Optimum OPTImill MZ 4 User manual

GB
OPTIMUM
MASCHINEN - GERMANY
Operating Manual
Version 1.0.1
Milling machine
Part no. 3346240

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2016-02-23Page 2 Original operating instructions
MZ4 │MZ4VGB
Table of contents
1 Safety
1.1 Glossary of symbols .................................................................................................................................7
1.2 Type plate .................................................................................................................................................7
1.3 Safety instructions (warning notes)...........................................................................................................8
1.3.1 Classification of hazards ...............................................................................................................8
1.3.2 Other pictograms...........................................................................................................................8
1.4 Intended use .............................................................................................................................................9
1.5 Reasonably foreseeable misuse.............................................................................................................10
1.5.1 Avoiding misuse ..........................................................................................................................10
1.6 Possible dangers caused by the milling machine...................................................................................11
1.7 Qualification of personnel .......................................................................................................................12
1.7.1 Target group................................................................................................................................12
1.7.2 Authorized persons .....................................................................................................................13
1.8 Operator positions ..................................................................................................................................13
1.9 Safety devices ........................................................................................................................................13
1.9.1 Lockable main switch ..................................................................................................................14
1.9.2 Emergency-stop push button ......................................................................................................15
1.9.3 Control technical protection........................................................................................................15
1.9.4 Polycarbonate windows..............................................................................................................15
1.9.5 Prohibition, warning and mandatory signs ..................................................................................16
1.10 Safety check ...........................................................................................................................................16
1.11 Personal protective equipment ...............................................................................................................17
1.12 Safety during operation...........................................................................................................................17
1.13 Safety during maintenance .....................................................................................................................18
1.14 Switching-off and securing the milling machine......................................................................................18
1.14.1 Using lifting equipment ................................................................................................................18
1.14.2 Mechanical maintenance work ....................................................................................................18
1.15 Accident report........................................................................................................................................18
1.16 Electrical system.....................................................................................................................................19
1.17 Inspection deadlines ...............................................................................................................................19
1.18 Clamping devices for workpieces and tools............................................................................................19
1.19 Environmental protection and water conservation..................................................................................19
2 Technical specification
2.1 Electrical connection...............................................................................................................................20
2.2 Spindle seat............................................................................................................................................20
2.3 Spindle drive...........................................................................................................................................20
2.4 Milling capacity + "Milling capacity of the machine“ on page 41.........................................................20
2.5 Vertical spindle .......................................................................................................................................20
2.6 Horizontal spindle ...................................................................................................................................21
2.7 Spindle speeds .......................................................................................................................................21
2.8 Table feed...............................................................................................................................................21
2.9 Horizontal milling table............................................................................................................................21
2.10 Vertical milling table................................................................................................................................21
2.11 Dimensions - + "Installation plan“ on page 28 ....................................................................................21
2.12 Work area ...............................................................................................................................................21
2.13 Dimensions.............................................................................................................................................21
2.14 Automatic feed - Rapid traverse .............................................................................................................21
2.18 Emissions ...............................................................................................................................................22
2.15 Coolant equipment..................................................................................................................................22
2.16 Central lubrication...................................................................................................................................22
2.17 Environmental conditions........................................................................................................................22

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2016-02-23 Page 3Original operating instructions
MZ4 │MZ4V GB
2.19 Tools and tool holding fixtures................................................................................................................ 23
2.20 Dimensions............................................................................................................................................. 24
3 Assembly and commissioning
3.1 Unpacking the machine.......................................................................................................................... 25
3.1.1 Standard accessories.................................................................................................................. 25
3.2 Transport ................................................................................................................................................ 26
3.3 Load suspension point ........................................................................................................................... 26
3.4 Set-up and assembly.............................................................................................................................. 28
3.4.1 Installation plan ........................................................................................................................... 28
3.4.2 Requirements regarding the installation site ...............................................................................28
3.5 Machine fixing ........................................................................................................................................ 29
3.5.1 Anchor-free mounting.................................................................................................................. 29
3.5.2 Anchored mounting..................................................................................................................... 30
3.5.3 Electrical connection ................................................................................................................... 31
3.5.4 Current in the Protective Earth Ground Wire .............................................................................. 32
3.6 First commissioning................................................................................................................................ 33
3.7 One-component paint............................................................................................................................. 34
3.8 Cleaning the machine............................................................................................................................. 34
3.8.1 Lubrication and oil levels............................................................................................................. 34
3.9 Function testing and mounting of accessories ....................................................................................... 34
3.10 Warming up the machine ....................................................................................................................... 34
4Operation
4.1 Overview ................................................................................................................................................ 35
4.1.1 Control panel, spindle drive and drive, table feed....................................................................... 36
4.1.2 Control panel spindle gear .......................................................................................................... 37
4.1.3 Direct run..................................................................................................................................... 37
4.2 Safety ..................................................................................................................................................... 38
4.3 Operational modes of the machine ........................................................................................................ 38
4.4 Switching on the machine ...................................................................................................................... 38
4.5 Switching off the machine ...................................................................................................................... 38
4.6 Resetting an emergency stop situation .................................................................................................. 39
4.7 Power failure, Restoring readiness for operation ................................................................................... 39
4.8 Stopping the machine in an emergency ................................................................................................. 39
4.9 Selecting the speed................................................................................................................................ 39
4.9.1 Diagram for determining speeds................................................................................................. 39
4.9.2 Setting the spindle speed and start spindle rotation ................................................................... 40
4.9.3 Diagram for determining feed rate .............................................................................................. 40
4.10 Milling capacity of the machine .............................................................................................................. 41
4.11 Switching automatic table feed on/off..................................................................................................... 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
4.12 Rotate milling head vertically.................................................................................................................. 43
4.12.1 Aligning the milling head ............................................................................................................. 43
4.13 Fastening horizontal table ...................................................................................................................... 44
4.14 Clamping the tool ................................................................................................................................... 45
4.15 Adjusting spindle guard .......................................................................................................................... 45
4.16 Conversion to horizontal milling ............................................................................................................. 46
4.16.1 Mounting counter bearing ........................................................................................................... 47
4.16.2 Arbors for side milling cutter........................................................................................................ 48
4.17 Conversion to vertical milling.................................................................................................................. 49
4.18 Coolant ................................................................................................................................................... 49
4.19 DP700 Quick start guide ........................................................................................................................ 50

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2016-02-23Page 4 Original operating instructions
MZ4 │MZ4VGB
5 Maintenance
5.1 Operating material ..................................................................................................................................53
5.1.1 Machine lubricants ......................................................................................................................53
5.1.2 Cooling lubricants........................................................................................................................53
5.2 Safety......................................................................................................................................................54
5.2.1 Preparation..................................................................................................................................54
5.2.2 Restarting ....................................................................................................................................54
5.3 Repair .....................................................................................................................................................55
5.3.1 Customer service technician .......................................................................................................55
5.4 Inspection and maintenance...................................................................................................................56
5.4.1 Cleaning the chip tray..................................................................................................................59
5.4.2 Cleaning and replacing of the polycarbonate windows ...............................................................59
5.4.3 Cleaning the electrical cabinet ....................................................................................................60
5.4.4 Refilling the oil in the central lubrication system..........................................................................60
5.4.5 Lubricating the vertical milling head ............................................................................................61
5.4.6 Ball screw, X axis ........................................................................................................................61
5.4.7 Ball screw, Y axis ........................................................................................................................62
5.4.8 Ball screw, Z axis ........................................................................................................................62
5.4.9 Filling, checking oil tank, main gear ............................................................................................63
5.4.10 Checking, filling oil tank, horizontal spindle .................................................................................63
5.4.11 Play adjustment of the machine stand guide in the Z axis ..........................................................64
5.4.12 Play adjustment of the guide in the X axis ..................................................................................65
5.4.13 Play adjustment of the guide in the Y axis ..................................................................................66
5.4.14 Adjust spindle bearing .................................................................................................................67
5.4.15 Maintenance and replacement of the wiper ................................................................................68
5.4.16 Cleaning the cooling lubricant tank .............................................................................................68
5.5 Recommended wearing parts.................................................................................................................68
5.6 Cooling lubricants and tanks...................................................................................................................69
5.6.1 Inspection plan for water-mixed cooling lubricants......................................................................70
6 Ersatzteile - Spare parts - MZ4
6.1 Ersatzteilbestellung - Ordering spare parts ............................................................................................71
6.2 Schaltplan - Wiring diagram....................................................................................................................71
6.3 Getriebe allgemein - General gear box...................................................................................................72
6.4 Allgemeine Kreuzschlittenanordnung - General cross slide assembly ...................................................74
6.5 Horizontales Spindelsystem - Horizontal spindle system .......................................................................75
6.6 Werkzeugspannung horizontal - Horizontal tool clamping system .........................................................76
6.7 Vertikales Spindelgetriebe - Vertical spindle transmission .....................................................................77
6.8 Vertikale Schwenkeinrichtung - Vertical head swivel device ..................................................................78
6.9 Vertikale Spindelbaugruppe - Vertical spindle assembly........................................................................79
6.10 Handgriff Spindelsystem - Spindle handle system .................................................................................80
6.11 Vertikales Getriebesystem - Vertical spindle transmission system.........................................................81
6.12 Baugruppe Frästisch - Working table assembly .....................................................................................82
6.13 Handradsystem - Handle wheel system .................................................................................................84
6.14 Baugruppe Maschinenrahmen - Machine frame assembly ....................................................................85
6.15 Getriebesystem Y Achse - Y axis transmission system..........................................................................86
6.16 Bediensystem Y Achse - Y axis operation system .................................................................................87
6.17 Sattelbaugruppe - Machine saddle assembly.........................................................................................89
6.18 Anschlusssystem Z Achse - Z axes connecting system ........................................................................90
6.19 Bediensystem X Achse - X axis operation system ................................................................................91
6.20 X-Z Achse Richtungssystem - X-Z axes direction system ......................................................................92
6.21 Bediensystem Z Achse - Z axis operation system..................................................................................93
6.22 Maschinengrundaufbau - Machine base assembly ................................................................................94
6.23 Universal-Kurbelsystem - Universal crank system .................................................................................95
6.24 Z-Achsen-Übertragungssystem - Z axis transmission system................................................................96

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2016-02-23 Page 5Original operating instructions
MZ4 │MZ4V GB
6.25 Baugruppe Winkeltisch - Angle table assembly ..................................................................................... 97
6.26 Horizontales Gegenlager - Horizontal steady device ............................................................................. 98
6.27 Werkzeuge Horizontalbearbeitung - Horizontal tools list........................................................................ 99
6.28 Schutzabdeckungen und Blechteile - Protective covers and sheet metal parts................................... 100
6.29 Zentralschmierung - Lubrication System.............................................................................................. 101
6.30 Kühlmittelpumpe und Arbeitsleuchte - Cooling pump and work lamp .................................................. 102
6.31 Dreharm Bedienfeld - Rotate Arm Operation Panel ............................................................................. 103
6.32 Schaltplan - Wiring diagram ................................................................................................................. 105
6.33 Baugruppe Schaltschrank - Electric box assembly .............................................................................. 106
7 Appendix
7.1 Copyright .............................................................................................................................................. 110
7.2 Changes ............................................................................................................................................... 110
7.3 Product follow-up.................................................................................................................................. 110
7.4 Liability claims for defects / warranty.................................................................................................... 110
7.5 Storage................................................................................................................................................. 111
7.6 Advice for disposal / Options of re-use................................................................................................. 112
7.6.1 Decommissioning...................................................................................................................... 112
7.6.2 Disposal of new device packaging ............................................................................................ 112
7.6.3 Disposal of the machine............................................................................................................ 112
7.6.4 Disposal of electrical and electronic components ..................................................................... 112
7.6.5 Disposal of lubricants and coolants........................................................................................... 113
7.7 Disposal via municipal collection facilities ............................................................................................ 113
7.8 RoHS, 2002/95/EC............................................................................................................................... 113
7.9 Change information operating manual ................................................................................................. 113
7.10 Terminology/Glossary .......................................................................................................................... 114
7.11 EC - Declaration of Conformity............................................................................................................. 115

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2016-02-23Page 6 Original operating instructions
MZ4 │MZ4VGB
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
Safety
Version 1.0.1 dated 2016-02-23 Page 7Original operating instructions
MZ4 │MZ4V GB
1 Safety
This part of the operating instructions
explains the meaning and use of the warning notes included in these operating instructions,
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 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 Type plate
Master Labels
Optimum Maschinen
Germany GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
3346240
1450 kg
3,75 kW
400 V ~50 Hz
MZ 4
20
NO.
SN Year
DE
GB
ES
FR
IT
CZ
DK
FI
GR
HU
NL
PL
PT
RO
SL
TR
Fräsmaschine
Milling machine
Fresadora
Fraiseuse
Fresatrice
Frézka
Freesmachine
Porajyrsin
Φρεζοδραπανο
Marógép
Freesmachine
Frezarka
Steberni vrtalni stroj
Freze Tezgahı
Engenhos de fresar
Maşină de găurit şi frezat
2250 U/min
/ min

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23Page 8 Original operating instructions
MZ4 │MZ4VGB
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.
1.3.2 Other pictograms
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.
ATTENTION!
Situation that could cause damage to the milling machine and product, as
well as other types of damage.
No risk of injury to persons.
INFORMATION
Practical 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 with
general danger with a warning of injury to hands, hazardous electrical
voltage,
rotating parts.
Activation forbidden! Do not step into the
machine!
Do not extinguish with
water!
Do not clean with com-
pressed air!
Use protective boots! Use ear protectors! Wear protective goggles! Wear protective gloves!

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23 Page 9Original operating instructions
MZ4 │MZ4V GB
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 met-
als 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 cool-
ing lubricants.  "Cooling lubricants“ on page 53
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.
Intended useIf the milling machine is used in any way other than described above, or modified without the
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 accord-
ance with the intended use.
We expressly point out that the guarantee or CE conformity will expire, if any constructive, tech-
nicalor procedural changes are not performed by the company Optimum Maschinen Germany
GmbH.
It is also part of intended use that you
the limits of performance of the milling machine are observed,
the operating manual is observed,
the inspection and maintenance instructions are observed.
Warning: biological hazard! Warning: suspended loads! Warning of oxidizing sub-
stances!
Caution, danger of explo-
sive substances!
Warning: danger of slip-
ping!
Filling position: oil Oil outlet Protect the environment! Contact address

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23Page 10 Original operating instructions
MZ4 │MZ4VGB
WARNING!
Severe injuries due to non-intended use.
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 allowed 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 adjustment 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 inflamma-
ble 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.
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.

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23 Page 11Original operating instructions
MZ4 │MZ4V GB
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.
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 main-
tenance 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

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23Page 12 Original operating instructions
MZ4 │MZ4VGB
1.7 Qualification of personnel
1.7.1 Target group
This manual is addressed to
the operating companies,
operators having sufficient specialist knowledge,
the maintenance personnel.
Consequently, the warning notes refer both to the use of the milling machine and to its mainte-
nance.
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 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 com-
pany.
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 sys-
tem 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.

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23 Page 13Original operating instructions
MZ4 │MZ4V GB
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.
Obligations of the operating company
Obligations of
the operating
company
train the personnel,
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 operat-
ing 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 operator
Obligations of
the operator
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.
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 worked on by a qualified electri-
cian or person working under the instructions and supervision of a qualified electrician.
1.8 Operator 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 inef-
fective.
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.

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23Page 14 Original operating instructions
MZ4 │MZ4VGB
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.
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.
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 main switch
In the "0" position, the lockable main switch can be secured against accidental or non-author-
ised switching on by means of a padlock.
The power supply is interrupted by switching off the main plug.
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.
The areas marked by the pictogram might contain live parts, even if the main switch is switched
off.

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23 Page 15Original operating instructions
MZ4 │MZ4V GB
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 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 switch, turn the knob of the particular push but-
ton to the right in order to restart the machine.
Img.1-1: Emergency-stop push button
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 age-
ing, 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 deteri-
oration of the polycarbonate windows. The result in reduced impact resistance of the polycar-
bonate windows.  "Cleaning and replacing of the polycarbonate windows“ on page 59

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23Page 16 Original operating instructions
MZ4 │MZ4VGB
1.9.5 Prohibition, warning and mandatory signs
INFORMATION
All warning and mandatory signs must be legible. They must be checked regularly.
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),
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 OK
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):

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23 Page 17Original operating instructions
MZ4 │MZ4V GB
1.11 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.
CAUTION!
Dirty or contaminated personnel protective equipment can cause illness. It must be
cleaned after each use and at least once a week.
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 dur-
ing 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.

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23Page 18 Original operating instructions
MZ4 │MZ4VGB
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 oper-
ational 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.
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 due to required works (e.g. functional control).
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 mainte-
nance 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.

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0.1 dated 2016-02-23 Page 19Original operating instructions
MZ4 │MZ4V GB
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 Electrical system
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 operating company 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 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 commissioning is not required if the operator receives confirma-
tion from the manufacturer or installer that the electrical systems and operating equipment com-
ply with the accident prevention regulations, see conformity declaration.
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 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.
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).

OPTIMUM
MASCHINEN - GERMANY
Technical specification
Version 1.0.1 dated 2016-02-23Page 20 Original operating instructions
MZ4 │MZ4VGB
2 Technical specification
The following information represents the dimensions and indications of weight and the manu-
facturer‘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 main-
tenance 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 KVA
Cross section connection cable according to DIN 5710/
VDE 0100 4 x 2 mm 2
Fusing performed by the operator 16 A
Operating mode, duty cycle S6 - 60%
2.2 Spindle seat
Spindle seat ISO 40 DIN 2080
Drawbar M16
2.3 Spindle drive
Power at 100% / 40% ED 3.75 / 4.0 KW
Speed 30 - 2250 rpm
Spindle torque at 1800 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°
Ø 44.45
16.1
10
max. 22.5
1.6
M16
32
93.4
Ø 25.3
Ø 63