Optimum 3346245, Optimill MZ 4S Operating Manual

Operating Manual
Version 1.0.4
Milling machine
Item no. 3346245
GB
Table of contents
Safety
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
2
Technical specification
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.19
2.15
2.16
2.17
2.18
2.20
2.21
3
3.2
2
Electrical connection.................................................................................................................................... 20
Spindle seat ................................................................................................................................................. 20
Spindle drive ................................................................................................................................................ 20
Milling capacity  Milling capacity of the machine on page 41 ................................................................ 20
Vertical spindle ............................................................................................................................................ 20
Horizontal spindle ........................................................................................................................................ 21
Spindle speeds ............................................................................................................................................ 21
Table feed.................................................................................................................................................... 21
Horizontal milling table................................................................................................................................. 21
Vertical milling table..................................................................................................................................... 21
Optional pneumatic tool clamp PD 200 ....................................................................................................... 21
Dimensions -  Dimensions, Installation plan on page 24 ....................................................................... 21
Work area .................................................................................................................................................... 21
Dimensions .................................................................................................................................................. 21
Emissions .................................................................................................................................................... 22
Automatic feed - Rapid traverse .................................................................................................................. 22
Coolant equipment....................................................................................................................................... 22
Central lubrication........................................................................................................................................ 22
Environmental conditions............................................................................................................................. 22
Tools and tool holding fixtures ..................................................................................................................... 23
Dimensions, Installation plan ....................................................................................................................... 24
Delivery, interdepartmental transport, assembly and commissioning
3.1
GB
Glossary of symbols ...................................................................................................................................... 7
Rating plate.................................................................................................................................................... 7
Safety instructions (warning notes)................................................................................................................ 8
1.3.1
Classification of hazards .................................................................................................................. 8
1.3.2
Other pictograms.............................................................................................................................. 8
Intended use .................................................................................................................................................. 9
Reasonably foreseeable misuse.................................................................................................................. 10
1.5.1
Avoiding misuse ............................................................................................................................. 10
Possible dangers caused by the milling machine ........................................................................................ 11
Qualification of personnel ............................................................................................................................ 11
1.7.1
Target group................................................................................................................................... 11
1.7.2
Authorized persons ........................................................................................................................ 12
User positions .............................................................................................................................................. 13
Safety devices ............................................................................................................................................. 13
1.9.1
Lockable master switch.................................................................................................................. 14
1.9.2
Emergency-stop push button ......................................................................................................... 14
1.9.3
Control technical protection............................................................................................................ 15
1.9.4
Polycarbonate windows ................................................................................................................ 15
1.9.5
Prohibition, warning and mandatory signs ..................................................................................... 15
Safety check ................................................................................................................................................ 15
Personal protective equipment .................................................................................................................... 16
Safety during operation................................................................................................................................ 17
Safety during maintenance .......................................................................................................................... 17
Switching-off and securing the milling machine........................................................................................... 17
1.14.1 Using lifting equipment................................................................................................................... 18
1.14.2 Mechanical maintenance work....................................................................................................... 18
Accident report............................................................................................................................................. 18
Electronics ................................................................................................................................................... 18
Inspection deadlines .................................................................................................................................... 19
Clamping devices for workpieces and tools................................................................................................. 19
Environmental protection and water conservation....................................................................................... 19
Notes on transport, installation, commissioning .......................................................................................... 25
3.1.1
General risks during internal transport ........................................................................................... 25
Unpacking the machine ............................................................................................................................... 26
3.2.1
Standard accessories..................................................................................................................... 26
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3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
4
Operation
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
5
Overview ......................................................................................................................................................34
4.1.1
Control panel, spindle drive and drive, table feed...........................................................................35
4.1.2
Control panel spindle gear ..............................................................................................................36
4.1.3
Direct run .......................................................................................................................................37
Safety ...........................................................................................................................................................37
Operational modes of the machine ..............................................................................................................38
Switching on the machine ............................................................................................................................38
Switching off the machine ............................................................................................................................38
Resetting an emergency stop condition .......................................................................................................38
Power failure, Restoring readiness for operation .........................................................................................38
Stopping the machine in an emergency .......................................................................................................38
Selecting the speed ......................................................................................................................................39
4.9.1
Diagram for determining speeds.....................................................................................................39
4.9.2
Setting the spindle speed and start spindle rotation .......................................................................39
4.9.3
Diagram for determining feed rate ..................................................................................................40
Milling capacity of the machine ....................................................................................................................41
Activate / deactivate automatic table feed....................................................................................................42
4.11.1 Switching the X - Y - Z axis feed on................................................................................................42
4.11.2 Switching the X - Y - Z axis feed off................................................................................................42
4.11.3 X - Y - Z axis rapid traverse ............................................................................................................42
Turning the milling head vertically ................................................................................................................43
4.12.1 Aligning the milling head.................................................................................................................43
Fastening horizontal table ............................................................................................................................44
Clamping the tool .........................................................................................................................................45
Adjusting spindle guard ................................................................................................................................45
Optional compressed air tool clamp of the vertical spindle ..........................................................................46
Conversion to horizontal milling ...................................................................................................................46
4.17.1 Mounting counter bearing ...............................................................................................................48
4.17.2 Arbors for side milling cutter ...........................................................................................................49
4.17.3 Central lubrication...........................................................................................................................49
Conversion to vertical milling........................................................................................................................50
Coolant .........................................................................................................................................................50
DP700 Quick start guide ..............................................................................................................................51
Maintenance
5.1
5.2
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Transport ......................................................................................................................................................26
Load attachment point in unpacked condition ..............................................................................................27
Set-up and assembly....................................................................................................................................27
3.5.1
Requirements regarding the installation site...................................................................................27
Machine mounting ........................................................................................................................................28
3.6.1
Anchor-free mounting .....................................................................................................................28
3.6.2
Anchored mounting.........................................................................................................................29
First commissioning......................................................................................................................................29
One-component paint ...................................................................................................................................30
Cleaning the machine...................................................................................................................................30
3.9.1
Lubrication and oil levels ................................................................................................................30
Function testing and mounting of accessories .............................................................................................30
Warming up the machine .............................................................................................................................30
Electrical connection ....................................................................................................................................31
3.12.1 Regulated drives in connection with residual current devices ........................................................32
3.12.2 Protection from Dangerous Shock Currents, use of ELCBs ...........................................................32
3.12.3 Current in the protective earth conductor - Leakage current ..........................................................32
3.12.4 When the ELCB triggers .................................................................................................................33
5.3
5.4
Operating material........................................................................................................................................54
5.1.1
Machine lubricants..........................................................................................................................54
5.1.2
Cooling lubricants ...........................................................................................................................54
Safety ...........................................................................................................................................................55
5.2.1
Preparation .....................................................................................................................................55
5.2.2
Restarting .......................................................................................................................................55
Repair ...........................................................................................................................................................56
5.3.1
Customer service technician...........................................................................................................56
Inspection and maintenance ........................................................................................................................57
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5.5
5.6
Ersatzteile - Spare parts
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
7
Malfunctions
8
Appendix
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
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4
Ersatzteilbestellung - Ordering spare parts ................................................................................................. 72
Hotline Ersatzteile - Spare parts Hotline...................................................................................................... 72
Service Hotline............................................................................................................................................. 72
Elektrische Ersatzteile - Electrical spare parts............................................................................................. 72
Schaltplan - Wiring diagram......................................................................................................................... 72
Getriebe allgemein - General gear box........................................................................................................ 73
Allgemeine Kreuzschlittenanordnung - General cross slide assembly ........................................................ 75
Horizontales / Vertikales Spindelsystem - Horizontal / vertical spindle system ........................................... 76
Vertikales Spindelgetriebe - Vertical spindle transmission .......................................................................... 78
Vertikale Spindelbaugruppe - Vertical spindle assembly............................................................................. 79
Handgriff Spindelsystem - Spindle handle system ...................................................................................... 80
Baugruppe Frästisch - Working table assembly .......................................................................................... 81
Handradsystem - Handle wheel system ...................................................................................................... 83
Baugruppe Maschinenrahmen - Machine frame assembly ......................................................................... 84
Getriebesystem Z Achse - Z axis transmission system ............................................................................... 85
Getriebesystem Y Achse - Y axis transmission system............................................................................... 86
Sattelbaugruppe - Machine saddle assembly.............................................................................................. 87
Horizontales Gegenlager - Horizontal steady device................................................................................... 89
Werkzeuge Horizontalbearbeitung - Horizontal tools list ............................................................................. 90
Schutzabdeckungen und Blechteile - Protective covers and sheet metal parts .......................................... 91
Zentralschmierung - Lubrication System ..................................................................................................... 92
Kühlmittelpumpe und Arbeitsleuchte - Cooling pump and work lamp ......................................................... 93
Dreharm Bedienfeld - Rotate Arm Operation Panel .................................................................................... 94
Schaltplan - Wiring diagram......................................................................................................................... 96
Option Druckluft Werkzeugspanner - Compressed air tool spanner option............................................... 102
Zubehör - Accessories............................................................................................................................... 105
Copyright ................................................................................................................................................... 112
Changes .................................................................................................................................................... 112
Product follow-up ....................................................................................................................................... 112
Liability claims for defects / warranty ......................................................................................................... 112
Storage ...................................................................................................................................................... 113
Advice for disposal / Options of re-use ...................................................................................................... 114
8.6.1
Decommissioning......................................................................................................................... 114
8.6.2
Disposal of new device packaging ............................................................................................... 114
8.6.3
Disposal of the machine............................................................................................................... 114
8.6.4
Disposal of electrical and electronic components ........................................................................ 114
8.6.5
Disposal of lubricants and coolants.............................................................................................. 115
Disposal through municipal collection facilities.......................................................................................... 115
Terminology/Glossary................................................................................................................................ 115
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5.4.1
Cleaning the chip tray .................................................................................................................... 60
5.4.2
Cleaning and replacing of the polycarbonate windows .................................................................. 60
5.4.3
Cleaning the electrical cabinet ....................................................................................................... 61
5.4.4
Refilling the oil in the central lubrication system ............................................................................ 61
5.4.5
Lubricating the vertical milling head ............................................................................................... 62
5.4.6
Ball screw, X axis ........................................................................................................................... 62
5.4.7
Ball screw, Y axis ........................................................................................................................... 63
5.4.8
Ball screw, Z axis ........................................................................................................................... 63
5.4.9
Filling, checking oil tank, main gear ............................................................................................... 64
5.4.10 Checking, filling oil tank, horizontal spindle.................................................................................... 64
5.4.11 Clearance adjustment of the guide of the machine stand in the Z axis.......................................... 65
5.4.12 Play adjustment of the guide in the X axis ..................................................................................... 66
5.4.13 Play adjustment of the guide in the Y axis ..................................................................................... 67
5.4.14 Adjusting the spindle bearing ......................................................................................................... 68
5.4.15 Maintenance and replacement of the wiper ................................................................................... 69
5.4.16 Cleaning the cooling lubricant tank ................................................................................................ 69
Recommended wearing parts...................................................................................................................... 69
Cooling lubricants and tanks........................................................................................................................ 70
5.6.1
Inspection plan for water-mixed cooling lubricants ........................................................................ 71
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Change information operating manual .......................................................................................................116
Example accuracy report............................................................................................................................118
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8.10
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Preface
Dear customer,
Thank you very much for purchasing a product made by OPTIMUM.
OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions
and convince by an outstanding price performance ratio. Continuous enhancements and product innovations guarantee state-of-the-art products and safety at any time.
Before commissioning the machine please thoroughly read these operating instructions and get
familiar with the machine. Please also make sure that all persons operating the machine have
read and understood the operating instructions beforehand.
Keep these operating instructions in a safe place nearby the machine.
Information
The operating instructions include indications for safety-relevant and proper installation, operation and maintenance of the machine. The continuous observance of all notes included in this
manual guarantee the safety of persons and of the machine.
The manual determines the intended use of the machine and includes all necessary information
for its economic operation as well as its long service life.
In the paragraph "Maintenance" all maintenance works and functional tests are described which
the operator must perform in regular intervals.
The illustration and information included in the present manual can possibly deviate from the
current state of construction of your machine. Being the manufacturer we are continuously seeking for improvements and renewal of the products. Therefore, changes might be performed
without prior notice. The illustrations of the machine may be different from the illustrations in
these instructions with regard to a few details. However, this does not have any influence on
the operability of the machine.
Therefore, no claims may be derived from the indications and descriptions. Changes and errors
are reserved!
Your suggestion with regard to these operating instructions are an important contribution to
optimising our work which we offer to our customers. For any questions or suggestions for
improvement, please do not hesitate to contact our service department.
If you have any further questions after reading these operating instructions and you are
not able to solve your problem with a help of these operating instructions, please
contact your specialised dealer or directly the company OPTIMUM.
Optimum Maschinen Germany GmbH
Dr.- Robert - Pfleger - Str. 26
D-96103 Hallstadt
Fax (+49)0951 / 96555 - 888
Email:
[email protected]
_preface_GB.fm
Internet: www.optimum-machines.com
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1
Safety
This part of the operating instructions
 explains the meaning and use of the warning notes included in these operating instructions,
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 defines the intended use of the milling machine,
 points out the dangers that might arise for you or others if these instructions are not obser-
ved,
 informs you about how to avoid dangers.
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In addition to these operating instructions, please observe
 the applicable laws and regulations,
 the statutory provisions for accident prevention,
 the prohibition, warning and mandatory signs as well as the warning notes on the milling
machine.
Always keep this documentation close to the milling machine.
1.1
Glossary of symbols
 provides further instructions
 calls on you to act
 listings
1.2
Rating plate
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Safety
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1.3
Safety instructions (warning notes)
1.3.1
Classification of hazards
We classify the safety warnings into different categories. The table below gives an overview of
the classification of symbols (ideogram) and the warning signs for each specific danger and its
(possible) consequences.
Symbol
Alarm expression
Definition / consequence
DANGER!
Impending danger that will cause serious injury or death to people.
WARNING!
A danger that can cause serious injury or death.
CAUTION!
A danger or unsafe procedure that can cause personal injury or damage
to property.
Situation that could cause damage to the milling machine and product, as
well as other types of damage.
ATTENTION!
No risk of injury to persons.
Practical tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.
INFORMATION
In case of specific dangers, we replace the pictogram with
general danger
GB
8
injury to hands,
hazardous electrical
voltage,
rotating parts.
Other pictograms
Activation forbidden!
Do not step into the
machine!
Do not extinguish with
water!
Do not clean with
compressed air!
Wear safety shoes!
Use ear protection!
Wear protective glasses!
Wear protective gloves!
MZ4S_GB_1.fm
1.3.2
with a warning of
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Warning: biological hazard!
Warning: suspended loads!
Warning of oxidizing
substances!
Caution, danger of
explosive substances!
Oil outlet
Protect the environment!
Contact address
Warning: danger of
slipping!
Filling position: oil
1.4
Intended use
WARNING!
In the event of improper use, the milling machine
 may be a hazard to personnel,
 the machine and other property of the operating company and
 the functionality of the milling machine may be compromised.
The milling machine is designed and manufactured to be used for milling and drilling cold
metals or other non-flammable materials or materials that do not constitute a health hazard
when commercial milling and drilling tools are used.
Using this machine it is possible to perform dry processing as well as processing by using cooling lubricants.  Cooling lubricants on page 54
The limit values of the balances of the tools need to be observed. Tools and tool holding fixtures on page 23
The milling machine must only be installed and operated in a dry and well-ventilated areas.
The milling machine is designed and manufactured to be used in a non-explosive environment.
If the milling machine is used in any way other than described above, or modified without the Intended use
approval of Maschinen Germany GmbH, then the milling machine is being used improperly.
We will not be held liable for any damages resulting from any operation which is not in accordance with the intended use.
We expressly point out that the guarantee or CE conformity will expire, if any constructive, technical or procedural changes are not performed by the company Optimum Maschinen Germany
GmbH.
It is also part of the intended use that you
MZ4S_GB_1.fm
 the limits of performance of the milling machine are observed,
 the operating manual is observed,
 the inspection and maintenance instructions are observed.
WARNING!
Severe injuries due to non-intended use.
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It is forbidden to make any modifications or alternations to the operating parameters
values of the milling machine. They could pose an accident hazard to persons and cause
damage to the milling machine.
1.5
Reasonably foreseeable misuse
Any other use other than that specified under "Intended use" or any use beyond the described
use shall be deemed as non-intended use and is not permissible.
Any other use has to be discussed with the manufacturer.
It is only permissible to process metal, cold and non-inflammable materials with the milling
machine.
In order to avoid misuse, it is necessary to read and understand the operating instructions
before first commissioning.  Operational modes of the machine on page 38
Operators must be qualified.
1.5.1
Avoiding misuse
INFORMATION
The milling machine is built to comply with EMC Class C2 to EN 61800-3. The control and drive
components of the milling machine are approved for industrial and commercial use in industrial
supply networks. Use in public supply networks requires a different configuration and/or
additional measures.
WARNING!
Class C (machine tools) is not intended for use in residential buildings, in which the
power supply is provided via a public low voltage supply system. In these areas it may
possibly be difficult to guarantee electromagnetic compatibility due to lead bound as
well as emitted interferences.
 Use of suitable cutting tools.
 Adapting the speed setting and feed to the material and workpiece.
 Clamp workpieces firmly and free of vibration.
 Risk of fire and explosion due to the use of flammable materials or cooling lubricants.
Before processing inflammable materials (e.g. aluminium, magnesium) or using inflammable auxiliary materials (e.g. spirit), you need to take additional preventive measures in
order to avoid health risks.
 When processing carbons, graphite and carbon-fibre-reinforced carbons, the machine is no
longer being used as intended. This causes the warranty to be null and void. When processing carbons, graphite and carbon-fibre-reinforced carbons and similar materials, the
machine can be damaged extremely quickly, even if the dusts generated are completely
sucked out during the work process.
ATTENTION!
The workpiece is always to be fixed by a machine vice, jaw chuck or by another
appropriate clamping tool such as for the clamping claws.
WARNING!
Risk of injury caused by flying workpieces.
 Use cooling and lubricating agents to increase the durability of the tool and to improve the
surface quality.
 Clamp the cutting tools and workpieces on clean clamping surfaces.
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10
MZ4S_GB_1.fm
Clamp the workpiece in the machine vice. Make sure that the workpiece is firmly clamped in the
machine vice and that the machine vice is firmly clamped onto the machine table.
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 Sufficiently lubricate the machine.
WARNING!
Do not use the quick action drill chuck for milling tools. Never clamp a milling cutter into
a quick action drill chuck. Use a collet chuck with collets for the end mill.
When milling make sure that
 the corresponding cutting speed is selected,
 for workpieces with normal strength values, e.g. steel 18-22 m/min,
 for workpieces with high strength values, 10-14 m/min,
 for hard materials commercial cooling / lubricating agents are used.
1.6
Possible dangers caused by the milling machine
The milling machine has been tested for operational safety. The construction and type are state
of the art.
Nevertheless, there is a residual risk, as the milling machine operates with
 rotating parts,
 electrical voltage and currents,
 and an automatic feed.
We have used design and safety engineering to minimize the health risk to personnel resulting
from these hazards.
If the milling machine is used and maintained by personnel who are not duly qualified, there
may be a risk resulting from its incorrect or unsuitable maintenance.
INFORMATION
Everyone involved in the assembly, commissioning, operation and maintenance must
 be duly qualified,
 and strictly follow these operating instructions.
In the event of improper use
 there may be a risk to personnel,
 the milling machine and other property and
 the functionality of the milling machine may be compromised.
Always switch off the milling machine and disconnect it from the mains, when cleaning or maintenance work is carried out.
WARNING!
The milling machine may only be used with fully functional safety devices. Disconnect
the milling machine immediately, whenever you detect a failure in the safety devices or
when they are not fitted!
All additional parts of the machine which had been added by the customer need to be
equipped with the prescribed safety devices.
This is your responsibility being the operating company!  Safety devices on page 13
1.7
Qualification of personnel
1.7.1
Target group
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This manual is addressed to
 the operating companies,
 operators having sufficient specialist knowledge,
 the maintenance personnel.
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Consequently, the warning notes refer both to the use of the milling machine and to its maintenance.
Determine clearly and explicitly who will be responsible for the different activities on the milling
machine (operation, setting up, maintenance and repair). Please note the name of the responsible person into an operators´s log.
INFORMATION
Unclear responsibilities constitute a safety risk!
Always lock the main switch after switching off the milling machine. This will prevent it from
being used by unauthorized persons.
The qualifications of the personnel for the different tasks are mentioned below:
Operator
The operator has been instructed by the operating company regarding the assigned tasks and
possible risks in case of improper behaviour. Any tasks which need to be performed beyond the
operation in standard mode must only be performed by the operator, if so indicated in these
instructions and if the operator has been expressively commissioned by the operating company.
Qualified electrician
With professional training, knowledge and experience as well as knowledge of respective standards and regulations, qualified electricians are able to perform work on the electrical system
and recognise and avoid any possible dangers.
Qualified electricians have been specially trained for the working environment, in which they are
working and know the relevant standards and regulations.
Qualified personnel
Due to their professional training, knowledge and experience as well as knowledge of relevant
regulations, qualified personnel are able to perform the assigned tasks and to independently
recognise and avoid any possible dangers.
Instructed person
Instructed persons were instructed by the operating company regarding the assigned tasks and
any possible risks of improper behaviour.
1.7.2
Authorized persons
INFORMATION
Sufficient expertise is required for working on the milling machine. No one must work on
the machine without having the necessary training, not even for a short while.
WARNING!
Inappropriate operation and maintenance of the milling machine constitutes a danger to
the personnel, objects and the environment.
Only authorized personnel may operate the milling machine !
Persons authorized to operate and maintain should be trained technical personnel and
instructed by the ones who are working for the operating company and for the manufacturer.
 train the personnel,
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12
Obligations of the
operating
company
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Obligations of the operating company
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 instruct the personnel in regular intervals (at least once a year) on





- all safety regulations relevant to the milling machine,
- operation of the milling machine,
- generally accepted engineering standards.
- possible emergency situations,
check the personnel‘s knowledge level,
document training/instruction in a operation book,
require personnel to confirm participation in training/instructions by means of a signature,
check whether the personnel is working safety and risk-conscious and observes the operating instructions.
Define and document the machine inspection deadlines in accordance with section 3 of the
Factory Safety Order and perform an operational risk analysis in accordance with section 6
of the Safety at Work Act.
Obligations of the user
 have obtained a training regarding the handling of the milling machine,
 keep an operator‘s log,
 before taking the machine in operation
- have read and understood the operating manual,
- be familiar with all safety devices and instructions.
For work on the following milling machine parts there are additional requirements:
 Electric components or operating materials: Must only be worked on by a qualified electri-
cian or person working under the instructions and supervision of a qualified electrician.
1.8
Obligations of the
operator
Additional
requirements
regarding the
qualification
User positions
The operator position is located in front of the milling machine at the inspection window, to the
side of the automatic feed for the cross table or on the control panel.
1.9
Safety devices
The milling machine must only be operated with fully functional safety devices.
Stop the milling machine immediately if there is a failure on the safety device or becomes ineffective.
This is your responsibility!
If a safety device has been activated or has failed, the milling machine must only be used if you
 have eliminated the cause of the fault and
 you have verified that there is no danger to personnel or objects.
WARNING!
If you bypass, remove or override a safety device in any other way, you are endangering
yourself and other persons working with the milling machine. The possible
consequences include:
 injuries due to tools, workpieces or fragments hereof which are flying off at high
speed,
 contact with rotating or moving parts,
 fatal electrocution,
 pulling-in of clothes.
MZ4S_GB_1.fm
WARNING!
Although the isolating safety devices provided and delivered with the machine are
designed to reduce the risks of workpieces being ejected or parts of tools or workpieces
breaking off, they cannot eliminate these risks completely. Always work carefully and
observe the limits of the machining process.
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The milling machine features the following safety devices:
 a lockable main switch,
 two emergency stop push buttons,
 a spindle guard for drilling with the spindle sleeve lever,  Adjusting spindle guard on
page 45
 a horizontal and vertical milling table with T-slots to fix the workpiece or the clamping
device.  Fastening horizontal table on page 44
 A chip and spray guard around the horizontal milling table.
CAUTION!
When milling with the vertical milling table - horizontal table is dismantled, chip and
spray guard is dismantled - e.g. when mounting a dividing apparatus on the vertical table
- , the machine operator must take additional precautions to ensure safe operation.
INFORMATION
When drilling with the spindle sleeve lever on the milling head, the spindle guard on the
milling head must be set and closed.
When milling with the automatic feed, the chip and spray guard around the milling table
must be closed.
When using the cooling lubricant pump, the chip and spray guard must always be
closed.
1.9.1
Lockable master switch
In the "0" position, the lockable main switch can be secured against accidental or non-authorised switching on by means of a padlock.
The power supply is cut off when the master switch is in the off position.
Except for the areas marked by the pictogram in the margin. In these areas there might be
voltage, even if the master switch is switched-off.
WARNING!
Dangerous voltage even if the main switch is switched off.
The areas marked by the pictogram might contain live parts, even if the master switch is switched off.
1.9.2
Emergency-stop push button
ATTENTION!
If a emergency-stop push button is activated, the drives are stopped with the maximum
possible braking torque. The spindle drive continues to run for a while depending on the
moment of inertia of all components and the mass of the tool in use.
Press the emergency stop button only if there is a risk! If this push button is actuated in
order to switch off the milling machine in the standard operation the tool or workpiece
might get damaged.
MZ4S_GB_1.fm
After having actuated the emergency-stop mushroom switch, turn the knob of the particular
push button to the right in order to restart the machine.
GB
14
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Abb.1-1:
Emergency-stop pushbutton
1.9.3
Control technical protection
WARNING!
If you bypass a controller you endanger yourself and other persons working on the
milling machine.
 injuries due to tools, workpieces or fragments hereof which are flying off at high
speed,
 contact with rotating parts,
 fatal electrocution,
 pulling-in of clothes.
If you temporarily bypass a controller in exceptional cases (e.g. during electrical repairs), you
must continuously monitor the milling machine.
1.9.4
Polycarbonate windows
Polycarbonate inspection windows, which have a safety-critical protective function in respect of
flying parts, must be visually inspected at regular intervals by responsible personnel provided
by the customer in order to guarantee the operational safety of the milling machine.
Polycarbonate viewing panes are subject to an ageing process and are classified as wear
parts.
The ageing of polycarbonate windows can not be detected by visual inspection. It is therefore
necessary to replace the polycarbonate windows after a certain time.
Prolonged exposure from polycarbonate windows to cutting fluids can lead to accelerated
ageing, i.e. deterioration of the mechanical properties (brittleness). Coolant vapours, detergents, greases and oils or other corrosive substances from the operator side can also lead to a
deterioration of the polycarbonate windows. The result in reduced impact resistance of the polycarbonate windows.
 Cleaning and replacing of the polycarbonate windows on page 60
1.9.5
Prohibition, warning and mandatory signs
INFORMATION
All warning and mandatory signs must be legible. They must be checked regularly.
MZ4S_GB_1.fm
1.10
Safety check
Check the milling machine at least once per shift. Inform the person responsible immediately of
any damage, defects or changes in the operating function.
Check all safety devices
 at the beginning of each shift (when the machine is operated continuously),
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 once per day (during one-shift operation),
 once per week (when operated occasionally),
 after all maintenance and repair work.
Check that prohibition, warning and information signs and the labels on the milling machine
 are legible (clean them, if necessary)
 and complete (replace them, if necessary).
INFORMATION
Organise the checks according to the following table;
General check
Equipment
Check
OK
Protective covers
Firmly bolted and not damaged
Signs, Markings
Installed and legible
Sight window
Check for mechanical damage (scratches, cracks) 
Polycarbonate windows on page 15
Date:
Checked by (signature):
Functional check
Equipment
Check
Emergency-stop
push button
After actuating an emergency stop push button the milling
machine must be switched off.
Switch cabinet cooling
The cabinet cooling must be running.
Spindle guard
The spindle drive can only be switched on if the spindle
guard is in the machining position.
Date:
Checked by (signature):
1.11
OK
Personal protective equipment
For certain work personal protective equipment is required.
Protect your face and your eyes: Wear a safety helmet with facial protection when performing
work where your face and eyes are exposed to hazards.
Wear protective gloves when handling pieces or tools with sharp edges.
Wear safety shoes when you assemble, disassemble or transport heavy components.
Use ear protectors if the noise level (emission) in the workplace exceeds 80 dB (A).
Before starting work make sure that the required personnel protective equipment is available at
the work place.
Dirty or contaminated personnel protective equipment can cause illness. It must be
cleaned after each use and at least once a week.
GB
16
MZ4S_GB_1.fm
CAUTION!
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1.12
Safety during operation
WARNING!
Before switching the milling machine on, make sure that there is no risk of personal
injury or damage to property.
Avoid any unsafe work methods:
 The instructions mentioned in these operating instructions have to be strictly observed
during assembly, operation, maintenance and repair.
 Do not work on the milling machine, if your concentration is reduced, for example, because
you are taking medication.
 Clamp the workpiece securely and firmly before switching on the milling machine.
WARNING!
When chipping magnesia materials (aluminium-/magnesium alloys), spontaneously
inflammable or explosive particles (powder, dust, chips) might be generated, which
might cause a fire and/or explosion (deflagration).
Magnesium is designated a dangerous material in the list of dangerous materials and
preparations according to para. 4a of the Ordinance of Hazardous Substances.
In case of a fire with magnesium, only use appropriate and admitted extinguishing
agents. Never extinguish using water. If burning magnesium is extinguished with water,
this might lead to dangerous reactions (hydrogen gas). Water would be decomposed in
its components hydrogen (H) and oxygen (O).
Only the following extinguishing agents are permissible:
solid extinguishing agent of fire class D (fires involving metals)
dry covering salts for magnesium
a mixture of sand and cast chips
argon (Ar) or nitrogen (N2)




If fine mist and smoke is generated at the workplace, suction units must be provided in
order to avoid the accumulation of ignitable mixtures and emissions.
We specifically point out the dangers in the description of work with and on the drilling machine.
1.13
Safety during maintenance
Inform the operators in good time of any maintenance and repair works.
Report all safety relevant changes and performance details of the milling machine or their operational behaviour. Any changes must be documented, the operating instructions updated and
machine operators instructed accordingly.
1.14
Switching-off and securing the milling machine
Turn off the main switch of the milling machine before starting any maintenance or repair work.
Use a padlock to prevent the switch from being turned on without authorization and keep the
key in a safe place.
All machine parts as well as all dangerous voltages are switched off.
Excepted are only the positions which are marked with the adjoining pictogram. These positions
may be live, even if the main switch is switched off.
Place a warning sign on the milling machine.
MZ4S_GB_1.fm
WARNING!
Live parts and moves of machine parts can injure you or others dangerously!
Proceed with extreme caution if you
the milling machine due to required works (e.g. functional control).
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1.14.1 Using lifting equipment
WARNING!
The use of unstable lifting and load suspension equipment that might break under load
can cause severe injuries or even death. Observe the accident prevention regulations
issued by your Employers Liability Insurance Association or other supervisory
authorities responsible for your company.
Check that the lifting and load-suspension equipment are of sufficient load-bearing
capability and are in perfect condition. Fasten the loads carefully. Never walk under
suspended loads!
1.14.2 Mechanical maintenance work
Remove or install protective safety devices before starting or after completing any maintenance work; this include:
 covers,
 safety instructions and warning signs,
 grounding cables.
If you remove protective or safety devices, re-fit them immediately after the completing the
work.
Check if they are working properly!
1.15
Accident report
Inform your supervisors and Optimum Maschinen Germany GmbH immediately in the event of
accidents, possible sources of danger and any actions which almost led to an accident (near
misses).
There are many possible causes for "near misses".
The sooner they are notified, the quicker the causes can be eliminated.
INFORMATION
We provide information about the specific dangers when working with and on the milling
machine in the descriptions for these types of work.
1.16
Electronics
Have the machine and/or the electric equipment checked regularly. Immediately eliminate all
defects such as loose connections, defective wires, etc.
A second person must be present during work on live components to disconnect the power in
the event of an emergency. Disconnect the machine immediately if there is a malfunction in the
power supply!
Comply with the required inspection intervals in accordance with the factory safety directive,
operating equipment inspection.
The operator of the machine must ensure that the electrical systems and operating equipment
are inspected with regards to their proper condition, namely,
 by a qualified electrician or under the supervision and direction of a qualified electrician,
prior to initial commissioning and after modifications or repairs, prior to recommissioning
 and at set intervals.
The relevant electro-technical rules must be followed during the inspection.
The inspection prior to initial commissioning is not required if the operator receives confirmation from the manufacturer or installer that the electrical systems and operating equipment comply with the accident prevention regulations, see conformity declaration.
GB
18
MZ4S_GB_1.fm
The intervals must be set so that foreseeable defects can be detected in a timely manner, when
they occur.
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Permanently installed electrical systems and operating equipment are considered constantly
monitored if they are continually serviced by qualified electricians and inspected by means of
measurements in the scope of operation (e.g. monitoring the insulation resistance).
1.17
Inspection deadlines
Define and document the inspection deadlines for the machine in accordance with § 3 of the
Factory Safety Act and perform an operational risk analysis in accordance with § 6 of the Work
Safety Act. The inspection intervals in the maintenance section should be used as reference
values.
1.18
Clamping devices for workpieces and tools
ATTENTION!
Attention when taking over existing clamping devices. Pleased thoroughly check that the
clamping device is appropriate for your milling machine.
 Only use clamping devices with a complete inherent rigidity.
 Contact the manufacturer of the clamping device regarding the reuse of clamping
devices after damage to the clamping device due to collisions.
 Correctly insert the workpiece and make sure that the machine is proper working
condition.
1.19
Environmental protection and water conservation
The milling machine is a device to produce, handle and use materials which are hazardous to
water according to para. 19g of the Water Resources Law.
MZ4S_GB_1.fm
Please follow the requirements of the Water Resources Law when operating, decommissioning
or disassembling the milling machine or parts hereof. Detailed information regarding this can be
found in the Ordinance on Installations for the Handling of Substances Hazardous to Water
(VAwS).
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2
Technical specification
The following information represents the dimensions and indications of weight and the manufacturer‘s approved machine data. The calculated envisaged life of the machine to EN ISO
13849 and EN ISO 12100 is at least 10 years with a daily operation of 8h at 220 working days
per year when keeping to the ambient conditions, proper use and keeping to the required maintenance intervals. Safety-related replacement parts are included in this calculation. Normal
replacement parts such as, for example, bearings, are not part of this calculation.
2.1
Electrical connection
Total connection
3 x 400V ~ 50Hz 5.4 kW
Cross section connection cable according to DIN 5710/
VDE 0100
4 x 2 mm2
Fusing performed by the operator
16 A
Operating mode, duty cycle
S6 - 60%
2.2
Spindle seat
Spindle seat
ISO 40 DIN 2080
Draw bar
M16
Ø 63
16.1
Ø 25.3
Ø 44.45
M16
max. 22.5
32
93.4
1.6
10
GB
20
Spindle drive
Power at 100% / 40% ED
3.75 / 4.0 KW
Speed
30 - 2250 min-1
Spindle torque at 1750 rpm
368 Nm
2.4
Milling capacity  Milling capacity of the machine on page 41
2.5
Vertical spindle
Spindle seat
ISO 40
Distance between spindle nose - cross table [mm]
40 - 440
Throat max. [mm]
185
Spindle sleeve travel [mm]
120
Vertical rotation range
± 90°
MZ4S_GB_2.fm
2.3
Technical specification
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2.6
Horizontal spindle
Spindle seat
ISO 40
Distance horizontal spindle - cross table [mm]
130 - 390
2.7
2.8
2.9
2.10
2.11
2.12
MZ4S_GB_2.fm
2.13
Spindle speeds
Speeds
 „Img.4-2: Speed table“ on page 36
Gear stages
18
Table feed
max. X axis travel
(cross table, manual travel))
560 mm
( 600 mm )
max. Z axis travel
(cross table, manual travel)
350 mm
( 390 mm )
max. Y axis travel
(cross table, manual travel)
440 mm
( 480 mm )
Feed force
1600N
Horizontal milling table
Table length [mm]
900
Table width [mm]
500 mm
T-slot size / distance / number
14 mm / 63 mm / 7
max. load horizontal cross table
360 kg
Scale on the X axis handwheel (cross table)
5 mm/rev - graduation 0.02 mm
Scale on the Y axis handwheel (milling head)
5 mm/rev - graduation 0.02 mm
Scale on the Z axis handwheel (cross table)
2.5 mm/rev - graduation 0.02 mm
Vertical milling table
max. load [ Nm ↓ ]
1800
Table size [ mm ]
250 x 1200
T-slot size / distance / number
14 mm / 63 mm / 3
Optional pneumatic tool clamp PD
200
Compressed air supply
0.62 MPa (6.2 bar)
Air motor torque
183 Nm
Dimensions -  Dimensions, Installation plan on page 24
Total weight [kg]
1890
Floor loading
10 KN m2
Work area
Keep a work area of at least one metre around the machine free for operation and maintenance.
2.14
Dimensions
Technical specification
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 Dimensions, Installation plan on page 24
2.15
2.16
2.17
2.18
2.19
Automatic feed - Rapid traverse
Feed [ mm/min ]
50 - 450
Feed axis
X│Z│Y
Rapid traverse rate [ mm/min ]
780
Coolant equipment
Power of the cooling lubricant pump [ W ]
100
Delivery volume [ L / min ]
25
Capacity cooling lubricant tank [ L ]
42
Delivery height [ meter ]
3
Central lubrication
Supply of lubrication points
automatic
Tank capacity
2
Interval of time
infinitely adjustable
Environmental conditions
Temperature
19 - 21 °C (for an optimum milling result)
permissible range + 10° to + 35°C
Admissible relative humidity
5...90 % no condensation
30% to 90% at 35°C
90 % at 21°C
Compressed air
700...1060 hPa
Environmental conditions - storage
5 ~ 45 °C
Emissions
Measurement in operating conditions in accordance with DIN ISO 8525 with surface areas
Measurement methods in accordance with DIN 45635.
The generation of noise emitted by the machine is 79 dB(A) on no-load running at 80% of max.
spindle speed and activated automatic feed on no-load running at 80% of the possible feed
speed, measured at a distance of one meter from the machine and at a height of 1.6m.
If the milling machine is installed in an area where various machines are in operation, the noise
exposure (immission) on the operator of the milling machine at the working place may exceed
80 dB(A).
INFORMATION
Furthermore, the noise emission also depends on production engineering factors, e.g. speed,
material and clamping conditions.
GB
22
MZ4S_GB_2.fm
This numerical value was measured on a new machine under the operating conditions specified
by the manufacturer. The noise behaviour of the machine might change depending on the age
and wear of the machine.
Technical specification
MZ4S
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INFORMATION
The specified numerical value represents the emission level and does not necessarily a safe
working level.
Though there is a dependency between the degree of the noise emission and the degree of the
noise disturbance it is not possible to use it reliably to determine if further precaution measures
are required or not.
The following factors influence the actual degree of the noise exposure of the operator:
 Characteristics of the working area, e.g. size or damping behaviour,
 other noise sources, e.g. the number of machines,
 other processes taking place in proximity and the period of time, during which the operator
is exposed to the noise.
Furthermore, it is possible that the admissible exposure level might be different from country to
country due to national regulations.
This information about the noise emission should, however, allow the operator of the machine
to more easily evaluate the hazards and risks.
CAUTION!
Depending on the overall noise exposure and the basic threshold values, machine
operators must wear appropriate hearing protectors.
We generally recommend the use of noise and ear protection.
2.20
Tools and tool holding fixtures
CAUTION !
When using tools with larger diameters or at higher speeds!
The balancing of the tools has to amount to
 0 - 6000 rpm - G 6.3
 from a speed of 6000 rpm - G 2.5
MZ4S_GB_2.fm
according to DIN / ISO 1940.
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2.21
Dimensions, Installation plan
MZ4S_GB_2.fm
Center of gravity
GB
24
Technical specification
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3
Delivery, interdepartmental transport, assembly and
commissioning
3.1
Notes on transport, installation, commissioning
Improper transport, installation and commissioning is liable to accidents and can cause damage
or malfunctions to the machine for which we do not assume any liability or guarantee.
Transport the scope of delivery secured against shifting or tilting with a sufficiently dimensioned industrial truck or a crane to the installation site.
WARNING!
Severe or fatal injuries may occur if parts of the machine tumble or fall down from the
forklift truck or from the transport vehicle. Follow the instructions and information on the
transport box.
Note the total weight of the machine. The weight of the machine is indicated in the "Technical data" of the machine. When the machine is unpacked, the weight of the machine
can also be read on the rating plate.
Only use transport devices and load suspension gear that can hold the total weight of
the machine.
WARNING!
The use of unstable lifting and load suspension equipment that might break under load
can cause severe injuries or even death. Check that the lifting and load suspension gear
has sufficient load-bearing capacity and that it is in perfect condition.
Observe the accident prevention regulations issued by your Employers Liability Insurance Association or other competent supervisory authority, responsible for your company. Fasten the loads properly.
3.1.1
General risks during internal transport
WARNING: TILTING DANGER!
The machine may be lifted unsecured by a maximum of 2 cm.
Employees must be outside the danger zone, i.e. the reach of the load.
Warn employees and advise them of the hazard.
Machines may only be transported by authorized and qualified persons. Act responsibly during
transport and always consider the consequences. Refrain from daring and risky actions.
Gradients and descents (e.g. driveways, ramps and the like) are particularly dangerous. If such
passages are unavoidable, special caution is required.
Before starting the transport check the transport route for possible danger points, unevenness
and faults.
Danger points, unevenness and disturbance points must be inspected before transport. The
removal of danger spots, disturbances and unevenness at the time of transport by other
employees leads to considerable dangers.
in-house_transport_en.fm
Careful planning of interdepartmental transport is therefore essential.
Delivery, interdepartmental transport, assembly and commissioning
EN
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25
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3.2
Unpacking the machine
INFORMATION
The milling machine is delivered pre-assembled. It is delivered in a transport box. After the
unpacking and the transportation to the installation site it is necessary to mount and assemble
the individual components of the milling machine.
Install the machine close to its final position before unpacking. If the packaging shows signs of
having possibly been damaged during transport, take the appropriate precautions to prevent
the machine being damaged when unpacking. If damage is discovered, the carrier and/or shipper must be notified immediately so the necessary steps can be taken to register a complaint.
Examine the complete machine carefully and check whether all materials, such as shipping
documents, instructions and accessories have been delivered with the machine.
3.2.1
-
3.3
Standard accessories
1 x Oil bottle for oil cups
1x grease gun for grease nipple
3 x Open-ended spanner (2)
1 set Allen key (3)
1 x Hand lever for spindle sleeve feed (4)
1 x Philips and flat screwdriver (5)
1 x ISO 40 - MT3 adapter (6)
1 x MT2 morse taper (7)
9
1 x MT1 morse taper (8)
1 x drill drift for morse taper (9)
Adjusting discs and adjusting screws (10)
Dirt cover: drive
Vertical spindles (11)
ISO 40 Collet chuck with 7 pcs collet
6, 8,10,12,16,20,25mm (12)
 Arbors for side milling cutter on page
49
Control cabinet key
Test report machine accuracy
Operating instructions in printed form
1
4
11
2
6
10
5
7
8
3
12
Transport
 Weights
 Requirements regarding the installation site on page 27
Weight of the milling machine 1890 kg
MZ4S_GB_3.fm
2.5 t
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3.4
Load attachment point in unpacked condition
WARNING!
Before lifting the milling machine, check that all clamping screws of the milling table and
the spindle head are tightened.
The milling machine is lifted by both eyebolts using a fork-lift truck or crane.
 Screw the two eyebolts included in the delivery into the milling head.
 The clamping screws of the milling table and the spindle head bearing must be tightened.
Eyebolts
Abb.3-1: Load suspension point
3.5
Set-up and assembly
 Dimensions, Installation plan on page 24
3.5.1
Requirements regarding the installation site
Keep a work area of at least one metre around the machine free for operation and maintenance.
In order to achieve sufficient safety against falls by slipping, the accessible area in the mechanical machining zone of the machine must be equipped with a slip resistance. The slip resistant
mat and/or the slip resistant floor must be at least R11 according to BGR 181. The determination of this requirement resulted in the risk assessment of the machine.
MZ4S_GB_3.fm
The used shoes must be suitable for being used in those machining areas. The accessible
areas must be cleaned.
Organise the working area around the milling machine machine according to the local safety
regulations.
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27
INFORMATION
In order to attain good functionality and a high processing accuracy as well as a long
service life of the machine, the place of installation should fulfil certain criteria.
Please observe the following points:
 The device must only be installed and operated in a dry and well-ventilated place.
 Avoid places close to machines which cause chips or dust.
 The installation site must be free from vibrations also at a distance of presses, planing
machines, etc.
 The foundation must be suitable for the milling machine. Pay attention also to the load-bea-
ring capacity and evenness of the floor.
 The ground must be prepared in such a way that any coolant used cannot penetrate into




the ground.
Any parts sticking out such as stops, handles, etc. have to be secured by measures taken
by the customer if necessary in order to avoid endangering persons.
Provide enough space for set-up and operating personnel and material transport.
Also bear in mind accessibility for installation and maintenance works.
Ensure adequate lighting is available (minimum value: 500 lux, measured at the tool tip). At
lower illumination intensities, additional illumination has to be ensured e.g. by means of a
separate workplace lamp.
INFORMATION
The main switch of the milling machine must be freely accessible.
3.6
Machine mounting
3.6.1
Anchor-free mounting
MZ4S_GB_3.fm
Provide a solid substructure at each support point of the levelling points between the foundation
and the machine foot or use adjustable feet (2) with adjusting screws (3) from the delivery.
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3.6.2 Anchored mounting
Use an anchored mounting to achieve a rigid connection to the substructure. An anchored
mounting is always appropriate if the intention is to machine large parts up to the maximum
capacity of the drilling-milling machine.
The milling machine is fastened to the floor with four anchor screws DIN 529 M20 x 200 through
the machine foot. The anchor screws are not included in the delivery.
 Dimensions, Installation plan on page 24
 Drilled core holes with a diameter of 120 to 150mm and a depth of 200mm are provided in
the foundation.
 Raise the machine from the floor and centre in the inner drill holes with the anchor screws.
 Roughly align the machine. Fill the drill holes with concrete and allow to set.
Aligning the machine
 Place a machine spirit level (0.05mm/m) on the cross table.
 Attach washers and nuts to the anchor screws.
 Check the alignment of the milling machine with a machine spirit level on the cross table
and place base plates underneath the machine foot.
ATTENTION!
All four corners of the machine foot must lie flat. The maximum height difference of the
bearing surfaces after tightening the anchor screws should not exceed 0.05mm per
1000mm. We recommend using a machine spirit level to align the milling machine.
 The the anchor screw nuts.
 Check the alignment of the milling machine again. Re-check the alignment after a few days
of use.
3.7
First commissioning
WARNING!
Commissioning should only take place after proper installation of the machine.
First commissioned of the milling machine by inexperienced personnel constitute a risk
to personnel and equipment.
We do not accept any liability for damages caused by incorrectly performed
commissioning.
 Qualification of personnel on page 11
WARNING!
The use of improper tool holders or their operation at inadmissible speeds constitutes a
hazard.
Only use the tool holders (e.g. drill chuck) which were delivered with the machine or
which are offered as optional equipment by OPTIMUM.
Only use tool holders in the intended admissible speed range.
Tool holders may only be modified in compliance with the recommendation of
OPTIMUM or of the manufacturer of the clamping devices.
MZ4S_GB_3.fm
ATTENTION!
Before commissioning the machine, all bolts, fastenings and protections must be
checked and retightened as necessary!
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3.8
One-component paint
The machine is lacquered with a one-component paint. Take this criterion into account when
selecting your cooling lubricant and cleaning the machine.
A one-component paint with added solvent sets when the solvent evaporates.
As soon as the paint is applied, the solvent escapes into the air. The binding agent becomes
felted and a dry film is formed. This process is reversible, i.e. the binding agent can always be
re-softened.
A two-component paint also consists of binding agent and solvent. However, the paint only
dries when a setting agent is added. This process is not reversible, i.e. the binding agent cannot be re-softened.
The company Optimum Maschinen Germany GmbH does not assume any guarantee for subsequent damages due to unsuitable cooling lubricants.
3.9
Cleaning the machine
ATTENTION!
Do not use compressed air to clean the machine.
Your new milling machine must be completely cleaned after unpacking to ensure that the
moving parts and sliding surfaces cannot be damaged when the machine is operated. Prior to
delivery, all blank parts and sliding surfaces in each unit are appropriately lubricated to protect
against rust in the period before commissioning. Remove all wrappings and clean all surfaces
with a degreaser to soften and remove protective greases and coatings.
Wipe all surfaces with a clean cotton cloth and lubricate the milling machine in accordance with
the maintenance section  Inspection and maintenance on page 57 before switching on the
power and putting the machine into service.
3.9.1
Lubrication and oil levels
During the initial lubrication and greasing of your new milling machine, the oil levels are checked and the machine lubricated after cleaning. Only when this has been done can commissioning of the machine proceed.
 Inspection and maintenance on page 57
3.10
Function testing and mounting of accessories
INFORMATION
The movement of the axes with the hand cranks on the table is only possible when the
machine is switched on.
 Mount hand lever, spindle sleeve feed, from the standard accessories on the milling head.
 Loosen mechanical limit stops of the travelling axles.
 Loosen the clamping level and check the smooth running and mobility of travelling axles
and components.
 Perform safety check.  Safety check on page 15
3.11
Warming up the machine
If the milling machine and in particular the milling spindle is immediately operated at
maximum load when it is cold it may result in damages.
If the machine is cold, e.g. directly after having transported the machine, it should be warmed
up at a spindle speed of only 500 1/min for the first 30 minutes.
GB
30
MZ4S_GB_3.fm
ATTENTION!
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3.12
Electrical connection
CAUTION!
Lay the connection cable to the electrical cabinet and the cable of the coded connector
from the machine to the electrical cabinet in such a way as to prevent a trip hazard.
WARNING!
The three-phase electrical connection may only be performed by an electrician or under
the guidance and supervision of an electrician.
Connect both coded connectors to the electrical cabinet.
We recommend using crossing plates, tread plates with black-yellow markings to cover
the connection cable from the machine to the electrical cabinet.
Please check that the type of current, voltage and protection fuse correspond to the values specified. A protective earth ground wire connection must be available.





Min. terminal cross-section per phase and grounding: 2.5mm2
Electric connected load: 5.4 KVA
Permissible voltage fluctuations in normal operation: +6% -10% Volt
Permissible frequency fluctuations: ± 1Hz (50/60 Hz)
Permissible phase imbalance: 3% or less
ATTENTION!
Ensure that all 3 phases (L1, L2, L3) and the ground wire are connected correctly.
The neutral conductor (N) of its power supply is not connected.
ATTENTION!
Check if the drive motor is turning in the correct rotation direction. If necessary, two
phase connections must be swapped.
In the event of an incorrect rotation direction, machine components may be damaged.
The guarantee will become null and void if the machine is connected incorrectly.
 Check the fusing (fuse) of your electrical supply according to the technical instructions
regarding the total connected power of the machine.
 Firmly connect the machine.
Please check that the type of current, voltage and protection fuse correspond to the values specified. A protective earth ground wire connection must be available.
MZ4S_GB_3.fm
 Mains fuse 16A.
 Observe the notes on the connection for machines with frequency converters.
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3.12.1 Regulated drives in connection with residual current devices
Speed-controlled drives are one of the standard equipment in machine and plant construction
and perform various tasks. Compared to a simple motor, the electronic rectifiers or converters
require some special features for the necessary safety measures for electrical safety. Depending on the application, the use of a fault current protection device, differential current monitoring or insulation monitoring can make more sense.
For electrical safety, DIN VDE 0100-410 (VDE 0100 part 410): 1997-01 "Erection of heavy current installations up to 1000V" is a basic standard. It describes both, the admissible net forms
and the necessary protective measures against dangerous body currents. Based on this standard DIN EN 50178 (VDE 0160): 1998-04 "Equipping of heavy current systems with electronic
equipment" specifies the protective measures to be applied to controlled drives in more detail. It
calls for: "In the case of electronic equipment, the protection of persons against dangerous
body currents must be carried out in such a way that a single fault does not cause any danger."
Regulated drives with residual current devices
The TN-S system is the most common network form for the operation of controlled drives. This
is done, among other things, for EMV reasons and to avoid vagabonding currents. In accordance with DIN VDE 0100-410 (VDE 0100-410): 1997-01, fault current protective devices
(ELCB) can be used as a protective measure against dangerous body currents. According to
DIN VDE 0100-482 (VDE 0100 part 482): 2003-06 "Electrical installations of buildings", cables
and wiring systems in fire-endangered plants must be protected by ELCBs with a rated differential current of 300 mA. According to IEC 60755, ELCBs differ in the type of fault currents they
can detect. In conjunction with electronic devices currents with DC components may occur.
3.12.2 Protection from Dangerous Shock Currents, use of ELCBs
To achieve increased safety in all installation systems, and in power supply ranges for which
the installation provisions stipulate or recommend the ELCB devices.
Measure for “Protection from Dangerous Shock Currents”, as regulated in DIN VDE 0100 Part
410. All measures are to be mentioned:
 Protection from indirect contact – as protection against fault by shutting down in the event of
inadmissibly high contact voltage by short circuit shock on the operating resource.
 Protection from direct contact – as additional protection by shutting down in the event of
contact with a live conductor. Dangerous shock currents are shut down within the shortest
possible time, if the rated fault current of the circuit breaker is 30 mA (e.g. Domestic
environment), for a personal protection system 10 mA (e.g Bathroom).
 Fire prevention – Prevention of the origination of electrically-ignited fires if the rated fault
current of the circuit breaker is 300 mA. Operating premises at risk of fire to VdS 2033:
2002-02 300 mA (e.g. Factory halls).
3.12.3 Current in the protective earth conductor - Leakage current
Therefore, a fixed earth connection is required and the minimum cross section of the protective
earthing conductor must conform to local safety regulations for devices with high leakage current. This is achieved by providing a permanent fixed earthing connection with two independent conductors, each having a cross section the same as the power supply cord or greater.
Preferably, machines with frequency converters are therefore to be permanently connected to a
terminal box, otherwise an additional fixed earth connection is required, which is not routed
over the plug, and must correspond to at least the cross-section of the cable in the plug.
Since a direct current may be caused by the frequency converter in the protective earthing conductor, if an upstream residual current device (ELCB / RCD) is required in the network, the following guidelines must be followed:
Converter-plus-ELCB-plus-EMV_GB.fm
With EMC filters in frequency converters, the leakage current is always greater than 3.5 mA
due to physics. Some types of frequency converters also achieve a leakage current of up to
300mA.
GB
32
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To avoid an operating fault, you need an AC/DC-sensitive ELCB. Be absolutely sure
which leakage current security is necessary for dangerous body currents, as regulated
in DIN VDE 0100 part 410, at your mains connection.
3.12.4 When the ELCB triggers
 Pulse current - sensitive ELCB type A
ELCB type A independent of rated voltage, for triggering when changing fault
currents and pulsing DC fault currents.
 AC/DC - sensitive ELCB type B
ELCBs of series type B also accept the detection of smooth AC fault
currents as well as the detection of fault current shapes of type A; they
are therefore suitable for all the circuits mentioned. ELCBs of this series therefore detect all
types of fault current according to the triggering characteristic B, i.e. both smooth DC fault
currents and also all AC fault currents of all frequencies and mixed frequencies up to 1 MHz
are detected and switched off reliably in the event of a fault.
 Alternating current - sensitive ELCBs of type AC (only alternating current) are
unsuitable for frequency converters. Alternating current - sensitive ELCBs of type
AC are not customarily used and are no longer permitted in Germany.
Type B must be used with 3-phase converters.
Converter-plus-ELCB-plus-EMV_GB.fm
When using an external EMC filter, to avoid false error shutdowns, a time delay of at least 50
ms is required. The leakage current can exceed the threshold trigger value for an error shutdown if the phases are not switched on at the same time.
GB
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33
4
Operation
4.1
Overview
5
8
11
4
6
10 1
10
12
13
2
3
3
Pos.
Designation
Item
Designation
1
Control panel with Newall DP700 position
display
 DP700 Quick start guide on page 51
8
Tool clamping
milling
2
Chip and spray guard
10
Emergency-stop
3
Hand crank table motion manual
11
Spindle gear
4
Hand crank milling head
12
Spindle vertical milling
12
Spindle horizontal milling  Clamping
the tool on page 45
13
Direct run, speed gear
5
6
Drive motor spindle drive
Spindle sleeve lever vertical spindle
device
for
horizontal
INFORMATION
MZ4S_GB_4.fm
The movement of the axes with the hand cranks on the table is only possible when the
machine is switched on.
GB
34
Operation
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4.1.1
Control panel, spindle drive and drive, table feed
2
1
10
8
6
9
5
4
7
3
10
Abb.4-1: Control panel
Designation
Item
Designation
1
Rev counter
6
Push button table feed "On/Off"
2
Push button "Rapid traverse" X-Y-Z axis
7
Emergency stop button
3
Coolant pump "On/Off"
8
stepless feed speed Z axis
4
Rotational direction spindle
9
stepless feed speed X-Y axis
5
Push button, spindle drive "On/Off"
10
Feed direction lever with detent position
MZ4S_GB_4.fm
Pos.
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4.1.2 Control panel spindle gear
WARNING!
Never grip the tool to rotate the spindle as this may engage a gear setting.
5I[\MZ4IJMT[
%
$
&
*
**
***
*
**
***
*
**
***
+
/
Img.4-2:
Speed table
UQV
ATTENTION!
Only change speeds and gear settings when the machine is at a stop.
Use the torque button to facilitate the engaging of gear settings.
MZ4S_GB_4.fm
Optionally, the handwheel on the rear of the spindle can be used to facilitate engagement in
gear positions.
GB
36
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4.1.3 Direct run
Use the torque button to facilitate the engaging of gear settings. The spindle begins to rotate
providing the torque button is pressed. For this, the spindle guard must be closed. Press the
torque button only briefly.
Optionally, the handwheel on the rear of the spindle can be used to facilitate engagement in
gear positions.
Direct run spindle
Direct run
Emergency stop button
Hand wheel
Abb.4-3: Direct run spindle drive
4.2
Safety
Use the milling-machine only under the following conditions:
During operation




The milling machine is in proper working order.
The milling machine is used as intended.
The operating instructions are followed.
All safety devices are installed and activated.
WARNING!
Stop the machine immediately in the event of any abnormality in operation and make
sure it cannot be started up accidentally or without authorisation.
Notify the person responsible immediately of any modification.
WARNING!
Protect your eyes against filings and other fragments that might fly off at high speed.
Wear protective goggles.
MZ4S_GB_4.fm
CAUTION!
Different noise levels can be reached depending on the operation. Use ear protection!
CAUTION!
Wear protective gloves while setting up the machine.
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4.3
Operational modes of the machine
 Manual operation with the hand wheels on the cross table.
- The protective housing should be closed, the spindle guard must be set to high. The protective housing must be closed if the cooling equipment is used.
 Operation with the automatic table feed.
- The protective housing must be closed.
 Drilling with the spindle sleeve lever on the milling head.
- The protective housing must be open, the spindle guard must be set to high.
4.4
Switching on the machine
 Switch on the master switch.
 Unlock both emergency-stop switches.
 Turn the spindle drive direction of rotation switch to the neutral position.
 When drilling with the spindle sleeve lever, attach and close the drill chuck guard.
 When milling, close the chip and spray guard around the milling table.
 Set the spindle speed at the selector switches of the gearbox.
 Push the button Spindle drive "ON"
 Set the direction of rotation switch of the spindle drive to the required position. The spindle
starts to rotate.
CAUTION!
When drilling with the spindle sleeve lever on the milling head, the spindle guard on the
milling head must be set and closed.
When milling with the automatic feed, the chip and spray guard around the milling table
must be closed.
When using the cooling lubricant pump, the chip and spray guard must always be
closed.
4.5
Switching off the machine
 Push the button Spindle drive "OFF"
 For a longer-term standstill of the machine, switch it off at the main switch.
4.6
Resetting an emergency stop condition
 If necessary, move the feed direction levers on the control panel to the neutral position.
 Set the direction of rotation switch for the spindle drive to the neutral position.
 Unlock the emergency stop switch again.
4.7
Power failure, Restoring readiness for operation
 Set the direction of rotation switch for the spindle drive to the neutral position.
 If necessary, move the feed direction levers on the control panel to the neutral position.
4.8
Stopping the machine in an emergency
ATTENTION!
MZ4S_GB_4.fm
The emergency stop stops the machine when actuated. Press the emergency stop only if
there is a risk! Release the emergency stop by turning.
GB
38
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4.9
Selecting the speed
The correct speed is an important factor for milling. The speed determines the cutting speed by
which the cutting edges cut the material. By selecting the correct cutting speed, the service life
of the tool is increased and the working result is optimized.
The optimum cutting speed mainly depends on the material and on the material of the tool. Higher speeds are possible with tools (mills) made from hard metal or cutting ceramics than with
tools made from high-alloy high speed steel (HSS). You will achieve the ideal cutting speed by
selecting the correct rotation speed.
Use upcut milling if at all possible. In upcut milling, the direction of feed is opposite to the direction of rotation.
Please refer to a table reference book (e.g. Tabellenbuch Metall, Europa Lehrmittel, ISBN
3808517220) or the following diagrams to determine the correct cutting speed for your tool and
the material to be machined.
4.9.1
Diagram for determining speeds
2500
2000
V
1000
=
44
min-1
1500
m
/m
800
700
600
500
in
V
=
=
/m
/m
in
m
25
m
35
V
400
in
300
200
d
100
d
4.9.2
mm
80
3
inches
4
5
6 7 8 9 10
.25"
.5"
20
30
1"
40 50 60
2"
70 100
150
3"
6"
4"
Setting the spindle speed and start spindle rotation
MZ4S_GB_4.fm
 Switch the drive motor on the control panel to "ON".
 Set the speed on the selector wheels. Where necessary, use button direct run.
 Close the spindle protection system.
 Select the direction of rotation on the control panel. The spindle starts to rotate.
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4.9.3
Diagram for determining feed rate
2
n= 8
0
mm/Ø
1
n= 1
60
n= 2
45
60
n= 3
90
n= 4
0.5
n= 7
20
0.2
1
n= 1
0.1
n=2
00
200
0.05
0.02
0.01
20
30
40
50
60 70 80
100
150
200
MZ4S_GB_4.fm
mm/min
GB
40
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4.10
Milling capacity of the machine
The diagram shows the possible milling depths and the feed rate for each mill diameter.
Example: Ø = 50 mm, t = 8 mm
Result Feed rate = 50 mm/min
Example: Ø = 50 mm ; Feed rate = 70 mm/min ; Result t = 6 mm
The values refer to low-carbon, unalloyed steel, e.g. ST37 (S235JR). For softer or harder materials, the values must be adjusted accordingly.
20
t
mm
15
Ø
Ø
10
9
8
t
25
Ø
Ø
7
Ø
Ø
6
Ø
20
80
32
40
50
5
4
3
2
20
30
40
50
60 70 80 90 100
200
mm/min
MZ4S_GB_4.fm
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150
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4.11
Activate / deactivate automatic table feed
The feed drives consist of a universal helical gear and an inverter motor in each axis. The feed
force is 1600 N with a continuously adjustable feed from 0.05 metres per minute to 0.45 metres
per minute. The rapid traverse speed is 0.78 metres per minute.
4.11.1 Switching the X - Y - Z axis feed on
ATTENTION!
+Z
Loosen clamping lever on the cross table.
+Y
Loosen clamping lever on the milling head.
 Set feed rate to "0".
 Switch on drive motor for the feed.
 Set the direction lever X, Z or Y in the desired
+X
feed direction and engage.
 Slowly increase the feed rate.
0
0
4.11.2 Switching the X - Y - Z axis feed off
 Set the feed direction lever to the neutral position.
 Switch off drive motor for the feed.
 Set feed rate to "0".
4.11.3 X - Y - Z axis rapid traverse
MZ4S_GB_4.fm
 Loosen the clamping lever.
 Switch on drive motor for the feed.
 Set the direction lever in the desired direction.
 Operate the push-button on the control panel.
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42
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4.12
Turning the milling head vertically
 Loosen clamping screws and
rotate milling head to 90°.
Clamping bolts
 Re-tighten clamping bolts.
Scale angle of rotation
4.12.1 Aligning the milling head
INFORMATION
MZ4S_GB_4.fm
The milling head should be aligned after resetting to the initial position with a dial indicator so
that holes can be produced with the spindle sleeve at a right angle.
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4.13
Fastening horizontal table
CAUTION!
When milling with the vertical milling table - horizontal table is dismantled, chip and
spray guard is dismantled - e.g. when mounting a dividing apparatus on the vertical table
-, the machine operator must take additional precautions to ensure safe operation.
We recommend mounting e.g. a dividing apparatus on the horizontal table and adjusting
the milling spindle to horizontal milling in order to maintain the same machining method.
The milling table is fixed to the vertical table with four T-slot screws DIN 787 M14 x 50.
The T-slots are executed similar to DIN 650.
Fastening
Horizontal table
+0.018
a = 14 -0
h
°
45
DIN 650
a
n
b = 25
c = 11
h = 25
= 0.005 a
c
r2
11
25
Type C1
45
14
°
23
MZ4S_GB_4.fm
b
GB
44
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4.14
Clamping the tool
WARNING!
When milling operations are performed the cone seat must always be fixed to the drawin rod. All cone connections with the taper bore of the work spindle without using the
draw-in rod is not allowed for milling operations. The cone connection should be
released by the lateral pressure. Injuries may be caused by parts flying off.
ATTENTION!
The conical seat of the tool and spindle sleeve must be free of grease and dirt.
 ISO 40 tool holder, M16 tie rod.
When vertical milling and horizontal milling, the tool is clamped with a tie rod.
 Dismantle protective cap, tie rod.
 Vertical milling - clamp tool from above via the drawbar with a 22mm wrench.
 Refit protective cap, drawbar.
 Horizontal milling - clamp tool via the drawbar with the rotating device.
Clamp tool:
Clamp tool:
for vertical milling
for horizontal milling
4.15
Adjusting spindle guard
When drilling, adjust the spindle guard to
the appropriate height with the spindle
sleeve lever.
When milling with closed protective
housing, the spindle guard can be set to its
top position.
INFORMATION
MZ4S_GB_4.fm
The spindle rotation is only released
when the spindle guard is closed.
Spindle sleeve lever
Close spindle guard
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45
4.16
Optional compressed air tool clamp of the vertical spindle
The pneumatic tool clamp can only be used when the spindle guard is open.
ATTENTION!
Loosening the tool when the spindle is running out can
lead to damage.
1
Wait until the spindle stops completely before pressing
the tool release button.
Functionality: The tightening rod of the tool is driven by an air
motor and rotates the tightening rod into the threaded hole of
the tool holder. To release the tool, the tightening rod is
turned back out of the threaded hole of the tool holder.
The compressed air tool clamp for turning the tightening rod
in and out can only be operated when the spindle guard is
open.
2
Shift the morse taper fixture into the spindle of the milling
machine.
Press the clamp or release button (2) to clamp or unclamp
the tool.
INFORMATION
If necessary, the tightening torque of the air motor can
be reduced.
This adjustment option (3) is located under the cover
cap of the compressed air wrench.
The factory setting was set to the number 6. Make sure
that compressed air with 6.2 bar is available.
3
4.17
Conversion to horizontal milling
 Loosen the hexagon screws (1) and hexagon socket screws (2).
 Swivel the vertical milling head aside (3) and move backwards on the rail.
 Assemble the protective cover (4) from the accessories of the toolkit for the spindle drive
MZ4S_GB_4.fm
"Vertical milling".
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46
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1
2
3
MZ4S_GB_4.fm
4
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4.17.1 Mounting counter bearing
CAUTION!
Always mount counter-bearing if machining with a side milling cutter
When mounting the counter-bearing, acceptable stress loads on the operator or
assembler may be exceeded.
Recommended threshold values when lifting and carrying loads
Reasonable load in kg and frequency of lifting and carrying
Occasionally
More frequently
Age in years
Women
Men
Women
Men
15 - 18
15
35
10
20
19 - 45
15
55
10
30
from 45
15
45
10
25
 Screw eyebolt into the counter-bearing, lift with a
crane or other lifting device.
Receiving thread
eyebolt
 Push the counter-bearing onto the centring
alignment on the milling head and mount
and tighten the counter-bearing on the milling head.
Counter-bearing, side milling cutter
MZ4S_GB_4.fm
Img.4-4:
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48
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4.17.2 Arbors for side milling cutter
Arbors for horizontal milling, morse tapers and adapters.
Spare parts  Werkzeuge Horizontalbearbeitung - Horizontal tools list on page 90
1
2
3
4
1
Arbor ISO 40 with counter-bearing
16mm external diameter
Arbor ISO 40 with counter-bearing
2
22mm external diameter
Arbor ISO 40 with counter-bearing
3
27mm external diameter
Arbor ISO 40 with counter-bearing
4
32mm external diameter
5
ISO40 - MT3 Adapter
6
MT2 Adapter
7
MT1 Adapter
5
6
7
4.17.3 Central lubrication
The central lubrication system is equipped with an on/off switch. The central lubrication system
supplies functionally important components on your milling machine. If the on/off switch is permanently switched off, important parts cannot be supplied with lubricant.
MZ4S_GB_4.fm
 Zentralschmierung - Lubrication System on page 92
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4.18
Conversion to vertical milling
 Dismantle the protective cover (1) for the "Vertical milling" spindle drive.
 Position the coupling nose of the vertical spindle horizontally (2).
 Position the coupling nose of the spindle drive horizontally (3).
 Swivel the vertical milling head on the spindle drive (3).
 Tighten the hexagon screws and hexagon socket screws.
1
2
3
4.19
Coolant
WARNING!
Ejection and overflowing of coolants and lubricants. Make sure you do not get the
cooling lubricants on the floor. Spilled on the floor cooling agents must be removed
immediately.
0 = Deactivate cooling agent feed
1 = switch on coolant delivery.
The amount of coolant is adjusted using the metering valve.
GB
50
MZ4S_GB_4.fm
The flow of cooling agent is activated and deactivated by means of a selector with on the control panel
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N
4.20
p
DP700 Quick start guide
For the complete manual please download from:
http://newall.com , Click technical Support to access the download
page.
Warnings
The mains supply is connected into a switch mode power supply (separate from your DP700) via a
detachable supply cord supplied. If another supply cord is used, it must have fitted a C5, 10A,
EARTHED mains connector with a cord rated for at least 10A.
If a mains plug is not already fitted to the supply cord or is of the wrong type, then a suitable EARTHED
plug should be used which complies with the relevant specifications for plugs and socket-outlets.
You can only use the DP700 with Newall Spherosyn and Microsyn analogue encoders.
The power supply must be disconnected before opening the unit and completed by qualified personnel.
Turn off the power by disconnecting the power supply connector, before you connect the encoder(s)
Technical Specification
Electrical
Environmental
Operating Temperature
-10°C to 50°C
Storage Temperature
-20 to 70°C
Environmental Conditions - IP40 (Stand Alone)
IP54 (Panel Mount)
EU Directive 73/23/EEC (Low Voltage
Directive)
BS EN 55022:1998 Class B
BS EN 55024:1998
Input to Power Supply Unit (Supplied)
Relative Humidity - maximum 95% for temperature up to 31°C 100-240V (47-63Hz)
External switch-mode
Output voltage 15VDC
Disposal
At the end of it’s life, you should dispose of the DP700 in a safe
Input Voltage to DP700
manner applicable to electronic goods.
15-24VDC ±10%
The case work is suitable for recycling. Please consult local
regulations on disposal.
Conforms to Low Voltage Directive
Note: Newall Measurements Systems reserves the right to change specifications without notice.
Connections
DP700_brief-instruction_GB.fm
Encoder Input
Connection
1,2 or 3 According
to Model
RS232 Output
External PSU Input
Cable Clamp
Cabinet equipotential terminal
for grounding to machine
DP700
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51
Understanding the Keypad
Message
Display
Axis 1
Axis 2
Axis 3
Power
LED
Digifind / Reference
Axis Selection Key
Switches between Zero
and Axis Preset modes
Switches between Absolute
and Incremental modes
Numeric Keys
Switches between Inch
and mm display
Enter Key
Information selection (scrolls
through options on Message
display)
Clear Numeric Entry
Function Menu Key
Centre Find
Function Navigation Keys
Undo Key
Zero an Axis in Zero Mode
Ensure DP700 is
in Zero Mode
of Axis 1, 2 or 3
Zero an Axis in Set Mode
of Axis 1, 2 or 3
Preset an Axis
Ensure DP700 is
in Set Mode
EN
52
=
-145.230
DP700_brief-instruction_GB.fm
Ensure DP700 is
in Set Mode
DP700
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Setting up the Unit
How to enter setup
Until display shows
,
FUNCS
SETUP
display shows s e t u p
COdE?
(1937)
Default Settings
setup
language
Optional Settings
francais
Eng gb
of axis 1
setup
TYPE
eSPANOL
iTALLIANO
DEUTSCH
RUSSIAN
eng us
DANSK
cZECH
PORTUGUE
TURKISH
MILL
LATHE
GENERIC
of axis 1
setup
ENCODER
SPH 2G
USN 10
Spherosyn or S2G
Microsyn 10
USN 5
Microsyn 5
of axis 1, 2 or 3
setup
RES
0.001
0.005
0.01
of axis 1, 2 or 3
setup
DIR
---|
0 . 0 0 2 Note:
0 . 0 2 values in
mm.
0.05
|---
of axis 1, 2 or 3
*
setup
MEASURE
DIA
RAD
of axis 1, 2 or 3
setup
ZERO APP
OFF
ON
of axis 1, 2 or 3
setup
ZERO LVL
user defined, use numeric keypad to enter value
12.700
of axis 1, 2 or 3
setup
ERR COMP
setup
PLANE
See full manual on website for more details
(----)
(----)
(----)
of axis 1
setup
FUNCS
setup
TOOLS
(----)
ON
OFF
of axis 1
to return to main menu
to scroll through functions,
setup
BEEP
(----)
(----)
ON
OFF
DP700_brief-instruction_GB.fm
of axis 1
setup
SLEEP
setup
RESET
0
user defined, use numeric keypad to enter value
(value is in whole minutes)
See full manual on website for more details
Must be set to match encoder’s on the machine
to exit setup
* Lathe version, X axis set to DIA as default
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53
5
Maintenance
In this chapter you will find important information about
 Inspection
 Maintenance
 Repair
of the milling machine.
ATTENTION!
Properly performed regular maintenance is an essential prerequisite for
operational safety,
failure-free operation,
a long working life of the milling machine and
the quality of the products which you manufacture.




Installations and equipment from other manufacturers must also be in good order and condition.
5.1
Operating material
5.1.1
Machine lubricants
Only use appropriate lubricants which guarantee a safe operation of the machine.
Recommended lubricant class: ISO V668
Recommended lubricant: Slideway oil Mobil Vactra (Oil No. 2)
5.1.2
Cooling lubricants
In order to avoid interferences during operation the water-mixed cooling lubricant and the slideway oil or grease need to be compatible.
Read also:  Cooling lubricants and tanks on page 70
INFORMATION
The milling machine has been painted with varnish. This fact must be taken into account when
selecting your cooling lubricant.
Optimum Maschinen Germany GmbH does not accept any liability for subsequent damages
due to unsuitable cooling lubricants.
The flashpoint of the emulsion must be higher than 140°C.
When using non-water-miscible cooling lubricants (oil content > 15%) with a flashpoint, ignitable
aerosol air mixtures might develop. There is a potential danger of explosion.
ATTENTION!
Only the correct selection of an appropriate combination of cooling lubricants and
slideway oils as well as the proper care and maintenance of the cooling lubricant can
ensure that no problems such as stick-slip effects or deposits are resulting.
The selection of cooling lubricants and slideway oils, lubricating oils or greases as well as their
care are being determined by the machine operator or operating company.
We would like to ask you to have the following machine-related properties of the cooling lubricant confirmed in writing by the manufacturer of the cooling lubricant.
GB
54
MZ4S_GB_5.fm
Therefore, Optimum Maschinen Germany GmbH cannot be held liable for machine damages
caused by unsuitable coolants and lubricants as well as by inadequate maintenance and servicing of the coolant. In case of problems with the cooling lubricant and the slideway oil or
grease, please contact your mineral oil supplier.
Maintenance
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 The products must comply with the provisions of the current statutory regulations and the
employers' liability insurance association.
 Request documentation for the products such as the product description VKIS and EC
safety data sheet from the cooling lubricants manufacturer. The EC safety data sheet gives
you information about the water hazard class.
They need to be environmentally friendly and workplace-friendly. Thus, they need to be free of
nitrite, PCB, chlorine and nitrosatable diethanolamine (DEA), according to TRGS 611.










The manufacturer should be able to provide a certificate concerning skin tolerance.
The mineral oil content according to DIN 51417 should be at least 40% in the concentrate.
If possible, it should be universally applicable for all chippings and materials.
Long service life of the emulsion e.g. long-term stable and resistant to bacteria.
Safe corrosion protection according to DIN 51360/2.
Re-emulsifiable and non-adhesive according to VKIS sheet 9: Sticking and residue behaviour.
It should not attack the varnish of the machine according to VDI 3035.
It should not attack any machine elements (metals, elastomers).
Low foaming behaviour of the emulsion.
It should be as finely dispersed as possible in order to avoid clogging in the needle slot
screen.
5.2
Safety
WARNING!
The consequences of incorrect maintenance and repair work may include:
 Severe injuries of persons working on the milling machine,
 damage to the milling machine.
Maintenance and repair work on the milling machine must be carried out by qualified
technical personnel only.
Validation
Check and maintain all safety-relevant stop, control and measuring devices (validation).
Documentation
Record all tests and works in a operator's log resp. log book.
5.2.1
Preparation
WARNING!
Only carry out work on the milling machine, if the main switch is switched off and
secured against restarting by means of a padlock.
 Switching-off and securing the milling machine on page 17. Attach a warning label.
5.2.2
Restarting
Before restarting, run a safety check.
 Safety check on page 15
MZ4S_GB_5.fm
WARNING!
Before starting the milling machine, it is essential that you ensure that this does not
constitute a risk to personal safety or damage to the milling machine.
Maintenance
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5.3
Repair
5.3.1
Customer service technician
For any repair work request the assistance of an authorised customer service technician. Contact your specialist dealer if you do not have customer service's information or contact Stürmer
Maschinen GmbH in Germany who can provide you with a specialist dealer's contact information. Optionally, the company Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Str. 26
D- 96103 Hallstadt
can provide a customer service technician, however, the request for a customer service technician can only be made via your specialist dealer.
If the repairs are carried out by qualified technical personnel, they must follow the indications
given in these operating instructions.
Optimum Maschinen Germany GmbH accepts no liability nor does it guarantee against damage
and operating malfunctions resulting from failure to observe these operating instructions.
For repairs, only use
 faultless and suitable tools,
 original parts or parts from series expressly authorised by Optimum Maschinen Germany
MZ4S_GB_5.fm
GmbH.
GB
56
Maintenance
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5.4
Inspection and maintenance
The type and level of wear depends to a large extent on the individual usage and operating
conditions. Any indicated intervals therefore are only valid for the corresponding approved conditions.  Technical specification on page 20
What?
Check
How?
Milling machine
Sight window
operator
after every maintenance or
Repair
Where?

 Safety check on page 15
Clean the polycarbonate sight windows using a
suitable cleaning agent.
 Cleaning and replacing of the polycarbonate
windows on page 60
Cleaning
Check the quantity and refill the lubricant tank of
the central lubrication system.
Lubricant tank
Slideway oil
Empirical value of the
Start of work, Daily
Start of work, after each
maintenance or repair work
Interval
 Refilling the oil in the central lubrication
system on page 61
Fill level control
 Cooling lubricants on page 54
 Lubricant on page 108
Cooling lubricant
lubricant
weekly
CAUTION !
The cooling lubricant needs to be
checked at least weekly, including
during downtimes, with regard to
its
concentration,
ph-value,
bacteria and fungal decay.
Fill level status
control
PH Value measurement
Check the pH value. If required, replace the cooling lubricant.
 Cleaning the cooling lubricant tank on page 69
 Inspection plan for water-mixed cooling lubri-
Vertical
Milling head
weekly
MZ4S_GB_5-1.fm
cants on page 71
Lubricate with grease.
Lubricating
 Lubricating the vertical milling head on page
62
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Main transmission
the slides
Slideway
Milling head
Oil level, Oil tank
Check
How?

Lubricate with grease.
Lubricating
 Ball screw, X axis on page 62
Check oil level,
Top up as required.
Check, refill
Change oil as required.
 Filling, checking oil tank, main gear on page
64
Check the wipers on the slides.
Check
 Maintenance and replacement of the wiper on
page 69
Cleaning
 Cleaning the electrical cabinet on page 61
Cleaning
 Cleaning the chip tray on page 60
Where necessary,
replace inspection
windows
 Cleaning and replacing of the polycarbonate
windows on page 60
MZ4S_GB_5-1.fm
Replace
Electrical cabinet
Wipers on
What?
Chip collection tray
operating hours
operator
Where?
Protective covers
Every 1000
60 months
Empirical value of the
Annually
Monthly
Interval
GB
58
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What?
How?
Check

 Obligations of the operating company on page
Electronics
in accordance with German DGUV (BGV A3)
Where?
12
Electrical inspection
 Electronics on page 18
 Validation on page 55
MZ4S_GB_5-1.fm
based on operator's
historic values
Interval
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5.4.1
Cleaning the chip tray
 To clean the chip tray, open the side cover or front cover.
CAUTION!
Wear protective gloves and use suitable tools to remove the chips.
Abb.5-1:
Side cleaning cover, chip tray
5.4.2
Cleaning and replacing of the polycarbonate windows
WARNING!
The polycarbonate inspection windows are part of the safety equipment on your milling
machine. Damaged, scratched or even broken polycarbonate sight windows must be
replaced immediately.
A soft cloth should be used to clean the machine safety glass. The following detergents have
been tested and approved by us:
Hahnerol glass cleaner (Hahnerol), Sidolin Streak Free (Henkel), Active Window Cleaner (Neumann).
We recommend replacing the polycarbonate inspection windows 60 months after commissioning of the milling machine.
In the following cases, an immediate replacement is strongly recommended:
plastic deformation (distortion) by previous impact stress,
cracks,
Damage to the edge seal,
destroyed or damaged protective panes.
MZ4S_GB_5-2.fm




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60
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5.4.3
Cleaning the electrical cabinet
Although the electrical cabinet is constructed to shut off external air, foreign particles such as dust and dirt may enter the
cabinet when the door is open.
Accumulation of foreign particles on the
printed circuit boards or other electronic
components could cause machine malfunction.
Clean the inside of the electrical cabinet
regularly.
Remove
dust
inside electrical cabinet with a vacuum cleaner. Do not use compressed air to clean the electrical cabinet.
Never touch circuit boards or parts around the connector. Also
avoid hitting these parts with the vacuum.
We recommend that the electrical cabinet is cleaned every 1000
operating hours.
The illustrated control cabinet key is included in the accessories.
5.4.4
Refilling the oil in the central lubrication system
The central lubrication system lubricates important functional parts of the milling machine. The
maximum fill amount is 2 litres. If levels drop below the minimum fill amount, an audible alarm is
triggered. The central lubrication system is equipped with an switch. The switch deactivates
central lubrication. Make sure that the central lubrication does not remain permanently switched off.
Filler hole
Manual trigger, lubrication
interval
Time setting
Max. fill level
Min. Fill level
MZ4S_GB_5-2.fm
Abb.5-2: Central lubrication system
INFORMATION
If the overload fuse of the pump motor trips, the motor switches off for about 5 minutes
to cool down.
Please press the manual button for no longer than 2 minutes to prevent an overload.
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5.4.5 Lubricating the vertical milling head
Using a grease gun, lubricate the lubricating nipples weekly with about 100ml of grease with a
lithium-soap base, e.g. Mobilux 3. Check the smooth running of the bearings after lubrication.
 Adjusting the spindle bearing on page 68
Lubricating nipple
Abb.5-3: Lubricating nipple, vertical milling head
5.4.6
Ball screw, X axis
Using a grease gun, lubricate the lubricating nipple monthly with about 50ml of grease with a lithium-soap base, e.g. Mobilux 3. Check the smooth running of the ball screw after lubrication.
Lubricating nipple
MZ4S_GB_5-2.fm
Abb.5-4: Spindle, X axis
GB
62
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5.4.7 Ball screw, Y axis
Using a grease gun, lubricate the lubricating nipple monthly with about 50ml of grease with a lithium-soap base, e.g. Mobilux 3. Check the smooth running of the ball screw after lubrication.
Lubricating nipple
Abb.5-5:
Spindle, Y axis
5.4.8
Ball screw, Z axis
Using a grease gun, lubricate the lubricating nipple monthly with about 50ml of grease with a lithium-soap base, e.g. Mobilux 3. Check the smooth running of the ball screw after lubrication. If
the table moves downwards independently due to the smooth running of the ball screw when
the clamping levers are open, the friction must be increased. Play adjustment of the guide in
the X axis on page 66
MZ4S_GB_5-2.fm
Lubricating nipple
Abb.5-6:
Spindle, Z axis
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5.4.9
Filling, checking oil tank, main gear
The oil must be visible in the inspection glass. The fill level in the oil inspection glass is between
0.75 litres and 0.9 litres. If the oil inspection glass is dirty or the oil level is not visible, the oil
must be changed.
ATTENTION!
Do not overfill, total fill amount 0.9 litres.
Oil sight glass
Abb.5-7: Oil, main gear
5.4.10 Checking, filling oil tank, horizontal spindle
 Dismantle the cover plate.
 Check the oil level.
The fill level should be approximately 0.15 litres. If the oil is visibly contaminated, the oil must
be changed.
ATTENTION!
Abb.5-8: Oil, horizontal gear
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64
MZ4S_GB_5-2.fm
Do not overfill, total fill amount 0.15 litres.
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5.4.11 Clearance adjustment of the guide of the machine stand in the Z axis
By adjusting the V-ledge at the top and/or bottom.
 Dismantle the wiper releasing the adjusting screw.
 Dismantle the chip tray and cover plate of the spindle.
 Dismantle the horizontal table.
Y
X
Perform measurement at the top:
If possible, use a dial gauge with drag pointer.
Z
 Position the dial gauge at the height of the top V-ledge.
 Press the machine stand down on the left and the vertical table on the right side and
release.
 Read the dial gauge, the deviation must be less than 0.01mm.
In the event of a larger deviation, push the V-ledge with the adjusting screw slightly.
Position the dial gauge on the underside and use the same method if the deviation is too large.
Dial gauge
Machine stand
V-ledge
Guide, milling table
Adjustment screw
MZ4S_GB_5-2.fm
Abb.5-9: Adjust guide, Z axis
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5.4.12 Play adjustment of the guide in the X axis
By adjusting the V-ledge to the left and/or right.
 Dismantle the horizontal table.
 Open the left and right bearing covers.
Y
X
Perform measurement on the left:
If possible, use a dial gauge with drag pointer.
 Fix dial gauge as shown.
 Press the vertical milling table down on the left side and release.
 Read the dial gauge.
 Press the vertical milling table up on the left side and release.
 Read the dial gauge, the total deviation must be less than 0.01mm.
Z
In the event of a larger deviation, push the V-ledge with the adjusting screw slightly.
Perform measurement on the right:
Position the dial gauge on the right side and proceed using the same method.
Dial gauge
Vertical milling table
Adjustment screw
V-ledge
Machine stand
MZ4S_GB_5-2.fm
Abb.5-10: Adjust guide, X axis
GB
66
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5.4.13 Play adjustment of the guide in the Y axis
By adjusting the V-ledge at the front and/or rear.
 Remove the sheet cover to the rear of the spindle bearing block.
 Remove protective cover on the front - if present.
Y
X
Perform measurement on the front:
If possible, use a dial gauge with drag pointer.
 Fix dial gauge as shown.
 Move the milling head to the left and right.
 Read the dial gauge, the total deviation must be less than 0.01mm.
Z
In the event of a larger deviation, push the V-ledge with the adjusting screw slightly.
Perform measurement at the rear:
Position the dial gauge on the rear and proceed using the same method.
Adjustment screw
Milling head
Machine stand
V-ledge
Dial gauge
MZ4S_GB_5-2.fm
Abb.5-11: Adjust guide, Y axis
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5.4.14 Adjusting the spindle bearing
Vertical spindle
 Remove the top cover and unscrew drawbar, remove.
 Loosen the stud screws on the bearing nut.
 Slightly adjust the play in the bearing with the bearing nut.
Draw bar
cover
Bearing nut
Abb.5-12: Adjust vertical spindle bearing
Horizontal spindle
Bearing nut
Abb.5-13: Adjust horizontal spindle bearing
GB
68
MZ4S_GB_5-2.fm
 Remove the top cover.
 Remove the transmission of the upper drive shaft.
 Loosen the stud screws on the bearing nut.
 Slightly adjust the play in the bearing with the bearing nut.
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5.4.15 Maintenance and replacement of the wiper
Wipers are used on each sliding rail. The wipers are used to prevent the penetration of impurities on the sliding rail.
Check the wipers at regular intervals. Carefully check for unusual wear, scratches or damage
caused by chips.
Damaged wipers negatively impact machine accuracy.
Replace damaged wipers immediately.
It is recommended to check the wipers at least every 1000 operating hours.
5.4.16 Cleaning the cooling lubricant tank
 Cooling lubricants and tanks on page 70
 Remove the cover plate on the machine toot.
Abb.5-14: Tank with coolant pump
5.5
Recommended wearing parts
MZ4S_GB_5-2.fm
V-belt bundle drive, feed rate
V-belt bundle drive, spindle
Wipers on the guide tracks
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5.6
Cooling lubricants and tanks
CAUTION!
The cooling lubricant can cause diseases. Avoid direct contact with cooling lubricant or
parts covered in cooling lubricant.
Cooling lubricant circuits and tanks for water-cooling lubricant mixtures must be completely
emptied, cleaned and disinfected as needed, but at least once per year or every time the cooling lubricant is replaced.
If fine chips and other foreign matters are accumulated in the coolant tank, the machine can no
longer be correctly supplied with coolant. Furthermore, the lifetime of the coolant pump is
reduced.
When processing cast iron or similar materials generating fine chips, cleaning the coolant tank
more often is recommended.
Limit values
The cooling lubricant must be replaced, the cooling lubricant circuit and tank emptied,
cleaned and disinfected if
 the pH value drops by more than 1 based on the value during initial filling. The maximum
permissible pH value during initial filing is 9.3
 there is a perceivable change in the appearance, odour, floating oil or increase of the bacte-
ria to more than 10/6/ml
 there is an increase in nitrite content to more than 20 ppm (mg/1) or nitrate content to more
than 50 ppm (mg/1)
 there is an increase in the N-nitrosodiethanolamine (NDELA) to more than 5 ppm (mg/a)
CAUTION!
Comply with the manufacturer's specifications for mixture ratios, hazardous substances,
e.g. system cleaners, including their permissible minimum use times.
CAUTION!
Since the cooling lubricant escapes under high pressure, pumping out the coolant by
using the existing cooling lubricant pump via a pressure hose into a suitable tank is not
recommended.
ENVIRONMENTAL PROTECTION
During work on the cooling lubricant equipment please make sure that
 collector tanks are used with sufficient capacity for the amount of liquid to be col-
lected.
 liquids and oils should not be spilled on the ground.
Clean up any spilled liquid or oils immediately using proper oil-absorption methods and dispose of them in accordance with current statutory environmental regulations.
Collect leakages
Do not re-introduce liquids spilled outside the system during repair or as a result of leakage
from the reserve tank, instead collect them in a collecting container for disposal.
Never dump oil or other substances which are harmful to the environment into water inlets,
rivers or channels. Used oils must be delivered to a collection centre. Consult your supervisor if
you do not know where the collection centre is.
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70
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Disposal
Coolant lubricating
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5.6.1
Inspection plan for water-mixed cooling lubricants
Company:
No.:
Date:
used cooling lubricant
size to be checked
Inspection methods
noticeable
changes
Appearance, odour
pH value
Laboratory techniques
electrometric with pH meter
(DIN 51369)
Local measurement method:
Inspection
intervals
daily
weekly 1)
Procedure and comment
Find and rectify causes,
e.g. skim off oil, check filter, ventilate cooling
lubricant system
if pH value decreases
> 0.5 based on initial filing:
Measures in accordance manufacturer's
recommendations
with pH paper
(Special indicators with
suitable measuring range)
Usage concentration
Manual refractometer
weekly 1)
Base reserve
Acid titration in accordance
with
Manufacturer's
recommendation
Test sticks method or
laboratory method
as required
> 1.0 based on initial filing:
Replace cooling lubricant, clean cooling
lubricant circulation system
Method results in incorrect values with tramp
oil content
Method is independent of tramp oil content
weekly 1)
> 20 mg/L nitrite:
Nitrite content
Replace cooling lubricant or part
or inhibiting additives;
otherwise NDELA (N-nitrosodiethanolamine)
in the cooling lubricant system and in the air
must be determined
> 5 mg/L NDELA in the cooling lubricant
system:
Nitrate/nitrite content
Test sticks method or
of the preparation water, if laboratory method
this is not removed from
the public
grid
as required
Replacement,
clean and disinfect cooling lubricant
circulation system, find nitrite source and, if
possible, rectify.
Use water from the public grid if there is
water from the pubic grid has
> 50 mg/l nitrate: Inform the waterworks
1) The specified inspection intervals (frequency) are based on continuous operation. Other operational
conditions can result in other inspection intervals; exceptions are possible in accordance with Sections 4.4
and 4.10 of the TGS 611.
Editor:
coolant_GB.fm
Signature:
Coolant lubricating
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71
6
Ersatzteile - Spare parts
6.1
Ersatzteilbestellung - Ordering spare parts
Bitte geben Sie folgendes an - Please indicate the following :




Seriennummer - Serial No.
Maschinenbezeichnung - Machines name
Herstellungsdatum - Date of manufacture
Artikelnummer - Article no.
Die Artikelnummer befindet sich in der Ersatzteilliste. The article no. is located in the spare
parts list. Die Seriennummer befindet sich am Typschild. The serial no. is on the rating plate.
6.2
Hotline Ersatzteile - Spare parts Hotline
+49 (0) 951-96555 -118
[email protected]
6.3
Service Hotline
+49 (0) 951-96555 -100
[email protected]
6.4
Elektrische Ersatzteile - Electrical spare parts
6.5
Schaltplan - Wiring diagram
milling-parts-preface_DE-GB.fm
Der aktuelle Schaltplan mit Ersatzteilliste befindet sich im Schaltschrank der Fräsmaschine.
The current circuit diagram and spare parts list is located in the control cabinet of the milling
machine.
DE | GB
72
Ersatzteile - Spare parts
Getriebe allgemein - General gear box
MZ4S_parts.fm
6.6
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
73
DE | EN
74
Bezeichnung
Getriebe
Welle
Abstandshalter
Zahnrad
Zahnrad
Zahnrad
Riemenscheibe
Handrad
Deckel
Kugellager
Kugellager
Kugellager
Haltering
Haltering
Passfder
Passfder
Welle
Zahnrad
Zahnrad
Abstandshalter
Kugellager
Welle
Zahnrad
Ring
Abstandshalter
Kugellager
Sicherungsring
Passfder
O-Ring
Welle
Platte
Getriebewelle
Zahnrad
Zahnrad
Öldeckel
Nadellager
Kugellager
Haltering
Haltering
Haltering
Passfder
O-Ring
Welle
Abstandshalter
Zahnrad
Zahnrad
Kugellager
Passfder
Welle
Buchse
Welle
Wellendichtring
Deckel
Zahnrad
Abstandshalter
Kugellager
Kugellager
Sicherungsring
Sicherungsring
O-Ring
Welle
Welle
Abdeckung
Welle
Feder
Stahlkugel
Zahnrad
Welle
Handrad
O-Ring
Sicherungsring
Flachkopfschraube
Ölschauglas
Öl Ablassschraube
Öldeckel
Getriebe allgemein - General gear box
Menge
Grösse
Artikelnummer
Designation
Qty.
Size
Item no.
Gear Box
1
UM41019
03346245101
Shaft
1
UM41025
03346245102
Spacer
1
068x4t
03346245103
Gear
1
M2x28T
03346245104
Gear
2
M2x24T
03346245105
Gear
1
M2x32T
03346245106
Belt Wheel
1
A2x127 PCD
03346245107
Handle Wheel
1
UM41039
03346245108
Cap
1
UM41038
03346245109
Ball Bearing
2
6206ZZ
03346245110
Ball Bearing
1
6008ZZ
03346245111
Ball Bearing
1
6008 DDU
03346245112
Retaining Ring
2
STW30
03346245113
Retaining Ring
1
STW40
03346245114
Key
2
8x7x90L
03346245115
Key
1
8x7x50L
03346245116
Shaft
1
UM41034
03346245117
Gear
1
M2x36T
03346245118
Gear
1
M2x48T
03346245119
Spacer
1
0 62x3t
03346245120
Ball Bearing
3
6006ZZ
03346245121
Shaft
1
M2x18T
03346245122
Gear
1
M2x52T
03346245123
Oil Cap
1
UM41033
03346245124
Spacer
1
055x3t
03346245125
Ball Bearing
1
6205ZZ
03346245126
Retaining Ring
1
RTW52
03346245127
Key
1
8x7x25L
03346245128
O-Ring
1
G45
03346245129
Shaft
1
M2x24T
03346245130
Plate
2
026x4t
03346245131
Gear Shaft
1
M2x40T
03346245132
Gear
1
M2x48T
03346245133
Gear
1
M2x44T
03346245134
Oil Cap
1
UM41060
03346245135
Needle Bearing
2
K20x26x20
03346245136
Ball Bearing
1
6007ZZ
03346245137
Retaining Ring
3
STW45
03346245138
Retaining Ring
3
STW35
03346245139
Retaining Ring
1
RTW55
03346245140
Key
1
8x7x32L
03346245141
O-Ring
1
G50
03346245142
Shaft
1
M2x20T
03346245143
Spacer
2
034x3t
03346245144
Gear
1
M2x48T/20T
03346245145
Gear
1
M2x36T
03346245146
Ball Bearing
1
6207ZZ
03346245147
Key
1
8x7x18L
03346245148
Shaft
1
UM41045
03346245149
Bushing
1
075x10t
03346245150
Shaft
1
UM41049
03346245151
Oil Seal
1
UM41140-02
03346245152
Cap
1
UM41048
03346245153
Gear
1
M2x54T/20T
03346245154
Spacer
1
UM41046
03346245155
Ball Bearing
1
6009 DDU
03346245156
Ball Bearing
1
6009ZZ
03346245157
Retaining Ring
1
RTW35
03346245158
Retaining Ring
1
RTW75
03346245159
O-Ring
1
G30
03346245160
Shaft
1
UM41024
03346245161
Racking Shaft
2
UM41022
03346245162
Cover
1
UM41021
03346245163
Rack Block
3
UM41023-05
03346245164
Spring
3
01x60x23L
03346245165
Steel Ball
3
06.5
03346245166
Gear
3
M1x31T
03346245167
Shaft
3
UM41079
03346245168
Plum Handle
3
ID-16
03346245169
O-Ring
3
P16
03346245170
Retaining Ring
3
S20
03346245171
Flat Head Screw
3
M8x70L
03346245172
Oil Sight Glass
1
1/2”PT
03346245173
Drain Oil Plug
1
368L-3/8”PTx70L 03346245174
Oil Cap
1
3/8”PT
03346245175
MZ4S_parts.fm
Pos
.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
6.7
Pos.
MZ4S_parts.fm
1
2
3
Allgemeine Kreuzschlittenanordnung - General cross slide assembly
Allgemeine Kreuzschlittenanordnung - General cross slide assembly
Menge
Grösse
Designation
Qty.
Size
Gehäuse
Cross Slide Body
1
UM41001-01
Abstandshalter
Spacer
1
60x120x11t
Halter
Holder
1
UM41003
Bezeichnung
4
Y-Achse Kugelumlaufspindel
Y axis Ball Screw
1
5
Schwenkkopf
Swivel Head Body
1
6
Linearführung
Linear Guide
2
7
8
9
10
11
12
13
14
15
16
17
Platte
Welle
Abstandshalter
Platte
Motorriemenscheibe
Hülse
Welle
Kegelradgetriebe
Motorständer
Einstellschraube
Platte
Slide Plate
Shaft
Spacer
Connecting Seat
Motor Pulley
Sleeve
Shaft
Bevel Gear
Motor Stand
Adjusting Bolt
Plate
1
1
1
1
1
1
1
1
1
4
2
Tr25xP5-LT
Artikelnummer
Item no.
03346235201
03346235202
03346235203
03346235204
UM41005
03346235205
BGXH25FN+BGR25
03346235206
UM41008-01
UM41012
036x6t
UM41014-01
UM41082
UM41083
UM41084
M2x18T
UM41088
UM41089
UM41118
03346235207
03346235208
03346235209
03346235210
03346245211
0334624212
03346245213
03346245214
03346245215
03346245216
03346245217
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
75
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Stahlstift
Buchse
Platte
Verschlussschraube
Griff
Abstandshalter
Block
Stift
Motor
Feder
Kugellager
Schraube
Sechskantschraube
Ölschraube
Stopper
Stahlstift
Keilriemen
Aluminiumschiene
Endanschlag
Abstandshalter
Platte
Solid Steel Pin
Bushing
Release Plate
Lock Screw
Handle
Spacer
Handle Block
Solid Taper Pin
Motor
Spring
Ball Bearing
Screw
Hex Bolt
Oil Plug
Stopper
Steel Pin
V-Belt
Aluminum Rail
Limit Block
Protecting Spacer
Plate
2
2
2
2
1
1
1
1
1
1
2
1
2
1
1
2
2
1
2
1
1
39
Label
label
1
03346245218
03346245219
03346245220
03346245221
03346245222
03346245223
03346245224
03346245225
03346245226
03346245227
03346245228
03346245229
03346245230
03346245231
03346245232
03346245233
03346245234
03346245235
03346245236
03346245237
03346245238
03346245239
Horizontales / Vertikales Spindelsystem - Horizontal / vertical spindle system
MZ4S_parts.fm
6.8
UM41127
UM41128
UM41129
M12
M10x60L
026x5t
UM41162
6
3.75kW,2P
X404114
6002ZZ
M6x16L
M12x60L
3/8”PT
X504055
010x40L
A 31”
630mmL
U1216-25
050x15t
DE | EN
76
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
Spindelsystem - Spindle system
Menge
Grösse
Artikelnummer
Qty.
Size
Item no.
Spacer
1
UM31024
03346235301
Spacer
1
UM31025
03346235302
Front Cover
1
UM41015
03346235303
03346235304
Pos.
Bezeichnung
Designation
1
Abstandshalter
2
Abstandshalter
3
Vorderseite
4
Vorderseite
Front Cover
1
UM41016
5
Getriebewelle
Transmission Shaft
1
UM41064-01
03346235305
6
Kupplung
Coupling
1
UM41065-01
03346235306
7
Abstandshalter
Spacer
1
UM41066
03346235307
03346245308
8
Abstandshalter
Spacer
1
UM41067
9
Horizontale Spindel
Horizontal Spindle
1
UM41068
03346245309
10
Zahnrad
Gear
1
UM41075
03346245310
11
Abstandshalter
Spacer
1
UM41076
03346245311
12
Zahnrad
Gear
1
UM41078-02
03346245312
13
Welle
Shaft
1
UM41111
03346245313
14
Ring
Collar
1
UM41112
03346245314
15
Kegelradgetriebe
Bevel Gear
1
UM41113
03346245315
16
Lagerring
Bearing Spacer
1
UM41121
03346245316
17
Lagerring
Bearing Spacer
1
UM41122
03346245317
18
Abstandshalter
Spacer
1
UM41138
03346245318
19
Positionierstift
Positioning Pin
2
UM41100
03346245319
20
Lagermutter
Bearing Nut
1
AN02
03346245320
21
Scheibe
Star Washer
1
AW02
03346245321
22
Lagermutter
Bearing Nut
1
PM-M50-4
03346245322
23
Kegelrollenlager
Taper Roller Bearing
1
32211
04032211
Axiallager
Thrust Bearing
1
51111
04051111
Kugellager
Ball Bearing
2
6009
0406009
26
Kugellager
Ball Bearing
2
6012
0406012
27
Passfeder
Key
2
KF2R12850
03346245327
28
Passfeder
Key
1
KF2R4420
03346245328
29
Passfeder
Key
1
KF2R8728
03346245329
30
Haltering
Retaining Ring
2
STW60
03346245330
31
Haltering
Retaining Ring
1
RTW75
03346245331
32
Haltering
Retaining Ring
2
RTW95
03346245332
MZ4S_parts.fm
24
25
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
77
6.9
Pos.
Vertikales Getriebesystem - Vertical spindle transmission system
Menge
Grösse
Artikelnummer
Bezeichnung
Designation
Qty.
Size
Item no.
Gehäuse
Housing
1
UM41095
03346245401
Welle
Shaft
1
UM41096
03346245402
Kegelradgetriebe
Bevel Gear
1
UM41117
03346245403
Abstandshalter
Spacer
1
UM41097
03346245404
Winkellager
Angular Bearing
1
7011C
03346245405
Winkellager
Angular Bearing
1
7013C
03346245406
Lagermutter
Bearing Nut
1
M40X1.5P
03346245407
Scheibe
Star Washer
1
AW08
03346245408
Passfeder
Key
1
8x7x40L
03346245409
MZ4S_parts.fm
1
2
3
4
5
6
7
8
9
Vertikales Spindelgetriebe - Vertical spindle transmission
DE | EN
78
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
6.10
Vertikale Spindelbaugruppe - Vertical spindle assembly
MZ4S_parts.fm
Vertikale Spindelbaugruppe - Vertical spindle assembly
Menge
Grösse
Artikelnummer
Qty.
Size
Item no.
Housing
1
U M41090
03346245601
Plate
1
UM41092
03346245602
Clamping nut
1
UM41110
03346245603
Pos.
Bezeichnung
Designation
1
Gehäuse
2
Platte
3
Klemmmutter
4
Stahlstift
Steel Pin
7
5x16
03346245604
5
Kegelradgetriebe
Bevel Gear
1
UM41116
03346245605
6
Abdeckung
Cover
1
UM41091
03346245606
7
Sicherungsstift
Lock Pin
1
UM41120
03346245607
8
Feder
Quill
1
UM41098
03346245608
9
Vertikale Spindel
Vertical Spindle
1
UM41102
03346245609
10
Abdeckung
Cover
2
UM41099
03346245610
11
Positionierstift
Positioning Pin
2
X002169
03346245611
12
Abstandhalter
Spindle Collar
1
UM41115
03346245612
13
Anzugstange
Draw Bar
1
UM41103
03346245613
14
Abdeckung
Head Cover
1
UM41094-1
03346245614
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
79
15
Abdeckung
Top Cover
1
UM41094-2
03346245615
03346245616
16
Klemmmutter
Screw Seat
4
UM32044
17
Innensechskantschraube
Hex Socket Cap Screw
4
M12x90L
03346245617
18
Lagermutter
Bearing Nut
1
PM-M68
03346245618
19
Lagermutter
Bearing Nut
1
PM-M50
03346245619
20
Stellschraube
Set Screw
1
M10x10L
21
Sperrgriff
Lock Handle
1
M12x20L
03346245621
22
Kugellager
Ball bearing
1
BA7016C
03346245622
23
Kugellager
Ball bearing
1
BA7014C
03346245623
24
Kugellager
Ball bearing
2
BA7010C
03346245624
25
Sicherungsring
Retaining Ring
1
STW48
03346245625
26
Spindelvorschub
Spindle Handle System
1
600VL-2GA-S01
03346245626
6.11
Handgriff Spindelsystem - Spindle handle system
Werkzeugspannung horizontal - Horizontal tool clamping system
Artikelnummer
Designation
Qty.
Size
Item no.
1
Getriebewelle
Transmission Shaft
1
UM41107-01
03346245701
2
Skalenring
Dial Plate
1
UM41105
03346245702
3
Abstandshalter
Spacer
1
UM41108
03346245703
4
Hülse
Oilless Bushing
1
SPB-252825
03346245704
5
Griff
Handle
1
180L
03346245705
6
Verschlussschraube
Lock Screw
1
M6x1.0Px30L
03346245706
7
Griff Sitz
Handle Seat
1
X002138
03346245707
8
Buchse
Bushing
1
B-176
03346245708
9
Schraube
Screw
1
M8x11L
03346245709
03346245710
10
Feder
Spring
1
X502096+97
11
Innensechskantschraube
Hex Socket Cap Screw
4
M5x16L
03346245711
12
Passfeder
Key
1
3x3x18L
03346245712
13
Stift
Pin
1
X502098-2
03346245713
MZ4S_parts.fm
Grösse
Bezeichnung
DE | EN
80
Menge
Pos
.
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
6.12
Baugruppe Frästisch - Working table assembly
MZ4S_parts.fm
Baugruppe Frästisch - Working table assembly
Menge
Grösse
Qty.
Size
Item no.
Protecting Spacer
2
UM33060
03346245901
03346245902
Pos.
Bezeichnung
Designation
1
Ring
Artikelnummer
2
Netz
Net
2
UM33068
3
Abdeckung
Cover
1
UM37007
03346245903
4
Motorplatte
Motor Seat
1
UM37060
03346245904
5
Hülse
Sleeve
1
UM37010
03346245905
6
Stange
Rod
1
UM37011
03346245906
7
Riemenscheibe
Motor Pulley
1
5Mx18Tx20W
03346245907
8
Riemenscheibe
Motor Pulley
1
5Mx54Tx20W
03346245908
9
Abstandshalter
Spacer
1
20x30x10t
03346245909
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
81
10
Abdeckung X-Achse
Cover X axis
1
UM41126A
03346245910
11
Arbeitstisch
Working Table
1
1200x250
03346245911
12
Klammer
Bracket-Right
1
UM43057-01
03346245912
13
Winkeltabelle
Angle Table
1
500x900
03346245913
14
Stützstange
Support Rod
2
1320 mm
03346245914
15
Scheibe
Thickness Washer
6
UM43082
03346245915
16
Klemmmutter
Nut
6
M6
03346245916
03346245917
Verschluss
Net
1
UM43085
18
X-Achse Kugelumlaufspindel
X axis Ball Screw
1
UM47005
03346245918
19
Halterung links
Bracket-Left
1
UM47006
03346245919
20
Abdeckung
Cover
1
UM47009
03346245920
21
Riemen
Belt
1
HTD 5M-20-450L
03346245921
22
Ring
Dial Seat
1
X5W04096
03346245922
23
T-Nut
T-Nut
6
M14xP2.0
03346245923
24
Drucklager
Thrust Bearing
2
51104
04051140
25
Lagermutter
Bearing Nut
2
YSR M20x1.0
03346245925
26
Motor
Motor
1
PF22-0400-7.5S4-40N
03346245926
27
Kugellager
Ball Bearing
4
6004ZZ
0406004
28
Sechskantschraube
Hex Bolt
6
M12x60L
03346245928
29
DRO-Platte für X-Achse
DRO Plate for X axis
1
UM37103
03346245929
30
DRO-Platte für X-Achse
DRO Plate for X axis
1
UM37103MR
03346245930
31
Aluminiumteller
Aluminum Plate
1
1250mmL
03346245931
32
Aluminiumschiene
Aluminum Rail
1
830mmL
03346245932
33
Endanschlag
Limit Block
2
U1216-25
03346245933
MZ4S_parts.fm
17
DE | EN
82
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
6.13
Handradsystem - Handle wheel system
Handradsystem - Handle wheel system
Menge
Grösse
Artikelnummer
Pos.
Bezeichnung
Designation
Qty.
Size
Item no.
1
Rundes Griffrad
Round Handle Wheel
2
0200-M10
033462451001
2
Abdeckung
Cover
2
W1-1/4" 20
033462451002
033462451003
Sicherungsring
Lock Ring
2
X204065
4
Skalenring X / Y-Achse
Dial Ring for X / Y axis
2
0.02/ 5 mm
033462451004
5
Kupplung
Clutch
2
X204064
033462451005
6
Nadellager
Needle Bearing
2
TLA-1622
033462451006
7
Griff
Grip
2
X504098
033462451007
8
Feder
Spring
2
X404114
033462451008
MZ4S_parts.fm
3
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
83
6.14
Pos.
Baugruppe Maschinenrahmen - Machine frame assembly
Menge
Grösse
Designation
Qty.
Size
Stift
Pin
2
UM32056
Teller
Plate
1
UM33031
Schalterhalterung
Switch Bracket
1
UM37027
Z-Achse Motorplatte
Z axis Motor Seat
1
UM9247
Maschinenrahmen
Machine Frame
1
UM42001-02
Keilleiste
Gib
1
25x590L
Nivellierpad
Leveling Pad
4
UM44009-01
Kühlmittelstand
Coolant Stand
1
UM44012
Maschinenbasis
Machine Base
1
UM9001
Riemenscheibe Z-Achse Motor Pulley Z axis
1
UM9071-28F
Wischer
Wiper
2
UM72007AS
Wischer
Wiper
2
UM72008AS
Nivellierbolzen
Leveling Bolt
4
M20xP2x80L
Flexibler Griff
Flexible Handle
2
M12x40L
Einstellschraube
Adjusting Screw
2
M8x37L
Kühlmittelpumpe
Coolant Pump
1
0.09KW,400V
Ölschraube
Oil Plug
1
1/2"PT
Aluminiumteller
Aluminum Plate
1
650mmL
Aluminiumschiene
Aluminum Rail
1
500mmL
Block
Limit Block
1
U1216-25
Schlüssellose Welle
Keyless Shaft
1
SI-28
Z-Achsen-Griff
Z Axis Handle Wheel
1
600VL- 4GA-S01
Motor
Motor
1
UM37059-XB
Bezeichnung
Artikelnummer
Item no.
033462451101
033462451102
033462451103
033462451104
033462451105
033462451106
033462451107
033462451108
033462451109
033462451110
033462451111
033462451112
033462451113
033462451114
033462451115
033462451116
033462451117
033462451118
033462451119
033462451120
033462451121
033462451123
033462451124
MZ4S_parts.fm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
24
Baugruppe Maschinenrahmen - Machine frame assembly
DE | EN
84
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
6.15
Pos.
Getriebesystem Z Achse - Z axis transmission system
Menge
Grösse
Designation
Qty.
Size
Abstandshalter
Spacer
2
UM42011
Kegelradgetriebe
Bevel Gear
1
M2x30T-RH
Halterung
Bracket
1
UM9081
Rolle
Pulley
1
UM9103
Handrad Übertragungsstange Hand Wheel Transmission Rod
1
UM9104
Lagerbock
Bearing Bracket
1
UM9105
Lagerbock
Bearing Bracket
1
UM9106
Kegelradgetriebe
Bevel Gear
1
UM9107
Getriebewelle
Transmission Shaft
1
UM9108
Getriebewelle
Transmission Shaft
1
UM9109
Universelle Kurbel
Universal Crank
1
SJS16(ST: 390-410)
Skalenhalter
Dial Holder
1
UM9111
Zahnradhalterung
Gear Bracket
1
UM9211
Sicherheitshandrad
Safety Hand Wheel
1
HAR-200G-CLM 016
Kugellager
Ball Bearing
6
6004ZZ
Skale
Dial Plate
1
X5W04096
Ring Z-Achse
Dial Ring Z axis
1
0.02/2.5 mm
Gürtel
Belt
1
HTD 8M-15-760L
Ring
Ring
1
Bezeichnung
Artikelnummer
Item no.
033462451201
033462451202
033462451203
033462451204
033462451205
033462451206
033462451207
033462451208
033462451209
033462451210
033462451211
033462451212
033462451213
033462451214
033462451215
033462451216
033462451217
033462451218
033462451219
MZ4S_parts.fm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Getriebesystem Z Achse - Z axis transmission system
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
85
6.16
Getriebesystem Y Achse - Y axis transmission system
Getriebesystem Y Achse - Y axis transmission system
Pos.
Bezeichnung
Designation
Menge
Grösse
Artikelnummer
Qty.
Size
Item no.
033462451301
Servomotor Riemenscheibe
Servo Motor Pulley
1
5Mx18Tx20W
2
Y-Achse Motorriemenscheibe
Y axis Motor Pulley
1
HTD-5Mx54Tx20W
033462451302
3
Muttergehäuse
Nut Housing
1
UM37017
033462451303
4
Kegelradgetriebe
Bevel Gear
1
M2x30T-LH
033462451304
5
Handradwelle
Hand Wheel Shaft
1
UM37020
033462451305
6
Halterung
Bracket
1
UM37021
033462451306
7
Abstandshalter
Spacer
1
UM42011
033462451307
8
Kegelradgetriebe
Bevel Gear
1
M2x30T-RH
033462451308
9
Halterung
Bracket
1
UM42028
033462451309
10
Abstandshalter
Spacer
1
UM42032
033462451310
11
Abstandshalter
Spacer
4
UM47010
033462451311
12
Teller
Plate
1
UM47019
033462451312
13
Motorplatte
Servo Motor Seat
1
UM47018
033462451313
14
Lagermutter
Bearing Nut
1
YSR M50x1.5
033462451314
15
Untersetzungsgetriebemotor
Reducing Gear Motor
1
PF22-0400-7.5S4-28N
033462451315
16
Winkellager
Angular Bearing
2
7010A
033462451316
17
Kugellager
Ball Bearing
3
6004ZZ
033462451317
18
Haltering
Retaining Ring
1
STW20
033462451318
19
Gürtel
Belt
1
5M-20-610L
033462451319
20
Skalenring
Dial Plate
1
X5W04096
033462451320
MZ4S_parts.fm
1
DE | EN
86
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
6.17
Sattelbaugruppe - Machine saddle assembly
MZ4S_parts.fm
Sattelbaugruppe - Machine saddle assembly
Menge
Grösse
Qty.
Size
Item no.
Stopper
2
UM33006-a1
033462351401
033462351402
Pos.
Bezeichnung
Designation
1
Stopper
Artikelnummer
2
Abdeckung
Cover
1
UM37028SL
3
Top Schutzhülle
Top Protecting Cover
1
UM41124
033462351403
4
Messingstück
Brass Piece
2
012.7x10
033462351404
5
Sattel
Saddle
1
UM43001S
033462351405
6
Trägerplatte-R
Support Plate-R
1
UM43002-02
033462351406
7
Stützplatte-L
Support Plate-L
1
UM43002-02MR
033462351407
8
Gib
Gib
2
29x580L
033462351408
9
Gib
Gib
1
29x580L
033462351409
10
Block
Lock Block
2
UM43005
033462351410
11
Keilleiste
Gib
1
19x640L
033462351411
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
87
12
Abdeckung
Ending Cover
1
UM47007
033462351412
033462351413
13
Teller
Plate
1
UM47004
14
Endschalterplatte
Limit Switch Plate
1
UM47031
033462351414
15
Lagersitz
Bearing Seat
1
UM9008
033462351415
033462351416
Hülse
Sleeve
1
UM9094
17
Z-Achse Kugelumlaufspindel & Mutter
Z axis Ball Screw & Nut
1
Tr40xP5x532L-LH
033462351417
18
Rolle
Pulley
1
8M-45-40T
033462351418
19
Ring
Bind Collar
1
UM9114
033462451419
20
Ring
Protect Ring
1
040x5t
033462451420
21
Bodenschutzhülle
Bottom Protecting Cover
1
UM9149SL
033462451421
22
Endschalterplatte
Limit Switch Plate
1
UM9242SL
033462451422
24
Flexibler Griff
Flexible Handle
2
M10x85L
033462451424
25
Flexibler Griff
Flexible Handle
2
M16x40L
033462451425
26
Einstellschraube
Adjusting Screw
7
M8x37L
033462451426
27
Lagermutter
Bearing Nut
1
YSR M55x2.0
033462451427
28
Riemen
Belt
1
HTD 8M-25-936L
033462451428
29
Nabe
Shaft-Hub Locker
1
SA-50
033462451429
30
Bushing
Oilless Bushing
1
55x60X20
033462451430
31
Kugellager
Ball Bearing
1
6011ZZ
0406011
32
Kugellager
Ball Bearing
1
6811ZZ
0406811
33
Drucklager
Thrust Bearing
1
8111
0408111
MZ4S_parts.fm
16
DE | EN
88
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
6.18
Pos.
Horizontales Gegenlager - Horizontal steady device
Menge
Grösse
Designation
Qty.
Size
Horizontales Gerät
Horizontal Steady Device
1
UM41131
Keilleiste
Gib
1
20x82
Halterung
Bracket
1
UM41132
Teller
Plate
2
UM41129
Buchse
Bushing
2
UM41128
Nadellager
Needle Bearing
1
KT303818
Ölbuchse
Oil Bushing
2
SPB303815
Innensechskantschraube
Hex Socket Cap Screw
1
M12x130L
Bezeichnung
Artikelnummer
Item no.
033462452301
033462452302
033462452303
033462452304
033462452305
033462452306
033462452307
033462452308
MZ4S_parts.fm
1
2
3
4
5
6
7
8
Horizontales Gegenlager - Horizontal steady device
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
89
6.19
Pos.
Werkzeuge Horizontalbearbeitung - Horizontal tools list
Menge
Grösse
Designation
Qty.
Size
Langer Fräsdorn
Longer Cutter Arbor
1
Ø16mm (ISO40)
Langer Fräsdorn
Longer Cutter Arbor
1
Ø22mm (ISO40)
Langer Fräsdorn
Longer Cutter Arbor
1
Ø27mm (ISO40)
Langer Fräsdorn
Longer Cutter Arbor
1
Ø32mm (ISO40)
MK3 Adapter
MT-3 Adapter
1
ISO40/MT3
MK2 Adapter
MT-2 Adapter
1
MT3/MT2
MK1 Adapter
MT-1 Adapter
1
MT3/MT1
Bezeichnung
Artikelnummer
Item no.
033462452401
033462452402
033462452403
033462452404
033462452405
033462452406
033462452407
MZ4S_parts.fm
1
2
3
4
5
6
7
Werkzeuge Horizontalbearbeitung - Horizontal tools list
DE | EN
90
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
6.20
Schutzabdeckungen und Blechteile - Protective covers and sheet metal parts
Schutzabdeckungen und Blechteile - Protective covers and sheet metal parts
MZ4S_parts.fm
Pos.
Bezeichnung
Designation
Menge
Grösse
Artikelnummer
Qty.
Size
Item no.
1
Abdeckung
Cover
1
UM41009
033462352501
2
Getriebedeckel
Gear Box Cover
1
UM41017-01
033462352502
3
Riemenscheibenabdeckung
Pulley Cover
1
UM41018-01
033462352503
4
Oberer Abschlussdeckel
Top Ending Cover
1
UM41141-OPT
033462352504
5
Magnethalterung
Magnet Bracket
1
UM41148-01
033462352505
6
Anschlusskasten
Terminal Box
1
UM41149
033462352506
7
Rahmenabdeckung-R
Frame Cover-R
1
UM42002
033462452507
8
Rahmenabdeckung-L
Frame Cover-L
3
UM42049
033462452508
9
Rückseite
Back Cover
2
UM42052-1
033462452509
10
Obere Abdeckung
Top Cover
1
UM42053
033462452510
11
Schutzhülle
Protecting Cover
1
UM42056-01
033462452511
12
Tube
Tube
1
UM42059
033462452512
13
Halterung
Bracket
1
UM43109
033462452513
14
Abdeckung
Cover
1
UM47029
033462452514
15
Sattelfrontabdeckung
Saddle Front Cover
1
UM47030
033462452515
16
Z Motorabdeckung
Z Motor Cover
1
UM47054
033462452516
17
X Motorabdeckung
X Motor Cover
1
UM47055VB
033462452517
18
Y Motorabdeckung
Y Motor Cover
1
UM47058
033462452518
19
Abdeckung
Cover
2
UM9207
033462452519
20
Basisabdeckung
Base Cover
1
UM9218
033462452520
21
Schutz komplett
Completely Table Guard
1
UM600-G1
033462452521
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
91
6.21
Zentralschmierung - Lubrication System
Zentralschmierung - Lubrication System
Pos.
Bezeichnung
1
Automatischer
Schmierstoffgeber
2
Innensechskantschraube
3
Flexibles Stahlrohr
4
Winkeladapter
5
Gerader Adapter
Menge
Grösse
Artikelnummer
Qty.
Size
Item no.
Automatic Lubricator
1
2L, Optional
033462452601
Hex Socket Cap Screw
4
M6x25L
033462452602
Flexible Steel Tube
1
d4x1800L
033462452603
Elbow Adaptor
3
AL-013
033462452604
Plane Straight Adapter
3
AL-020
033462452605
Designation
Aluminiumrohr
Aluminum Pipe
6
d4
033462452606
7
Innensechskantschraube
Hex Socket Cap Screw
2
M5x25L
033462452607
8
Verteiler
Distributor
1
d4, 8 holes
033462452608
MZ4S_parts.fm
6
DE | EN
92
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
6.22
Kühlmittelpumpe und Arbeitsleuchte - Cooling pump and work lamp
Kühlmittelpumpe und Arbeitsleuchte - Cooling pump and work lamp
Menge
Grösse
Qty.
Size
Artikelnummer
Pos.
Bezeichnung
Designation
1
Kunststoffdüse
Plastic Nozzle
1
Metalldüse
Metal Nozzle
1
Optional
2
Ventil
Valve
1
PT 3/8” x 1/2”
033462452702
3
Wanne
Tub
1
M6x40
033462452703
Item no.
033462452701
0334624527011
4
Scheibe
Washer
4
06
033462452704
5
Innensechskantschraube
Hex Socket Cap Screw
2
M6x12
033462452705
033462452706
6
Schlauch
Hose
1
1/2”
7
Schlauchanschluss
Hose Fitting
2
PT 3/8” x 1/2” (90° )
033462452707
8
Schlauchschelle
Hose Clamp
2
5/6” (11 ~ 20)
033462452708
9
Kühlmittelpumpe
Coolant pump
1
1/8HP
033462452709
10
Halogenlampe
Halogen Lamp
1
24V 500L
033462452710
LED-Lampe
LED Lamp
1
24V 500L (Optional)
0334624527101
M4x16
Rundkopfschraube
Round Head Cap Screw
4
Lampenhalter
Work Light Bracket
1
13
Innensechskantschraube
Hex Socket Cap Screw
2
033462452711
033462452712
M6X16
033462452713
MZ4S_parts.fm
11
12
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
93
Dreharm Bedienfeld - Rotate Arm Operation Panel
MZ4S_parts.fm
6.23
DE | EN
94
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
Dreharm Bedienfeld - Rotate Arm Operation Panel
Menge
Bezeichnung
Designation
Qty.
Rundschraube mit Innensechskant
Hex Socket Round Screw
21
OP-Box-Abdeckung
Operation Box Cover
1
Innensechskantschraube
Hex Socket Cap Screw
12
Scheibe
Flat Washer
4
Kontrollkasten
Control Box
1
Einbaurahmen
Mounting Frame
1
Digitalanzeige und lineare Skala
DRO & Linear Scale
1
Bedienmuster-Bedienfeld
Operation Pattern Panel
1
Geschwindigkeitsanzeige
Speed Display
1
Schnellvorschubschalter
Rapid Feed Switch
1
Schnellwahltaste
Speed Select Button
1
Ein / Aus Schalter
ON/OFF Switch
1
Sicherheitsschalter
Safety switch
1
Sicherheitsschalter
Safety switch
1
Ein / Aus Schalter
ON/OFF Switch
1
Schnellwahltaste
Speed Select Button
1
Schalter für Kühlmittelpumpe
Coolant Pump Switch
1
Not-Halt-Schlagschalter
Emergency Switch
1
Spindel-F / R-Auswahlschalter
Spindle F/R Select Switch
1
Geschwindigkeitsregler
Speed Adjuster
1
Haltegrif
Curve Grab Handle
1
Steuerkastensitz
Control Box Seat
1
Sperrgriff
Lock Handle
1
Drehpunkt
Pivot
2
Stellschraube
Set Screw
4
Stützarm
Support Arm
1
Abdeckung
Cover
1
Stützsitz
Support Seat
1
Scheibe
Flat Washer
10
Innensechskantschraube
Hex Socket Cap Screw
10
Anschlusskasten
Connector Box
1
Steckerabdeckung
Connector Cover
1
Kontrolpanel
Jog Control Panel
1
Schalter
Jog Switch
1
Not-Halt-Schlagschalter
Emergency Switch
1
Sicherungskasten
Electrical Cabinet
1
Lichtschalter
Power Light
1
Schaltschrankschlüssel
Key electrical cabinet
1
Schrankhalterung
Cabinet Support Bracket
1
Grösse
Size
M5x12
UM35029
M6x16
6
UM35078
UM35102
NEWALL DP700
UM35103
UM13002
E-SB003
E-VR002
E-SB010
E-SA003
E-SA004
E-SB010
E-VR002
E-SA002
E-SB001
E-SA001
E-VR003
ES-121300B
UM35023
M8x30L-06x5
UM35024
M5x8
UM35025
UM35026
UM35027A
8.5
M8x25
UM35065
UM35040
UM35014
E-SB003
E-SB001
UM35060AS
E-PL001
A-172-2
UM35100
Artikelnummer
Item no.
033462453202
033462453204
033462453205
033462453206
033462453207
033462453208
033462453209
033462453210
033462453211
033462453212
033462453213
033462453214
033462453215
033462453216
033462453217
033462453218
033462453219
033462453220
033462453221
033462453222
033462453223
033462453224
033462453225
033462453226
033462453227
033462453228
033462453229
033462453231
033462453232
033462453233
033462453234
033462453235
033462453236
033462453237
033462453238
033462453239
MZ4S_parts.fm
Pos
.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
95
Schaltplan - Wiring diagram
MZ4S_parts.fm
6.24
DE | EN
96
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
MZ4S_parts.fm
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
97
MZ4S_parts.fm
DE | EN
98
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
MZ4S_parts.fm
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
99
MZ4S_parts.fm
DE | EN
100
MZ4S
Originalbetriebsanleitung
Version 1.0.4 - 2020-7-31
MZ4S_parts.fm
MZ4S
Version 1.0.4 - 2020-7-31
Originalbetriebsanleitung
DE | EN
101
Option Druckluft Werkzeugspanner - Compressed air tool spanner option
PD150-PD200-tool-spanner_parts.fm
6.25
DE | EN
102
PD150 | PD200 (3346225)
Kopie Original
Version 1.0.4 - 2020-7-31
PD150 / PD200 - Druckluft Werkzeugspanner - Compressed air tool spanner
PD150-PD200-tool-spanner_parts.fm
Pos.
Bezeichnung
Designation
Anmerkung
Grösse
Artikelnummer
Note
Size
Item no.
1
Deckelgruppe
Cover groups
03346225P02901
2
Luftschlagschrauber
Air impact wrench
03346225PDM1V
3
Steuerventil
Control valve
4
Motorgehäuse
Motor housing
ADC 12
03346225P02008
03346225P02013
5
Drosselventil
Throttle valve
Ø 21 x 57 .4
03346225P02009
6
Stößel-Anschlagplatte
Plunger stop plate
SPCE
03346225P02010
7
Drosselklappenstößel
Throttle plunger
S45C
03346225P02011
8
Feder
Spring
SWPA Ø 0.5x13
03346225X00052
9
O-Ring
0-Ring
SBR
03346225Q00050
10
Drosselventil
Throttle valve
S45C
03346225P02012
11
Gehäusedeckel-Dichtung
Housing cover gasket
T1.6
03346225Q10001
12
Motor-Dichtung
Motor gasket
Ø 39.2 x T1.6
03346225Q10002
13
Motor-Stift
Motor pin
S45C Ø2x55
03346225U42055
14
Lager
Bearing
626Z
03346225800001
15
Hintere Endplatte
Rear end plate
ADC 12
03346225P02016
S45C
03346225P02017
16
Rotor
Rotor
17
Rotorblatt
Rotor blade
03346225P02018
18
Zylinder
Cylinder
S45C
03346225P02019
19
Vordere EBT-Platte
Front EBT plate
ADC12
03346225P02020
20
Öldichtung
Oil seal
Ø6 Ø10 Ø16
03346225Q20001
21
Lager
Bearing
628z
040628z
22
Dichtung Schlagschrauberkäfig
Hammer gage gasket
Ø3.5 x Ø37.7 x Ø44.7
03346225P02078
23
Schlagbolzen
Hammer pin
Ø3.5 x Ø39.7 x Ø46.7
03346225P02076
24
Hammerkäfig
Hammer cage
Ø10 x Ø34 x T 0.3
03346225P02075
25
Anschlag
Dog
Fc15
03346225P02077
26
Amboß
Anvil
SNCM 220
03346225P02074
28
Hammertasche
Hammer case
Fc15
03346225P02072
29
Ölverschluss
Oil plug
M8 x 12
03346225T98012
03346225Q20002
30
Öldichtung
Oil seal
Ø12.5 x Ø20.5 x T
3.6
31
Gummi-Nasenschutz
Rubber nose guard
Ø12.6 x 15
03346225P02073
32
Unterlegscheibe
Washer
Ø5
03346225W20050
33
Schraube
Screw
M6 x 25
03346225T60001
34
Lufteinlassblock
Air inlet block
ZDC1
03346225P02002
35
Feder
Spring
SWPA
03346225X00051
36
Regulator-Kugel
Regulator ball
43865
03346225P02003
37
O-Ring
O-ring
P7
03346225Q0070
38
Regulator
Regulator
ZDC1
03346225P02004
39
Regulator-Platte
Regulator plate
SPCC
03346225P02005
40
Unterlegscheibe
Washer
SPCE
03346225W40030
41
Schraube
Screw
M4 x 16
03346225T14016
42
Schnellverbindung
Rapid joint
8
03346225A10001
43
Gehäusedeckel
Housing cover
ADC12
03346225P02006
44
Befestigungsring
Fixing ring
Ø16 x T 16 L
03346225P02007
PD150 | PD200 (3346225)
Version 1.0.4 - 2020-7-31
Kopie Original
DE | EN
103
45
Sicherungsstift
Retainer pin
Ø1.5 x 16 L
0334622545
46
Unterlegscheibe
Washer
Ø4
03346225W20040
47
Schraube
Screw
M4 x 16
03346225T54016
48
Steuerventil-Baugruppe
Control valve assy
A2024P
03346225P02013
48
Lufteinlassventil-A
Air inlet valve-A
S45C
03346225P02014
50
O-Ring
O-ring
P5
03346225Q00050
51
Schraube
Screw
M10 x 10
03346225T71010
52
Lufteinlassventil-B
Air inlet valve-B
S45C
03346225P02015
53
O-Ring
O-ring
P7
03346225Q00070
54
Nebengelenk
Parid joint
Ø4
03346225A10002
55
Stellring
Set ring
56
Schraube
Screw
M5 x 16
03346225T56030
Ø0.5 x 13
03346225X00053
57
Feder
Spring
58
Luftzylinder-Halterung
Air cylinder holder
03346225P02030
59
Führungsstange
Guide bar
03346225U46055
O-Ring
O-ring
Schnellverbindung
Rapid joint
62
Kolben
Piston
63
O-Ring
64
Kunststoffbuchse
03346225Q00480
Ø4
03346225A20001
O-ring
Ø5.7 x Ø57.6 x Ø69
03346225Q00570
Plastic bushing
Pa6
03346225P02032
03346225W12030
03346225P02031
03346225P02033
65
Kupplung
Clutch
66
Unterlegscheibe
Washer
Ø20 x 30 x T1
67
Halbmondring
Crescent ring
IRTW-32
68
Untere Abdeckung
Bottom cover
69
Innenring
Inner ring
70
Kopf Anzugsstange
Drawbar head
03346225P02036
70
Anzugsstange
Drawbar
03346225P02037
03346225F00032
03346225P02034A
Ø32 x Ø18 x T13
03346225P02035
71
Ring Anzugsstange
Drawbar ring
72
Schlagschrauber-Bolzen
Hammer cage pin
03346225P02038
73
Schlagschrauberkäfig
Hammer cage
74
Schlagschraubernocken
Hammer cam
PD-150
03346225P02022
75
Anschlag
Dog
PD-150
03346225P02023
Ø5.9 x 32L
03346225U46032
03346225P02021
76
Amboß
Anvil
PD-150
03346225P02025
77
Gummi-Nasenschutz
Rubber nose guard
PD-150
03346225P02027
78
Hammertasche
Hammer case
PD-150
03346225P02026
79
Baugruppe Schlagschrauber
Hammer case groups
PD-150
03346225P02907
80
Baugruppe Schlagschrauber
Hammer case groups
PD-200
03346225P02912
81
Baugruppe Kopf Schlagschrauber
Host groups
PD-150
03346225PDM1-2V
81
Baugruppe Kopf Schlagschrauber
Host groups
PD-200
03346225P02913
82
Steuerventil-Baugruppe
Control valve groups
03346225PDM2-1V
83
Stellring-Baugruppe
Set ring groups
03346225PFR3-33
84
Baugruppe Luftzylinder
Air cylinder groups
03346225PDM567
85
Baugruppe Kolben
Piston groups
03346225PDM7-3
86
Baugruppe untere Abdeckung
Bottom cover groups
03346225PDM8-9
87
Baugruppe Anzugsstange
Drawbar groups
03346225PDM1415A
PD150-PD200-tool-spanner_parts.fm
60
61
DE | EN
104
03346225P02028
PD150 | PD200 (3346225)
Kopie Original
Version 1.0.4 - 2020-7-31
Zubehör - Accessories
PD150-PD200-tool-spanner_parts.fm
6.26
PD150 | PD200 (3346225)
Version 1.0.4 - 2020-7-31
Kopie Original
DE | EN
105
PD150 / PD200 - Zubehör Druckluft Werkzeugspanner - Compressed air tool spanner accessories
Anmerkung
Grösse
Artikelnummer
Note
Size
Item no.
Designation
1
Abdeckung Schaltkasten
Control box cover
2
Schraube
Screw
3
Gehäuse der Steuerbox
Control box housing
03346225P02040
4
Magnetventilsatz
Solenoid valve set
03346225PDC6
5
Magnetventil
Solenoid valve
03346225PDC3-1
6
Schaltungsanschluss
Circuit connector
7
Kabel
Wire
8
Schnellverbindung
9
Schnellverbindung
10
T-Stück mit Schnellverbindung
T-Way with rapid joint
11
Schnellverbindung
Rapid joint
SPL-6-02
03346225A20003
12
Schnellverbindung
Rapid joint
SPL-8-02
03346225A10003
03346225P02039
M4 x 6
03346225T14006
03346225E60004
18AWG
03346225E11102
Rapid joint
SPL-4-01
03346225A20001
Rapid joint
SPL-06-01
03346225A20002
03346225PDC9-11
13
Gelenk T-Stück
T-way joint
03346225P02051
14
Luftschlauch-Baugruppe
Air pipe assy
03346225PDC1415
Gelenk
Joint
03346225E60006
15
Luftschlauch
Air pipe
Gelenkbaugruppe
Joint assy
03346225A00001
3/8" x 2.5M
03346225P02908
16
Mutter
Nut
03346225P02043
17
Kappe
Cap
03346225P02041
18
Gelenk
Joint
03346225P02042
19
Mutter
Nut
03346225P02044
20
Mutter
Nut
03346225P02045
21
Mutter
Nut
03346225P02046
26
Lampe
Light
03346225P02056
27
Sicherungshalter
Fuse holder
03346225E50901
28
Sicherung
Fuse
4A
03346225E50051
29
Anschlusskabel
Power cord
3 x 0.75 x 2m
03346225E23012
30
Kabel
Wire
18AWG
03346225E10106
31
Kabelhalter
Wire holder
UC-1
03346225A0100-08A
32
Zugentlastung
Wire clamp
03346225P02057
33
Schraube
Screw
M4 x 6
03346225T14006
34
Schnellverbindung
Rapid joint
PF 20
03346225A10004
35
Schaltkasten
Switch box
03346225P02058
36
Kabel
Wire
03346225E11105
37
Drucktaster Ein
Button switch-On
03346225E32001
Drucktaster Aus
Button switch-Off
03346225E32002
38
Schaltkastenabdeckung
Switch box cover
03346225D20001
39
Schraube
Screw
40
Kabelhalter
Wire holder
41
Schraube
Screw
42
Zugentlastung
Wire clamp
03346225P02057
43
Kabelstecker
Wire connector
03346225E60005
44
Steuerkabel
Control cord
45
Schlauch- und Verbindungsbaugruppe
Hose & joint assy
DE | EN
106
Bezeichnung
M4 x 6
03346225T14006
03346225A0100-08A
M5 x 6
4 x 0.75 x 2.5m
03346225T15006
03346225E24001
03346225PDF345
PD150-PD200-tool-spanner_parts.fm
Pos.
PD150 | PD200 (3346225)
Kopie Original
Version 1.0.4 - 2020-7-31
46
Schlauch
Hose
03346225A00002
47
Schlauchschelle
Hose clamp
03346225P02060
48
Schnellverbindung
Rapid joint
03346225A10005
49
Filterbaugruppe
Filter assy
03346225PDF
50
Filter
Filter
03346225P02061
51
Filterhalter
Filter holder
52
Schnellverbindung
Rapid joint
53
Druckanzeige
Pressure gauge
54
Schraube
Screw
M6 x 20
03346225T36020
55
Schraube
Screw
M6 x 16
03346225T36016
56
Schraube
Screw
M5 x 10
03346225T15010
57
Schraube
Screw
M4 x 10
03346225T14010
58
Unterlegscheibe
Washer
Ø5 x 12 x 1mm
03346225W10050
59
Federscheibe
Spring washer
Ø5
03346225W20050
60
Federscheibe
Spring washer
Ø6
03346225W20060
03346225P02062
PM-20
03346225P02063
03346225P02064
Steuerbox Baugruppe 110V
Control Box Assy-110V
03346225PPC-01
61
Steuerbox Baugruppe 220V
Control Box Assy-220V
03346225PPC-02
61
Steuerbox Baugruppe AC 24V
Control Box Assy-AC 24V
03346225PPC-03
PD150-PD200-tool-spanner_parts.fm
61
PD150 | PD200 (3346225)
Version 1.0.4 - 2020-7-31
Kopie Original
DE | EN
107
108
Viskosität
Schmierstoffe
Viskosity
Lubricant
Viscosité ISO VG
Lubrifiant
DIN 51519 mm²/s
(cSt)
Kennzeichnung nach
DIN 51502
VG 680
CLP 680
Aral Degol BG
680
BP Energol
GR-XP 680
SPARTAN
EP 680
Klüberoil
GEM 1-680
Mobilgear
636
Shell Omala
680
Meropa 680
VG 460
CLP 460
Aral Degol BG
460
BP Energol
GR-XP 460
SPARTAN
EP 460
Klüberoil
GEM 1-460
Mobilgear
634
Shell Omala
460
Meropa 460
VG 320
CLP 320
Aral Degol BG
320
BP Energol
GR-XP 320
SPARTAN
EP 320
Klüberoil
GEM 1-320
Mobilgear
632
Shell Omala
320
Meropa 320
VG 220
CLP 220
Aral Degol BG
220
BP Energol
GR-XP 220
SPARTAN
EP 220
Klüberoil
GEM 1-220
Mobilgear
630
Shell Omala
220
Meropa 220
VG 150
CLP 150
Aral Degol BG
150
BP Energol
GR-XP 150
SPARTAN
EP 150
Klüberoil
GEM 1-150
Mobilgear
629
Shell Omala
150
Meropa 150
VG 100
CLP 100
Aral Degol BG
100
BP Energol
GR-XP 100
SPARTAN
EP 100
Klüberoil
GEM 1-100
Mobilgear
627
Shell Omala
100
Meropa 100
VG 68
CLP 68
Aral Degol BG
68
BP Energol
GR-XP 68
SPARTAN
EP 68
Klüberoil
GEM 1-68
Mobilgear
626
Shell Omala
68
Meropa 68
VG 46
CLP 46
Aral Degol BG
46
BP Bartran
46
NUTO H 46
(HLP 46)
Klüberoil
GEM 1-46
Mobil DTE
25
Shell Tellus
S 46
Anubia EP
46
VG 32
CLP 32
Aral Degol BG
32
BP Bartran
32
NUTO H 32
(HLP 32)
Klübersynth
GEM 4- 32 N
Mobil DTE
24
Shell Tellus
S 32
Anubia EP
32
VG 32
CLP 32
Aral Vitam GF
32
BP Energol
HLP HM 32
NUTO H 32
(HLP 32)
LAMORA
HLP 32
Mobil Nuto
HLP 32
Shell Tellus
S2 M 32
Rando HD
HLP 32
VG 46
CLP 46
Aral Vitam GF
46
BP Energol
HLP HM 46
NUTO H 46
(HLP 46)
LAMORA
HLP 46
Mobil Nuto
HLP 46
Shell Tellus
S2 M 46
Rando HD
HLP 46
G 00 H-20
Aral FDP 00
(Na-verseift)
Aralub MFL 00
(Li-verseift)
BP
Energrease
PR-EP 00
FIBRAX EP
370
(Na-verseift)
MICROLUBE GB 00
Mobilux
EP 004
Shell Alvania GL 00
(Li-verseift)
Marfak 00
Getriebeöl
Gear oil
Originalbetriebsanleitung
Huile de réducteur
Hydrauliköl
Hydraulic oil
Huile hydraulique
Getriebefett
Version 1.0.4 - 2020-07-31
Gear grease
Graisse de réducteur
oil-compare-list.fm
Version 1.0.4 - 2020-07-31
oil-compare-list.fm
Spezialfette,
wasserabweisend
Special greases, water
resistant
ALTEMP
Q NB 50
Aral Aralub
K 3 K-20
(Li-verseift)
Aralub HL 3
BP
Energrease
LS 3
BEACON 3
CENTOPLEX 3
Mobilux 3
Shell Alvania R 3 Alvania G 3
Multifak Premium 3
CGLP 68
Aral Deganit
BWX 68
BP
Maccurat
D68
ESSO Febis
K68
LAMORA
D 68
Mobil Vactra
Oil No.2
Shell Tonna
S2 M 68
Way lubricant X 68
Deol BG 68
Emergol
HLP-D68
Spartan EP
68
Drucköl KLP
68-C
Shell Omala
68
ARALUB
BAB 000
Grease
EP 000
Shell Gadus
S4 V45AC
Klüberpaste
ME 31-52
Graisses spéciales,
déperlant
Wälzlagerfett
Bearing grease
Graisse de roulement
Öle für Gleitbahnen
Oils for slideways
VG 68
Huiles pour glissières
Originalbetriebsanleitung
Öle für Hochfrequenzspindeln
Oils for Built-in spindles
VG 68
Huiles pour broches à
haute vitesse
Fett für Zentralschmierung
(Fließfett)
Grease for central lubrication
Mobilux EP
0
Energrease
PR 9143
NLGI Klasse 000
NLGI class 000
Graisse pour lubrification
centrale
CENTOPLEX
GLP 500
Mobil Greaserex 47
Mobilux
EP 023
Multifak 264
EP 000
Fett für Hochfrequenzspindeln
METAFLUX-Fett-Paste (Grease paste) Nr. 70-8508
Grease for Built-in spindles
METAFLUX-Moly-Spray Nr. 70-82
Graisse pour broches à
haute vitesse
Techno Service GmbH ; Detmolder Strasse 515 ; D-33605 Bielefeld ; (++49) 0521- 924440 ; www.metaflux-ts.de
Schneidöl Aquacut C1,
Kühlschmiermittel
Cooling lubricants
Lubrifiants de refroidissement
10 L Gebinde, Artikel Nr. 3530030
EG Sicherheitsdatenblatt
http://www.optimum-daten.de/
data-sheets/Optimum-Aquacut_C1-EC-datasheet_3530030_DE.pdf
Aral Emusol
BP Sevora
Esso Kutwell
Mobilcut
Shell Adrana
Chevron
Soluble Oil B
109
7
Malfunctions
Malfunction
Cause/
possible effects
Solution
Noise during work.
Spindle runs dry.
Grease spindle
Tool blunt or incorrectly clamped.
Use new tool and check clamping.
Incorrect speed.
Choose a different speed, excessive
feed.
Chips are not coming out of the
drilled hole.
Retract tool more often during work.
Tool "burnt".
Blunt tool.
Sharpen or replace tool.
Use coolant.
Operating without cooling agent.
Tool deformed
Replace the tool.
Bearings worn down in the spindle
head.
Have the bearings in the spindle head
replaced.
Tool badly clamped.
Clamp the tool properly.
Defective clamping chuck.
Replace the clamping chuck.
Taper cannot be inserted
in quill.
Remove any dirt, grease or oil from
the internal conical surface of the
spindle sleeve or the taper.
Clean surfaces well.
Motor does not start.
Motor is wrongly connected.
Defective fuse.
Have it checked by qualified
personnel.
Motor is overheating and
there is no power.
Motor overloaded.
Reduce feed, disconnect if necessary
and have it checked by authorised
personnel.
Tool running off-centre
or "hopping"
Precision of the work
deficient.
Spindle bearing
overheating.
Insufficient mains voltage.
Keep surfaces free from grease.
Motor wrong connected.
Have it checked by authorised
personnel.
Heavy and unbalanced or
deformed work-piece.
Balance the piece statically and
secure without straining.
Inexact horizontal position of the
work-piece holder.
Adjust workpiece-holder.
Bearing worn down.
Replace.
Bearing pretension is too high.
Reduce bearing clearance in the fixed
bearing.
Reduce feed rate.
MZ4S_GB_6.fm
Working at high speeds for a long
time.
GB
110
Malfunctions
MZ4S
Translation of the original instructions
Version 1.0.4 - 2020-07-31
Malfunction
Cause/
possible effects
Solution
Rattle the spindle if the
workpiece surface is
rough.
Excessive slack in bearing.
Readjust the bearing slack or replace
the bearing.
Spindle moves up and down.
Adjustment strip loose.
Readjust bearing slack (fixed
bearing).
Chuck loose.
Adjust strip to the correct slack using
the adjusting screw.
Tool is blunt.
The workpiece is not fastened.
Check, re-tighten.
Sharpen or renew the tool.
Clamp the workpiece firmly.
Smooth DC residual currents
 Current in the protective earth
conductor - Leakage current on page
32
MZ4S_GB_6.fm
Earth leakage circuit
breaker trips
Malfunctions
Version 1.0.4 - 2020-07-31
MZ4S
Translation of the original instructions
GB
111
8
Appendix
8.1
Copyright
Optimum Maschinen Germany GmbH
This document is protected by copyright. All derived rights are reserved, especially those of
translation, re-printing, use of figures, broadcast, reproduction by photo-mechanical or similar
means and recording in data processing systems, either partial or total.
8.2
Changes
Any changes in the construction, equipment and accessories are reserved for reasons of
enhancement. Therefore, no claims may be derived from the indications and descriptions.
Errors excepted!
8.3
Product follow-up
We are required to perform a follow-up service for our products which extends beyond shipment.
We would be grateful if you could send us the following information:




Modified settings
Any experiences with the milling machine which might be important for other users
Recurring malfunctions
Difficulties with the documentation
Optimum Maschinen Germany GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
email: [email protected]
8.4
Liability claims for defects / warranty
Besides the legal liability claims for defects of the customer towards the seller, the manufacturer of the product, OPTIMUM GmbH, Robert-Pfleger-Straße 26, D-96103 Hallstadt, does not
grant any further warranties unless they are listed below or were promised as part of a single
contractual provision.
through one of its dealers.
Any defective products or components of such products will either be repaired or replaced
by components which are free from defects. Ownership of replaced products or components is transferred to OPTIMUM Maschinen Germany GmbH.
 The automatically generated original proof of purchase which shows the date of purchase,
the type of machine and the serial number, if applicable, is the precondition in order to
assert liability or warranty claims. If the original proof of purchase is not presented, we are
not able to perform any services.
 Defects resulting from the following circumstances are excluded from liability and warranty
claims:
- Using the product beyond the technical options and proper use, in particular due to
overstraining of the machine.
- Any defects arising by one's own fault due to faulty operations or if the operating manual
is disregarded.
- Inattentive or incorrect handling and use of improper equipment
- Unauthorized modifications and repairs
- Insufficient installation and safeguarding of the machine
- Disregarding the installation requirements and conditions of use
- atmospheric discharges, overvoltage and lightning strokes as well as chemical influences
GB
112
MZ4S_GB_appendix.fm
 Liability or warranty claims are processed at OPTIMUM GmbH's discretion either directly or
Appendix
MZ4S
Translation of the original instructions
Version 1.0.4 - 2020-07-31
 The following items are also not subject to liability or warranty claims:
- Wearing parts and components which are subject to normal and intended wear, such as
V-belts, ball bearings, lighting, filters, seals, etc.
- Non reproducible software errors
 Any services, which OPTIMUM GmbH or one of its agents performs in order to fulfil any
additional warranty are neither an acceptance of the defects nor an acceptance of its obligation to compensate. These services neither delay nor interrupt the warranty period.
 The court of jurisdiction for legal disputes between businessmen is Bamberg.
 If any of the aforementioned agreements is totally or partially inoperative and/or invalid, a
provision which nearest approaches the intent of the guarantor and remains within the framework of the limits of liability and warranty which are specified by this contract is deemed
agreed.
8.5
Storage
ATTENTION!
Incorrect and improper storage might result in damage or destruction of electrical and
mechanical machine components.
Store packed and unpacked parts only under the intended environmental conditions.
Follow the instructions and information on the transport box:
 Fragile goods
(Goods require careful handling)
 Protect against moisture and humid environment
 Prescribed position of the packing case (Marking
of the top surface - arrows pointing to the top)
 Maximum stacking height
Example: not stackable - do not stack further packing case on top of the first one.
MZ4S_GB_appendix.fm
Consult Optimum Maschinen Germany GmbH if the milling machine and accessories are stored
for more than three months or are stored under different environmental conditions than those
specified here.  Environmental conditions - storage on page 22
Appendix
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8.6
Advice for disposal / Options of re-use
Please dispose of your equipment in an environmentally friendly manner, by not placing waste
in the environment but in a professional manner.
Please do not simply throw away the packaging and later the disused machine, but dispose of
both in accordance with the guidelines laid down by your city council/local authority or by an
authorised disposal company.
8.6.1
Decommissioning
CAUTION !
Immediately decommission used machines in order to avoid later misuse and
endangering of the environment or of persons.
Cut the connection cable.
Remove all environmentally hazardous operating fluids from the used device.
If applicable remove batteries and accumulators.
Disassemble the machine if required into easy-to-handle and reusable assemblies and
component parts.
Dispose of machine components and operating fluids using the intended disposal
methods.
8.6.2
Disposal of new device packaging
All used packaging materials and packaging aids from the machine are recyclable and generally need to be supplied to the material reuse.
The packaging wood can be supplied to the disposal or the reuse.
Any packaging components made of cardboard box can be chopped up and supplied to the
waste paper collection.
The films are made of polyethylene (PE) and the cushion parts are made of polystyrene (PS).
These materials can be reused after reconditioning if they are passed to a collection station or
to the appropriate waste management enterprise.
Only forward the packaging materials correctly sorted to allow direct reuse.
8.6.3
Disposal of the machine
INFORMATION
Please take care in your interest and in the interest of the environment that all
component parts of the machine are only disposed of in the intended and admitted way.
Please note that the electrical devices comprise a variety of reusable materials as well as
environmentally hazardous components. Please ensure that these components are
disposed of separately and professionally. In case of doubt, please contact your
municipal waste management. If appropriate, call on the help of a specialist waste
disposal company for the treatment of the material.
8.6.4
Disposal of electrical and electronic components
The machine is composed of electrical and electronic components and must not be disposed of
as household waste. According to the European Directive 2011/65/EU regarding electrical and
electronic used devices and the implementation of national legislation, used power tools and
electrical machines need to be collected separately and supplied to an environmentally friendly
recycling centre.
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Please make sure that the electrical components are disposed of professionally and according
to the statutory provisions.
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As the machine operator, you should obtain information regarding the authorised collection or
disposal system which applies for your company.
Please make sure that the electrical components are disposed of professionally and according
to the legal regulations. Please only throw depleted batteries in the collection boxes in shops or
at municipal waste management companies.
8.6.5
Disposal of lubricants and coolants
ATTENTION!
Please imperatively make sure to dispose of the used coolant and lubricants in an
environmentally compatible manner. Observe the disposal instructions of your municipal
waste management companies.
INFORMATION
Used coolant emulsions and oils should not be mixed since it is only possible to reuse
oils without pre-treatment when they have not been mixed.
The disposal instructions for used lubricants are made available by the manufacturer of
the lubricants. If necessary, request the product-specific data sheets.
8.7
Disposal through municipal collection facilities
Disposal of used electrical and electronic components
(Applicable in the countries of the European Union and other European countries with a separate collecting system for those devices).
The sign on the product or on its packing indicates that the product must not be handled as
common household waste, but that is needs to be disposed of at a central collection point for
recycling. Your contribution to the correct disposal of this product will protect the environment
and the public health. Incorrect disposal constitutes a risk to the environment and public health.
Recycling of material will help reduce the consumption of raw materials. For further information
about the recycling of this product, please consult your District Office, municipal waste collection station or the shop where you have purchased the product.
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8.8
Terminology/Glossary
Term
Explanation
Cross table
Bearing surface, clamping surface for the workpiece with X- and Y-axis
travel
Taper mandrel
Tool housing taper, drill taper, drill chuck taper.
Workpiece
piece to be milled, drilled or machined.
Draw bar
Threaded rod to fix the taper mandrel in the quill.
Drill chuck
Drill bit adapter
Collet
Holder for end mill
Drill-mill head
Upper part of the milling machine
Quill
Hollow shaft in which the milling spindle turns.
Milling spindle
Shaft activated by the motor
Drilling table
Supporting surface, clamping surface
Taper mandrel
Cone of the drill or of the drill chuck
Spindle sleeve lever
Manual operation for the drill feed
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Term
Explanation
Quick action Drill chuck
Drill bit adapter can be fixed by hand.
Tool
Milling cutter, drill bit, etc.
8.9
Change information operating manual
Short summary
new version number
2;3
Machine foot dimension
1.0.1
4.1
Note on manual movement with the hand cranks on
the milling table in de-energised condition.
1.0.2
2 + Spare parts + 4.16
Tool spanner option
1.0.3
3
Interdepartmental transport
1.0.4
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EC Declaration of Conformity
according to Machinery Directive 2006/42/EC Annex II 1.A
The manufacturer / distributor
Optimum Maschinen Germany GmbH
Dr.-Robert-Pfleger-Str. 26
D96103 Hallstadt
hereby declares that the following product
Product designation:
Hand-controlled milling machine
Type designation:
MZ4S
fulfills all the relevant provisions of the directive specified above and the additionally applied directives (in
the following) - including the changes which applied at the time of the declaration.
Description:
Hand-controlled milling machine with continuously operated axles up to 2 m/min feed and / or with rapid
traverse controlled up to 5 m/min by command device with self-acting reset (jogging switch).
The following additional EU directives have been applied:
EMC Directive 2014/30/EU ; Restriction of the use of certain hazardous substances in electrical and electronic equipment 2015/863/EU
The following harmonized standards were applied:
EN 13128:2001+A2:2009/AC:2010 Safety of machine tools - Milling machines (including boring machines)
EN 60204-1:2014 - Safety of machinery - Electrical equipment of machines - Part 1: General requirements
EN 13849-1:2015 - Safety of machinery - Safety related parts of controls - Part 1: General design principles
EN 13849-2:2012 - Safety of machinery - Safety related parts of controls - Part 2: Validation
EN ISO 12100:2013 - Safety of machinery - General principles for design - Risk assessment and risk
reduction
EN 61000-6-2 - Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity standard for
industrial environments
EN 55011:2014-11 - Industrial, scientific and medical equipment - Radio-frequency disturbance characteristics - Limits and methods of measurement - class A
EN 61000-3-2:2015-03 - Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic current emissions (equipment input current <= 16 A per phase)
EN 61000-3-3:2014-03 - Electromagnetic compatibility (EMC) - Part 3-3: Limits - Limitation of voltage
changes, voltage fluctuations and flicker in public low-voltage supply systems, for equipment with rated current <= 16 A per phase and not subject to conditional connection
Name and address of the person authorized to compile the technical file:
Kilian Stürmer, phone: +49 (0) 951 96555 - 800
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Kilian Stürmer (CEO, General Manager)
Hallstadt, 2019-12-11
8.10
Example accuracy report
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The accuracy report is enclosed with the machine.The values to be observed correspond to the
German industrial standard from 1979 - DIN 8515.
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Index
A
P
Accessories .......................................................... 26
Accident report ..................................................... 18
Anchored mounting .............................................. 29
Panels ...................................................... 34, 36, 37
Personal protective equipment .............................25
Power failure .........................................................38
Prohibition, warning and mandatory signs ............15
Protective
equipment ........................................................16
C
Commissioning ..................................................... 29
Coolant ................................................................. 50
Cooling lubricant .................................................. 54
Cooling lubricants ................................................. 54
Copyright ............................................................ 112
Customer service ................................................. 56
Customer service technician ................................ 56
D
Declaration of conformity ................................... 117
Dimensions .......................................................... 21
Direct run .............................................................. 37
Disinfection
Cooling lubricant tank ..................................... 70
Disposal ............................................................. 115
E
Earth leakage switch ............................................ 32
EC - declaration of conformity ............................ 117
EC declaration .................................................... 117
Electrical connection ............................................ 20
Electronics ............................................................ 18
Emergency stop
resetting .......................................................... 38
Emergency-stop push button ............................... 14
Environmental conditions ..................................... 22
F
First commissioning ............................................. 29
H
Hotline Ersatzteile ................................................ 72
I
Inspection ............................................................. 57
Interdepartmental transport .................................. 25
L
Lubrication ............................................................ 30
M
Main switch .................................................... 14, 17
Maintenance work ................................................ 18
Maintenance, Inspection ...................................... 54
Malfunctions ............................................... 110, 118
Mounting
anchored ......................................................... 29
Q
Qualification of personnel
Safety ...............................................................11
R
Replace wiper .......................................................60
Replacement
wiper ................................................................60
Restoring
readiness for operation ....................................38
S
Scope of delivery ..................................................27
Service Hotline ......................................................72
Spare parts Hotline ...............................................72
Specialist dealer ...................................................56
Speeds ..................................................................21
Spindle capacity ....................................................22
Spindle seat ..........................................................20
Storage and packaging .........................................27
Switching off the machine .....................................38
T
Technical data
Speeds .............................................................21
Technical specification ..........................................20
Dimensions ......................................................21
Electrical connection ........................................20
Environmental conditions .................................22
Spindle seat .....................................................20
Work area ........................................................21
Transport ........................................................25, 27
U
Using lifting equipment .........................................18
W
Warming up the machine ......................................30
Work area .............................................................21
Obligations
of the operating company ............................... 12
of the operator ................................................. 13
Operating material ................................................ 54
Operation ............................................................. 34
operator's log ....................................................... 55
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