Optimum OPTIMILL MF 2V User manual

GB
OPTIMUM
MASCHINEN - GERMANY
Operating manual
Version 1.3.0
Multi-functional milling machine
3336030

OPTIMUM
MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16Page 2 Original operating instructions
MF2 VarioGB
Table of contents
1 Safety
1.1 Type plate.................................................................................................................................................4
1.2 Safety instructions (warning notes)...........................................................................................................5
1.2.1 Classification of hazards...........................................................................................................................5
1.2.2 Other pictograms......................................................................................................................................5
1.3 Intended use.............................................................................................................................................6
1.4 Reasonably foreseeable misuses.............................................................................................................7
1.4.1 Avoiding misuses......................................................................................................................................7
1.5 Possible dangers caused by the milling-machine.....................................................................................8
1.6 Qualification of personnel.........................................................................................................................9
1.6.1 Target group.............................................................................................................................................9
1.6.2 Authorized personnel..............................................................................................................................10
1.7 Operator positions ..................................................................................................................................10
1.8 Safety devices ........................................................................................................................................10
1.8.1 Lockable main switch..............................................................................................................................11
1.8.2 EMERGENCY STOP push button..........................................................................................................11
1.8.3 Protective cover pulleys..........................................................................................................................11
1.8.4 Separating protective equipment............................................................................................................11
1.8.5 Milling table.............................................................................................................................................12
1.9 Prohibition, warning and mandatory labels.............................................................................................12
1.9.1 Control technical protection ...................................................................................................................12
1.9.2 Prohibition, warning and mandatory labels.............................................................................................12
1.10 Safety check...........................................................................................................................................12
1.11 Personnel protective equipment .............................................................................................................13
1.12 Safety during operation...........................................................................................................................13
1.13 Safety during maintenance.....................................................................................................................14
1.14 Switching-off and securing the milling-machine......................................................................................14
1.14.1 Using lifting equipment ...........................................................................................................................15
1.14.2 Mechanical maintenance work ...............................................................................................................15
1.15 Accident report........................................................................................................................................15
1.16 Electrical system.....................................................................................................................................16
1.17 Inspection deadlines...............................................................................................................................16
1.18 Clamping devices for workpieces and tools............................................................................................16
2 Technical data
2.1 Electrical connection...............................................................................................................................17
2.2 Dimensions.............................................................................................................................................17
2.3 Milling capacity / removal........................................................................................................................17
2.4 Adjustment travels / swiveling range ......................................................................................................17
2.5 Speeds / feeds........................................................................................................................................18
2.6 Operating material..................................................................................................................................18
2.7 Environmental conditions........................................................................................................................18
2.7.1 Emissions ...............................................................................................................................................18
3 Assembly
3.1 Scope of delivery....................................................................................................................................20
3.2 Transport ................................................................................................................................................20
3.3 Load suspension point............................................................................................................................20
3.4 Installation and assembly .......................................................................................................................21
3.4.1 Installation site requirements..................................................................................................................21
3.4.2 Installation...............................................................................................................................................21
3.5 Fastening................................................................................................................................................22
3.6 First commissioning................................................................................................................................24

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MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16 Page 3Original operating instructions
MF2 Vario GB
3.7 Warming up the machine .......................................................................................................................24
3.8 Electrical connection ..............................................................................................................................24
3.9 Electrical connection of machines with frequency converter..................................................................25
3.9.1 Regulated drives in connection with residual current devices................................................................25
3.9.2 Protection from Dangerous Shock Currents, use of ELCBs...................................................................25
3.9.3 Current in the protective earth conductor - Leakage current..................................................................25
3.9.4 When the ELCB triggers.........................................................................................................................26
4Operation
4.1 Overview ................................................................................................................................................27
4.1.1 Control panel..........................................................................................................................................28
4.1.2 Safety devices.......................................................................................................................................28
4.1.3 Separating protective equipment............................................................................................................28
4.2 Design of the multi-milling machine MF2 Vario......................................................................................29
4.2.1 Spindle head ..........................................................................................................................................29
4.2.2 Switch cabinet........................................................................................................................................29
4.2.3 Coolant pump.........................................................................................................................................29
4.3 Safety.....................................................................................................................................................30
4.3.1 Warming up the machine .......................................................................................................................30
4.4 Switching the machine on and off ..........................................................................................................30
4.4.1 Switch on................................................................................................................................................30
4.4.2 Switching off...........................................................................................................................................30
4.4.3 Locking the main switch.........................................................................................................................30
4.5 Raising / lowering the cross table...........................................................................................................31
4.6 Moving the cross table left or right (X-axis)............................................................................................32
4.6.1 Manual movement on the X axis............................................................................................................32
4.6.2 Automatic movement of the X-axis using the feed motor.......................................................................33
4.7 Moving the cross table forward / back (Y-axis) ......................................................................................33
4.8 Inclining the spindle head up or down....................................................................................................34
4.9 Orienting the spindle head to the right or left .........................................................................................35
4.10 Moving the spindle head-holder forward or back ...................................................................................35
4.11 Turning the spindle head-holder.............................................................................................................36
4.12 Adjusting the spindle speed ...................................................................................................................36
4.13 Pulleys....................................................................................................................................................36
4.13.1 Gear switch ............................................................................................................................................37
4.13.2 Fine adjustment of the motor speed.......................................................................................................38
4.14 Spindle Left - Stop - Right selector.........................................................................................................38
4.15 Spindle brake .........................................................................................................................................38
4.16 Drill depth stop .......................................................................................................................................38
4.16.1 End stop operating lever ........................................................................................................................39
4.17 Spindle sleeve feed................................................................................................................................39
4.17.1 Manual spindle sleeve feed....................................................................................................................39
4.17.2 Automatic spindle sleeve feed................................................................................................................40
4.17.3 Feed reverse button...............................................................................................................................41
4.18 Cooling agent .........................................................................................................................................41
4.19 Tool change............................................................................................................................................42
4.19.1 Installation..............................................................................................................................................42
4.19.2 Disassembly..........................................................................................................................................42
4.20 Stopping the machine in the event of an emergency ............................................................................43
4.20.1 Position of the emergency stop knob .....................................................................................................43
5 Cleaning, maintenance, repair
5.1 Safety.....................................................................................................................................................44
5.1.1 Measures before repair works................................................................................................................44
5.1.2 Notes for repair.......................................................................................................................................44
5.1.3 Measures before switching on again and after repair measures............................................................44

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MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16Page 4 Original operating instructions
MF2 VarioGB
5.2 Cleaning..................................................................................................................................................44
5.3 Lubricating..............................................................................................................................................45
5.4 Maintenance...........................................................................................................................................46
5.5 Repair.....................................................................................................................................................47
5.5.1 Customer service technician...................................................................................................................47
5.6 Cooling lubricants and tanks...................................................................................................................48
5.6.1 Inspection plan for water-mixed cooling lubricants.................................................................................49
6 Ersatzteile - Spare parts - MF2 Vario
6.1 Spindelkopf Multifräsmaschine - Multi-milling machine spindle head.....................................................50
6.2 Grundkörper Multifräsmaschine - Body of the multi-milling machine......................................................54
6.3 Spindeln Frästisch - Spindles milling table.............................................................................................57
6.4 Zentralschmierung - Central lubrication..................................................................................................59
6.5 Spindelantrieb - Drive mechanism of the spindle ...................................................................................60
6.6 Bedienpanel ab Jahr 2016 - Control panel from year 2016....................................................................63
6.7 Maschinenschilder - Machine labels.......................................................................................................64
6.8 Schaltplan 1 von 2 - Wiring diagram 1 of 2.............................................................................................65
6.9 Schaltplan 2 von 2 - Wiring diagram 2 of 2.............................................................................................66
6.9.1 Ersatzteilliste elektrische Bauteile - Spare part list electrical components.............................................67
7 Malfunctions
7.1 Malfunctions on the multi-milling machine..............................................................................................70
8 Appendix
8.1 Copyright ................................................................................................................................................72
8.2 Terminology/Glossary.............................................................................................................................72
8.3 Change information operating manual....................................................................................................72
8.4 Liability claims for defects / warranty......................................................................................................73
8.5 Storage...................................................................................................................................................74
8.6 Note regarding disposal / options to reuse: ............................................................................................74
8.6.1 Decommissioning ...................................................................................................................................75
8.6.2 Disposal of the packaging of new devices..............................................................................................75
8.6.3 Disposing of the old device.....................................................................................................................75
8.6.4 Disposal of electrical and electronic components...................................................................................75
8.6.5 Disposal of lubricants and coolants ........................................................................................................76
8.7 Disposal via municipal collection............................................................................................................76
8.8 EC - Declaration of Conformity...............................................................................................................77

OPTIMUM
MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16 Page 5Original operating instructions
MF2 Vario GB
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 main-
tenance 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 eco-
nomic 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 hesi-
tate 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
Mail: [e-mail]
Internet: www.optimum-maschinen.com

OPTIMUM
MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16Page 4 Original operating instructions
MF2 VarioGB
1 Safety
Glossary of symbols
This part of the operating instructions
explains the meaning and use of the warning notices included in these operating instruc-
tions,
defines the intended use of the milling-machine.
points out the dangers that might arise for you or others if these instructions are not
observed,
informs you about how to avoid dangers.
In addition to these operation instructions, please observe
the applicable laws and regulations,
the legal regulations for accident prevention,
the prohibition, warning and mandatory signs as well as the warning labels on the milling-
machine.
When installing, operating, maintaining and repairing the milling machine it is necessary to
observe the European standards.
With regard to relevant national legislation which has not yet been adjusted to the European
standards, the applicable national legislation needs to be observed.
If required it is necessary to take the corresponding measures to comply with the country-spe-
cific regulations before commissioning the milling-machine.
Always keep this documentation close to the milling-machine.
INFORMATION
If you are unable to solve a problem using these operating instructions, please contact us for
advice:
Optimum Maschinen Germany GmbH
Dr. Robert-Pfleger-Str. 26
D-96103 Hallstadt
Email: [e-mail]
1.1 Type plate
gives further advice
calls on you to act
enumerations
Master Labels
NO.
SN
Year
MF 2V
3336030
DE
EN
ES
FR
IT
CZ
DK
FI
GR
HU
NL
PL
PT
RO
RU
SL
TR
Fräsmaschine
Milling machine
Fresadora
Fraiseuse
Fresatrice
Univerzální frézka
Freesmachine
Porajyrsin
Φρεζοδραπανο
Multifunkciós marógép
Freesmachine
Frezarka
Φ
резерный станок
Frezalni stroj
Freze Tezgahı
Màquina freadora
Maşină de frezat
5002

OPTIMUM
MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16 Page 5Original operating instructions
MF2 Vario GB
1.2 Safety instructions (warning notes)
1.2.1 Classification of hazards
We classify the safety warnings into various levels. The table below gives an overview of the
classification of symbols (ideogram) and the warning signs for each specific danger and its
(possible) consequences.
1.2.2 Other pictograms
Ideogram Warning alert Definition / consequence
DANGER! Threatening danger that will cause serious injury or death to people.
WARNING! A danger that might cause severe injury to the personnel or can lead to
death.
CAUTION! Danger or unsafe procedure that might cause injury to people or damage
to property.
ATTENTION!
Situation that could cause damage to the milling machine and products
and other types of damage.
No risk of injury to people.
INFORMATION
Application tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.
In case of specific dangers, we replace the pictogram by
or
general danger by a warning of injury of hands, hazardous electrical
voltage, rotating parts.
Warning danger of slipping! Warning risk of stumbling! Warning hot surface! Warning biological hazard!
Warning of automatic
start-up! Warning tilting danger! Warning of suspended loads! Caution, danger of explosive substances!

OPTIMUM
MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16Page 6 Original operating instructions
MF2 VarioGB
1.3 Intended use
WARNING!
In the event of improper use, the milling-machine
will endanger personnel,
the milling-machine and other material property of the operating company will be
endangered,
the correct function of the milling-machine may be affected.
The milling-machine is designed and manufactured to be used for milling and drilling cold met-
als or other non-flammable materials or materials that do not constitute a health hazard by
using commercial milling and drilling tools.
Using this machine it is possible to perform dry processing as well as processing by using cool-
ing lubricants.
The limit values of the balances of the tools need to be observed.
The milling-machine must only be installed and operated in a dry and well-ventilated place.
The milling-machine is designed and manufactured to be used in a non-explosive environment.
Intended useIf the milling-machine is used in any way other than described above, modified without the
approval of the company Optimum 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 accord-
ance with the intended use.
We expressly point out that the guarantee or CE conformity will expire due to any constructive
technical or procedural changes which had not been performed by the company Optimum
Maschinen Germany GmbH.
It is also part of intended use that
the maximum values for the milling-machine are complied with,
the operating manual is observed,
the inspection and maintenance instructions are observed.
WARNING!
Heaviest injuries through improper use.
Activation forbidden! Read the operating
instructions before
commissioning!
Disconnect the mains plug! Use protective glasses!
Use protective gloves! Use protective boots! Use protective suit! Use ear protection!
Only switch in standstill! Protect the environment! Contact address

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MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16 Page 7Original operating instructions
MF2 Vario GB
It is forbidden to make any modifications or alternations to the operation values of the
milling-machine. They could endanger the personnel and cause damage to the milling-
machine.
INFORMATION
The control and drive components of the machine are approved for industrial and commercial
use within industrial supply systems. Utilization in public supply systems requires another con-
figuration and/or additional measures.
WARNING!
The milling machine is not intended for use in residential facilities where the power is
supplied via a public low voltage supply system. In these areas, it may be difficult to
guarantee electromagnetic compatibility due to conducted and emitted interference.
ATTENTION!
If the milling machine is not used as intended or if the safety directives or the operating
instructions are ignored the liability of the manufacturer for any damages to personnel
or objects resulting hereof is excluded and the claim under guarantee is becoming null
and void!
1.4 Reasonably foreseeable misuses
Any other use as the one determined under the "Intended use" or any use beyond the
described use shall be deemed as not in conformity and is forbidden.
Any other use has to be discussed with the manufacturer.
It is only allowed to process metal, cold and non-inflammable materials with the milling-
machine.
In order to avoid misuses it is necessary to read and understand the operating instructions
before the first commissioning.
The operators must be qualified.
1.4.1 Avoiding misuses
Use of suitable cutting tools.
Adapting the speed adjustment and feed to the material and workpiece.
Clamp workpieces firmly and vibration-free.
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 workpieces flying off.
Clamp the workpiece in the machine vice. Make sure that the workpiece is firmly clamped in the
machine vice resp. that the machine vice is firmly clamped on the machine table.
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.
Sufficiently lubricate the machine.
Correctly adjust the bearing clearance and the guidings.

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MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16Page 8 Original operating instructions
MF2 VarioGB
It is recommended:
Insert the drill in a way that it is exactly positioned between the three clamping jaws of the
quick action chuck.
Clamp and mills by means of the collet chuck and the corresponding collets.
Clamp end face mills by means of shell end mill arbors.
When drilling make sure that
the suitable speed is set depending on the diameter of the drill,
the pressure must only be such that the drill can cut without load
in case of too strong pressure the drill will get worn early or even might break resp. get
jammed in the hole. If the drill gets jammed immediately stop the main motor by pressing
the emergency stop button,
for hard materials, e.g. steel, use commercial cooling / lubricating agents,
generally always drive the turning spindle out of the workpiece.
ATTENTION!
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,
the pressure is selected in a way that the cutting speed remains constant,
for hard materials commercial cooling / lubricating agents are used.
1.5 Possible dangers caused by the milling-machine
The milling-machine has undergone a safety inspection. The construction and type are state of
the art.
Nonetheless there remains a residual risk, since the milling-machine operates with
rotating parts,
electrical voltage and currents,
compressed air,
rapid moves.
We have used construction resources and safety techniques to minimize the health risk to per-
sonnel resulting from these hazards.
If the milling-machine is used and maintained by the personnel who are not duly qualified,
there may be a risk resulting from incorrect or unsuitable maintenance of the milling-machine.
INFORMATION
Everyone involved in the assembly, commissioning, operation and maintenance must
be duly qualified,
strictly follow these operating instructions.
In the event of improper use
there may be a risk to the personnel,
there may be a risk to the milling-machine and other material values,
the correct function of the milling-machine may be affected.
Always switch off the milling-machine and disconnect it from the mains if you perform cleaning
or maintenance works.

OPTIMUM
MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16 Page 9Original operating instructions
MF2 Vario GB
WARNING!
The milling-machine may only be used with 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 10
1.6 Qualification of personnel
1.6.1 Target group
This manual is addressed to
the operating companies,
operators having sufficient specialist knowledge,
the maintenance personnel.
Therefore, the warning notes refer to both, operation and maintenance personnel of the milling-
machine.
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 responsi-
ble 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 personnel.
The qualifications of the personnel for the different tasks are mentioned below:
Operator
The operator is instructed by the operating company about the assigned tasks and possible
risks in case of improper behaviour. Any tasks which need to be performed beyond the opera-
tion in the standard mode must only be performed by the operator if it is indicated in these
instructions and if the operating company expressively commissioned the operator.
Electrical specialist
Due to his professional training, knowledge and experience as well as his knowledge of respec-
tive standards and regulations the electrical specialist is able to perform works on the electrical
system and to recognise and avoid any possible dangers himself.
The electrical specialist is specially trained for the working environment in which he is working
and knows the relevant standards and regulations.
Qualified personnel
Due to their professional training, knowledge and experience as well as their knowledge of rele-
vant regulations the qualified personnel is able to perform the assigned tasks and to recognise
and avoid any possible dangers themselves.
Instructed person
Instructed personnel were instructed by the operating company about the assigned tasks and
any possible risks in case of improper behaviour.

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MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16Page 10 Original operating instructions
MF2 VarioGB
1.6.2 Authorized personnel
INFORMATION
For working on the milling-machine sufficient expertise is required. No one must work
on the machine without having the necessary education, not even for a short while.
WARNING!
Inappropriate operation and maintenance of the milling-machine constitutes a danger for
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.
The operating company must
Obligations of
the operating
company
train the personnel,
instruct the personnel in regular intervals (at least once a year) on
- all safety standards that apply to the milling-machine,
- operation of the milling-machine,
- accredited technical guidelines,
- possible emergency situations,
check personnel‘s state of knowledge,
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 observe the operat-
ing instructions.
The operator must
Obligations of
the operator
be specially trained in handling and programming the milling-machine,
know and understand the program sequence and which effects the individual process
parameters will have,
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.
Additional
requirements
regarding the
qualification
For work on the following milling-machine parts there are additional requirements:
Electric components or operating materials: Must only be performed by a qualified electri-
cian or person working under the instructions and supervision of a qualified electrician.
1.7 Operator positions
The operator position is in front of the milling-machine at the sight window or on the machine
control panel.
1.8 Safety devices
Use the milling-machine only with properly functioning safety devices.
Stop the milling-machine immediately if there is a failure on the safety device or if it is not func-
tioning for any reason.
It is your responsibility!
If a safety device has been activated or has failed, the milling-machine must only be used if you
have removed the cause of the failure,
have verified that there is no danger resulting for the personnel or objects.

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MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16 Page 11Original operating instructions
MF2 Vario GB
WARNING!
If you bypass, remove or deactivate a safety device in any other way, you are
endangering yourself and other personnel working with the milling-machine. The
possible consequences are
injuries due to tools, workpieces or fragments hereof which are flying off at high
speed,
contact with rotating or moving parts,
a fatal electrocution,
seizing of clothes.
The milling machine includes the following safety devices:
a lockable main switch,
an EMERGENCY STOP push button,
two protective covers of the V-belt on the milling head,
a milling table with T-slots to fix the workpiece or the clamping device.
1.8.1 Lockable main switch
In the position " 0 " the lockable main switch can be secured against accidental or non-author-
ized switching-on by means of a padlock.
When the main switch is switched-off, the current supply is interrupted.
Except for the areas marked by the pictogram in the margin. In these areas there might be volt-
age, even if the main switch is switched-off.
WARNING!
Dangerous voltage even if the main switch is switched-off.
In the areas marked by the ideogram in the margin, there might be voltage, even if the main
switch is switched off.
1.8.2 EMERGENCY STOP push button
ATTENTION!
The EMERGENCY STOP push button immediately stops the operation of the milling-
machine.
Press the EMERGENCY STOP push 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.
After having actuated the EMERGENCY STOP, turn the knob of the particular push button to
the right in order to restart the machine.
Img.1-1: Control panel
1.8.3 Protective cover pulleys
Two protective covers for the belt pulleys is mounted on the drilling head. A switch is integrated
in the protective cover which controls if the system is closed.
INFORMATION
It is not possible to start the machine if the protective covers are not mounted.
1.8.4 Separating protective equipment
Adjust the protective equipment to the correct height before you start working.
To do so, detach the clamping screw, adjust the required height and re-tighten the clamping
screw.

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MASCHINEN - GERMANY
Version 1.3.0 dated 2016-12-16Page 12 Original operating instructions
MF2 VarioGB
A switch is integrated in the fixture of the spindle protection which monitors that the cover is
closed.
INFORMATION
You cannot start the machine if the spindle protection is not closed.
1.8.5 Milling table
Seats for T-slots are attached to the milling table.
WARNING!
Risk of injury due to parts flying off at high speed. Securely fix the workpiece on the
milling table.
1.9 Prohibition, warning and mandatory labels
INFORMATION
All warning signs must be legible. Check them regularly.
1.9.1 Control technical protection
WARNING!
If you bypass a controller you endanger yourself and other personnel 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 bypass a controller in exceptional cases (e.g. during electrical repairs) short term you
must continuously monitor the milling-machine during this time.
1.9.2 Prohibition, warning and mandatory labels
INFORMATION
All warning and mandatory labels must be legible. Check them regularly.
1.10 Safety check
Check the milling-machine at least once per shift. Inform the person responsible immediately of
any damage, defect or change in operating function.
Check all safety devices
at the beginning of each shift (when the machine is operated continuously),
once per day (during one-shift operation),
once per week (when operated occasionally),
after every maintenance and repair work.
Check that prohibition, warning and information signs and the labels on the milling-machine
are legible (clean them, if necessary),
are complete (replace them, if necessary).

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INFORMATION
Use the following table in order to organize the checks.
1.11 Personnel protective equipment
For certain work personal protective equipment is required.
Protect your face and eyes: Wear a safety helmet with facial protection when performing works
where your face and eyes are exposed to hazards.
Use protective gloves when handling pieces or tools with sharp edges.
Use safety shoes when you assemble, disassemble or transport heavy components.
Use ear protection if the noise level (emission) in the workplace exceeds 80 dB (A).
Before starting work make sure that the prescribed personnel protective equipment is available
at the working place.
CAUTION!
Dirty or contaminated personnel protective equipment can cause diseases. Clean it each
time after use and once a week.
1.12 Safety during operation
WARNING!
Before activating the milling-machine assure yourself that this will neither endanger
other personnel nor cause damage to equipment.
Avoid any unsafe working practices:
The instructions mentioned in these operating instructions have to be strictly observed dur-
ing assembly, operation, maintenance and repair.
Wear safety goggles.
Switch off the milling machine machine before measuring the workpiece.
Do not work on the milling-machine, if your concentration is reduced, for example, because
you are taking medication.
General check
Equipment Check
Protective covers Mounted, firmly bolted and not damaged
Signs,
Markings Installed and legible
Date: checked by (signature):
Functional check
Equipment Check
EMERGENCY-STOP
switch When the EMERGENCY-STOP button is activated, the milling-machine should switch off. Make sure that it is only possible to restart the
machine if the EMERGENCY STOP push button is unlocked and the
main switch was activated.
Date: checked by (signature):

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Observe the accident prevention regulations issued by your Employers Liability Insurance
Association or other competent supervisory authority, responsible for your company.
Inform the supervisor about all endangerments or errors.
Stay on the milling-machine until the movements are completely stopped.
Use the prescribed personnel protective equipment. Make sure to wear a well-fitting work
suit and, if necessary, a hairnet.
Do not use protective gloves when drilling or milling.
Switch off the milling machine on the main switch before changing the tool.
Use appropriate auxiliary materials to remove drilling and milling chips.
Make sure that nobody is endangered by your work.
Safely and firmly clamp the workpiece before switching on the milling machine.
CAUTION!
Risk due to inhaling of health hazardous dusts and mist.
Dependent on the material which need to be processed and the used auxiliaries dusts
and mist may be caused which might impair you health.
Make sure that the generated health hazardous dusts and mist are safely sucked off at
the point of origin and is dissipated or filtered from the working area. To do so, use a
suitable extraction unit.
WARNING!
When chipping magnesia materials (aluminium-/magnesium alloys) spontaneously
inflammable or explosive particles (powder, dust, chips) might be generated which might
result in a fire and/or an explosion (deflagration).
Magnesium is designated as a dangerous material in the list of dangerous materials and
preparations according to §4a of Ordinance of Hazardous Substances.
In case of a fire with magnesium only use appropriate and admitted extinguishing
agents. Never extinguish using water. If you extinguish burning magnesium with water it
might lead to dangerous reactions (detonating gas). Water would be decomposed in its
components hydrogen (H) and oxygen (O).
Only the following extinguishing agents are admitted:
solid extinguishing agent of the fire class D (fires of 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 in the working room, suction unites need to provided
in order to avoid the accumulation of ignitable mixtures and emissions.
We specially point out the specific dangers when working with and on the milling-machine.
1.13 Safety during maintenance
Inform the operators in good time about any maintenance and repair works.
Report all safety relevant changes and performance details of the milling-machine. Document
all changes, have the operating instructions updated accordingly and train machine operators.
1.14 Switching-off and securing the milling-machine
Switch off the milling-machine by turning off the main switch before starting any maintenance
andrepair 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 tensions 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.

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Place a warning sign on the milling-machine.
WARNING!
Live parts and moves of machine parts can injure you or others dangerously!
Proceed with extreme care if you cannot switch off
the milling-machine by turning off the main switch due to required works (e.g. functional
control).
1.14.1 Using lifting equipment
WARNING!
The use of unstable lifting and load suspension gear 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 competent supervisory
authority, responsible for your company.
Check that the lifting equipment and load-suspension gears are of sufficient load
capacity and are in perfect condition.
Fasten the loads properly.
Never walk under suspended loads!
1.14.2 Mechanical maintenance work
Remove or install protection safety devices before starting any maintenance work and re-install
them once the work has been completed.This includes:
Covers,
Safety indications and warning signs,
earth (ground) connections.
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 superiors 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 faster the causes can be eliminated.
INFORMATION
We point out the specific dangers when performing works with and on the milling-machine
when describing such works.

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1.16 Electrical system
Have the electrical equipment on the machine 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. Immediately disconnect the milling machine if there are any anoma-
lies in the power supply!
Comply with the required inspection intervals in accordance with the factory safety directive,
operating equipment inspection.
The operating company responsible for 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 start-up and after modifications or repairs, prior to restarting the equipment
and at certain intervals.
The deadlines must be set so that arising, foreseeable defects can be detected in a timely man-
ner.
The relevant electro-technical rules must be followed during the inspection.
The inspection prior to initial operation 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.
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. Also use the inspection intervals in the maintenance section as reference values.
1.18 Clamping devices for workpieces and tools
ATTENTION!
Attention when taking over the existing clamping devices. Pleased check critically if the
clamping device is appropriate for your milling-machine.
Only use clamping devices which have a complete inherent stiffness.
Contact the manufacturer of the clamping device regarding the reuse of the clamping
devices after damages on the clamping devices due to collisions.
Correctly insert the workpiece and make sure that the machine is proper working
condition.

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2 Technical data
The following information gives the dimensions and weight and is the manufacturer‘s
authorised machine data.
2.1 Electrical connection
Total connection rate 3 x 400 V; 50 Hz; 1.5 KW
Degree of protection IP 54
2.2 Dimensions
Taper ISO 40 (DIN 2080, DIN 69871)
Spindle sleeve diameter Ø 85.7 mm
Clamping surface of cross table 230 x 1244 mm
Max. dist. from spindle head to table 446 mm
Max. dist. from centre of spindle to upright 680 mm
Min. dist. from centre of spindle to upright 200 mm
Height 2150 mm
Width 1400 mm
Depth 1450 mm
Total weight 900 kg
Max. load of cross table 230 kg
Number of the T-slots 3
Size of the slot nut 16 x 63 mm
Throat depth 213 - 533 mm
2.3 Milling capacity / removal MF2 Vario
End-milling cutter ø18 6 mm
Face milling cutter ø76 2.5 mm
2.4 Adjustment travels / swiveling range
Spindle sleeve travel 127 mm
Adjustment travel of cross table (X-axis) 800 mm
Adjustment travel of cross table (Y-axis) 305 mm
Vertical adjustment travel of cross table 406 mm
Swivel range spindle head carrier ± 90°
Up/down spindle head inclination ± 45°

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2.7.1 Emissions
Maximum sound pressure level at 1 m distance from the machine and 1.60 m above the ground
according to DIN ISO 8525 is 70 to 76 dB(A).
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
80dB(A).
INFORMATION
This numerical value was measured on a new machine under proper operating conditions.
Depending on the age respectively on the wear of the machine it is possible that the noise
behaviour of the machine changes.
Furthermore, the factor of the noise emission is also depending on manufacturing influencing
factors, e.g. speed, material and clamping conditions.
INFORMATION
The mentioned numerical value is the emission level and 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,
Left/right spindle head swivelling range ± 90°
2.5 Speeds / feeds
Spindle speed 10 - 5100 min-1
Number of steps 6 and variable
Spindle sleeve feed per revolution of spindle 0,04; 0,08; 0,15 mm
Feed speed
Of cross table (X-axis) 0.3 - 12 mm/second
Fast motion speed
of cross table (X-axis) 15 mm/second
Max. torque of feed 73.5 Nm
2.6 Operating material
Machine oil 628 Mobil (Vis. 100/150"
Grease Commercial bearing grease
2.7 Environmental conditions
Temperature 5 - 35 °C
Humidity 25-28 %
2.4 Adjustment travels / swiveling range