISO 14119:2014
Safety of machinery - Interlocking devices associated
with guards - Principles for design and selection
EN ISO 4413:2011
Hydraulic fluid power. General rules and safety
requirements for systems and their components
EN ISO 349:1993+A1:2008
Safety of machinery - Minimum gaps to avoid crushing of
parts of the human body
EN ISO 14120:2016
Safety of machinery - Guards - General requirements for
the design and construction of fixed and movable guards
EN ISO 1037:1995+A1:2008
Safety of machinery - Prevention of unexpected start-up
EN ISO 14738:2009
Safety of machinery - Anthropometric requirements for
the design of workstations at machinery
EN ISO 1005-2:2003+A1:2009
Safety of machinery - Human physical performance -
Part 2: Manual handling of machinery and component
parts of machinery

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EN ISO 1005-5:2007
Safety of machinery - Human physical performance -
Part 5: Risk assessment for repetitive handling at high
frequency
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, 01.07.2022 ......................................
Managing Director

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2 General safety instructions
1. The operating organisation's duty
to take due care
The MAYER 6160 Big Bale Breaker 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. It therefore meets the state of the
art and guarantees a maximum degree of safety.
However, only if all the measures required for such
are taken can this safety be achieved in actual
operational practice. Planning these measures and
checking their implementation is subject to the
operating organisation's duty to take due care.
The operating organisation must in particular
guarantee that:
•… the machine is only used in accordance
with its intended use (cf. the Product
description 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 instructed
about all relevant matters concerning
industrial safety and environmental
protection and that they know the
Operating Instructions and especially the
safety instructions they contain.
•… none of the safety and warning signs
attached to the machine are removed and
that all remain legible.
•Users must obligate themselves only to
ever operate the machine when it is flawless
condition. No unauthorised conversions or
alterations are allowed that influence the
machine's safety.
•Only when it has stopped, must any work
ever be carried out on the machine.
•Before beginning with any work on the
machine, secure its drives and accessory parts
against being switched on unintentionally.
•The protective devices may only be removed
when the machine has been stopped.
•Local safety and accident-prevention
regulations always apply to any operation of
the machine.
•The machine may not be started if any safety
devices are removed.

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•The machine can be operated SOLELY
connected to a Mayer Potting machine. The
maximum distance between Soil breaker and
movable guards (A and B) is 50 mm
•In the working area the operator is responsible
for other people.
•In case of non-compliance with any one of
the points cited above, the manufacturer
shall be released from all liability.
2. Explanation of the safety symbols used
The safety symbols along with the text of the safety instructions
are meant to point out unavoidable residual dangers that exist
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 lives and
health of people. In addition, there might also be dangers for
machines, things or the environment.
If these instructions are not followed, then severe and even fatal
injuries may result.
This symbol indicates that entering or reaching into the area
identified by this sign is not allowed while the machine is in
operation.
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
malfunctions and damage to the machine. Property damage
and environmental damage might also come about.

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This symbol identifies instructions contributing to better
understanding of the machine information that helps you to use
the machine in optimum fashion. This symbol does not identify
safety instructions.
This symbol indicates that reaching into the area identified by
this sign is not allowed while the machine is in operation.
This symbol warn against the danger of electric shock.
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 measures
Always be sure that:
•… tight-fitting working clothes are worn at all the
workplaces.
•… it is not allowed to wear chains, rings, bracelets 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.
4. Requirements upon the operating personnel
The machine may only be operated by personnel who have
been trained for such, shown what is involved and are
authorised to do so. These individuals have to know and act in
accordance with the Operating Instructions. The respective
authorisations for the operation personnel must be clearly
prescribed.
In addition 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
activities with the machine have to read
the Operating Instructions and confirm
by their signature that they have
understood the Operating Instructions.

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3 Transport
To prevent damage to the machine as well as injuries while
transporting the machine, it is absolutely necessary to
comply with the following points:
•The transport work may only be carried out by individuals
qualified to do so, complying with the safety instructions.
•The machine may only be lifted by the supporting points
provided for such.
•Only the load-lifting devices and tackle specified here may
be used to transport the machine.
•Be sure to also read the "General 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.

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1. Dimensions and weight
Length:
330 cm
Width:
169 cm
Height:
220 cm
Weight:
1100 kg
2. Transport equipment allowed
During transports, avoid both impacts and the
formation of condensation water caused by great
temperature fluctuations.
For transport and handling with forklifts, it is
stipulated that transport equipment and lifting gear
from Mayer GmbH & Co. KG be used.
Transport equipment

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3. Transport to and at the set-up
location
The Big Bale Breaker is equipped with two solid
rubber tyres, on one axle in the front and two feet
on the base frame. A device (a hitch) or a manual
lift is provided for lifting the rear of the machine
(depending on the equipment).
When moving the machine, pay special attention to
the supply lines to the machine so as to avoid
damaging or pulling out the line by running over
them with the front wheels.
Before moving the machine, the soil hopper has
to be completely emptied.
If the machine should have to be transported
over an uneven surface, then:
•… the soil hopper has to be completely
emptied.
•… sufficient safety precautions have to be
taken to prevent the machine from sliding off in
an uncontrolled fashion.

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4 How to set up
To prevent damage to the machine as well as
injuries when setting up the machine, be absolutely
sure to comply with the following points:
•The set-up work (assembly and installation of
the machine) may only be carried out by
personnel qualified to do so, complying with
the safety instructions.
•Before beginning with the set-up work, check
the machine for any transport damage.
•Also read the section "General Safety
Instructions".
When setting up the machine, the following special
dangers have to be expected.
•Any parts of the machine incorrectly placed or
improperly attached can drop or fall over.
•There is a danger of getting injured by sharp-
edged parts of the machine still open and
accessible.
•Voltage-carrying cable ends and components
can result in injuries from electric current.
•Parts lying loosely on top of one another can
slip and fall off.
•Improperly installed lines (such as with a
bending radius that is too small) can cause
smoulder fires and cable fires.
•Lubricants or fertilisers that have escaped can
result in caustic burns on direct contact with
the skin.
1. Ambient requirements for setting up
•The ground supporting the machine should be
level and stable to avoid having the wheels or
feet sink in.
•Electrical connection: 400V/50Hz; connection
is only allowed to sockets protected by a 300-
mA differential-current switch.
•There has to be sufficient space available for
the supply work. Position upstream and
downstream machines appropriately.

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2. Stability
For the maintenance to be stable, the two support
feet have to be attached on the front of the
machine.
The rolling mechanism is only for transports within
the working area or in the greenhouse.
Before moving the machine, the support feet
have to be removed.
3. Setting up / Alignment
Transport the machine by forklift to the position
desired. Move with the hitch into the precise
alignment for filling the following machine.
Support foot, rear
Support foot, front

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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.
•Before the first start-up, check whether all the tools and
parts not belonging in 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 before the first start-up
•Are all the protective devices present?
•Was the machine damaged during transport?
•Before the initial start-up of the machine, check the
machine's connecting lead for any damage.
•Make sure that no parts that do not belong there (such as
toolboxes or the like) are in the soil hopper.
•Before connecting your machine's connecting lead to the
mains supply, set the switch on the electrical-system
cabinet to "Zero".
•Check to be sure all the supports have been extended.
•Before the initial start-up, remove the transport securing
device.
•Transport securing, please remove before installation.
(in the picture marked)

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2. Starting the machine for the first time
After you have established the connection between the mains
supply and the machine, set the master switch to "1 ON". The
control cabinet is then supplied with electric power. The master
switch is located in the door of the control cabinet.
When the "EMERGENCY SHUT-OFF" is depressed,
"CONTROL ON" is not possible!
When starting up the machine, be sure to check that the
"EMERGENCY SHUT-OFF" switches (there are two of them)
are not depressed and locked into place.
To bring the soil hopper into the loading position, push down
the HYDRAULIC LEVER (2) and hold it down until the position
is reached. If the soil hopper does not move, then the direction
of rotation has to be changed on the supply line. (Pay attention
to the direction-of-rotation arrow for the pump motor.)
Move the soil hopper into the unloading position. When
reached, the "In position" lamp will light up. Release the lever.
When you then press the "START" button, all the electric
functions on the Big Bale Breaker will be ready to operate.
The scraping chain and break-up system will begin to run (the
laser sensor must not be engaged).
Stop the scraping chain and the break-up system by moving out
of the unloading position or by pressing the "STOP" button.
3. Start Check after the first start-up
If there are no irregularities during the trial run (such as unusual
noises), the machine can be operated as described in the
section "Operation".

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6 Operation
To prevent damage to the machine as well as
injuries while operating the machine, it is absolutely
necessary to comply with the following points:
•The machine may only be used/utilised in
accordance with its intended use.
•Before switching on the machine, inform
yourself about the correct behaviour for
malfunctions.
•Before switching on the machine, carry out
operational checks of the EMERGENCY
SHUT-OFF switches.
•The machine may only be operated from the
prescribed workplaces.
•Only the operating personnel may be present
at the machine during operation.
•Also read the section "General Safety
Instructions".
1. The workplace for the operating
personnel
The workplaces are spread over various areas of
the machine.
•Filling the soil hopper with substrate from the
rear side
•Operating the hydraulic tipping mechanism on
the left-hand side.
When operating the machine and when it is in
normal operation, the following special dangers
have to be expected:
•Any types of use not in accordance with the
intended use can cause injuries to people
as well as damage to machinery to come
about.
•Incorrect behaviour in cases of malfunctions
can cause severe injuries to people as well
as damage to machinery. So, familiarise
yourself with the regulations for
malfunctions.
The responsibilities for the various activities with
the machine have to be clearly defined and
complied with!
Unclear instances of competency are a risk to
safety!

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2. Description of the control elements
2.1EMERGENCY SHUT-OFF elements
There are three EMERGENCY SHUT-OFF switches on the
machine.
They are attached on both sides of the machine.
2.2 Control cabinet
Warning signal
Empty container signal
STOP button
Malfunction
button
Emptying position lighting
button
Start of emptying button
Emergency-STOP
lighting button
Emergency-STOP button

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2.3 Control lever
1
Unloading direction
0
Standby position
2
Loading direction
Main switch