Optimum 3346245 Operating Manual Download Page 95

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Version 1.0.4 - 2020-7-31

Originalbetriebsanleitung

MZ4S DE | EN

_pa

rts.

Dreharm Bedienfeld - Rotate Arm Operation Panel

Pos

Bezeichnung

Designation

Menge

Grösse

Artikelnummer

Qty.

Size

Item no.

Rundschraube mit Innensechskant

Hex Socket Round Screw

M5x12

OP-Box-Abdeckung

Operation Box Cover

UM35029

033462453202

Innensechskantschraube

Hex Socket Cap Screw

M6x16

Scheibe

Flat Washer

033462453204

Kontrollkasten

Control Box

UM35078

033462453205

Einbaurahmen

Mounting Frame

UM35102

033462453206

Digitalanzeige und lineare Skala

DRO & Linear Scale

NEWALL DP700

033462453207

Bedienmuster-Bedienfeld

Operation Pattern Panel

UM35103

033462453208

Geschwindigkeitsanzeige

Speed Display

UM13002

033462453209

Schnellvorschubschalter

Rapid Feed Switch

E-SB003

033462453210

Schnellwahltaste

Speed Select Button

E-VR002

033462453211

Ein / Aus Schalter

ON/OFF Switch

E-SB010

033462453212

Sicherheitsschalter

Safety switch

E-SA003

033462453213

Sicherheitsschalter

Safety switch

E-SA004

033462453214

Ein / Aus Schalter

ON/OFF Switch

E-SB010

033462453215

Schnellwahltaste

Speed Select Button

E-VR002

033462453216

Schalter für Kühlmittelpumpe

Coolant Pump Switch

E-SA002

033462453217

Not-Halt-Schlagschalter

Emergency Switch

E-SB001

033462453218

Spindel-F / R-Auswahlschalter

Spindle F/R Select Switch

E-SA001

033462453219

Geschwindigkeitsregler

Speed Adjuster

E-VR003

033462453220

Haltegrif

Curve Grab Handle

ES-121300B

033462453221

Steuerkastensitz

Control Box Seat

UM35023

033462453222

Sperrgriff

Lock Handle

M8x30L-06x5

033462453223

Drehpunkt

Pivot

UM35024

033462453224

Stellschraube

Set Screw

M5x8

033462453225

Stützarm

Support Arm

UM35025

033462453226

Abdeckung

Cover

UM35026

033462453227

Stützsitz

Support Seat

UM35027A

033462453228

Scheibe

Flat Washer

8.5

033462453229

Innensechskantschraube

Hex Socket Cap Screw

M8x25

Anschlusskasten

Connector Box

UM35065

033462453231

Steckerabdeckung

Connector Cover

UM35040

033462453232

Kontrolpanel

Jog Control Panel

UM35014

033462453233

Schalter

Jog Switch

E-SB003

033462453234

Not-Halt-Schlagschalter

Emergency Switch

E-SB001

033462453235

Sicherungskasten

Electrical Cabinet

UM35060AS

033462453236

Lichtschalter

Power Light

E-PL001

033462453237

Schaltschrankschlüssel

Key electrical cabinet

A-172-2

033462453238

Schrankhalterung

Cabinet Support Bracket

UM35100

033462453239

Summary of Contents for 3346245

Page 1: ...GB Operating Manual Version 1 0 4 Milling machine Item no 3346245 ...

Page 2: ...18 1 14 2 Mechanical maintenance work 18 1 15 Accident report 18 1 16 Electronics 18 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 spin...

Page 3: ...ine 38 4 6 Resetting an emergency stop condition 38 4 7 Power failure Restoring readiness for operation 38 4 8 Stopping the machine in an emergency 38 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 39 4 9 3 Diagram for determining feed rate 40 4 10 Milling capacity of the machine 41 4 11 Activate deactivate automatic ta...

Page 4: ...pindelsystem Horizontal vertical spindle system 76 6 9 Vertikales Spindelgetriebe Vertical spindle transmission 78 6 10 Vertikale Spindelbaugruppe Vertical spindle assembly 79 6 11 Handgriff Spindelsystem Spindle handle system 80 6 12 Baugruppe Frästisch Working table assembly 81 6 13 Handradsystem Handle wheel system 83 6 14 Baugruppe Maschinenrahmen Machine frame assembly 84 6 15 Getriebesystem ...

Page 5: ...Version 1 0 4 2020 07 31 5 Translation of the original instructions MZ4S GB MZ4S_GBIVZ fm 8 9 Change information operating manual 116 8 10 Example accuracy report 118 ...

Page 6: ...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 see king for improvements and renewal of the products Therefore changes might be performed with...

Page 7: ...applicable laws and regulations the statutory provisions for accident prevention the prohibition warning and mandatory signs as well as the warning notes on the milling machine Always keep this documentation close to the milling machine 1 1 Glossary of symbols provides further instructions calls on you to act listings 1 2 Rating plate 5I MZ 4IJMT 0QUJNVN BTDIJOFO FSNBOZ NC S 3PCFSU 1GMFHFS 4US BMM...

Page 8: ...n 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...

Page 9: ...ll ventilated areas The milling machine is designed and manufactured to be used in a non explosive environment Intended use If 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 accor danc...

Page 10: ...age supply system In these areas it may possibly be difficult to guarantee electromagnetic compatibility due to lead bound as well as emitted interferences Use of suitable cutting tools Adapting the speed setting and feed to the material and workpiece Clamp workpieces firmly and free of vibration Risk of fire and explosion due to the use of flammable materials or cooling lubricants Before processi...

Page 11: ...illing 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 oth...

Page 12: ...espective stan dards and regulations qualified electricians are able to perform work on the electrical system and recognise and avoid any possible dangers Qualified electricians have been specially trained for the working environment in which they are working and know the relevant standards and regulations Qualified personnel Due to their professional training knowledge and experience as well as k...

Page 13: ...nents 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 User positions The operator position is located in front of the milling machine at the inspection window to the side of the automatic feed for the cross table or on the control panel 1 9 Safety devices The milling machine must only ...

Page 14: ...icant pump the chip and spray guard must always be closed 1 9 1 Lockable master switch In the 0 position the lockable main switch can be secured against accidental or non authori sed switching on by means of a padlock The power supply is cut off when the master switch is in the off position Except for the areas marked by the pictogram in the margin In these areas there might be voltage even if the...

Page 15: ...iewing panes are subject to an ageing process and are classified as wear parts The ageing of polycarbonate windows can not be detected by visual inspection It is therefore necessary to replace the polycarbonate windows after a certain time Prolonged exposure from polycarbonate windows to cutting fluids can lead to accelerated ageing i e deterioration of the mechanical properties brittleness Coolan...

Page 16: ...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 Gener...

Page 17: ...wing 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 des...

Page 18: ...s can be eliminated INFORMATION We provide information about the specific dangers when working with and on the milling machine in the descriptions for these types of work 1 16 Electronics Have the machine and or the electric equipment checked regularly Immediately eliminate all defects such as loose connections defective wires etc A second person must be present during work on live components to d...

Page 19: ...ENTION 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 tha...

Page 20: ...luded in this calculation Normal replacement parts such as for example bearings are not part of this calculation 2 1 Electrical connection Total connection 3 x 400V 50Hz 5 4 kW Cross section connection cable according to DIN 5710 VDE 0100 4 x 2 mm2 Fusing performed by the operator 16 A Operating mode duty cycle S6 60 2 2 Spindle seat Spindle seat ISO 40 DIN 2080 Draw bar M16 2 3 Spindle drive Powe...

Page 21: ...h mm 500 mm T slot size distance number 14 mm 63 mm 7 max load horizontal cross table 360 kg Scale on the X axis handwheel cross table 5 mm rev graduation 0 02 mm Scale on the Y axis handwheel milling head 5 mm rev graduation 0 02 mm Scale on the Z axis handwheel cross table 2 5 mm rev graduation 0 02 mm 2 10 Vertical milling table max load Nm 1800 Table size mm 250 x 1200 T slot size distance num...

Page 22: ...sured on a new machine under the operating conditions specified by the manufacturer The noise behaviour of the machine might change depending on the age and wear of the machine Furthermore the noise emission also depends on production engineering factors e g speed material and clamping conditions Dimensions Installation plan on page 24 2 15 Automatic feed Rapid traverse Feed mm min 50 450 Feed axi...

Page 23: ...he number of machines other processes taking place in proximity and the period of time during which the operator is exposed to the noise Furthermore it is possible that the admissible exposure level might be different from country to country due to national regulations This information about the noise emission should however allow the operator of the machine to more easily evaluate the hazards and...

Page 24: ...Technical specification Version 1 0 4 2020 07 31 24 Translation of the original instructions MZ4S GB MZ4S_GB_2 fm 2 21 Dimensions Installation plan Center of gravity ...

Page 25: ...suspension equipment that might break under load can cause severe injuries or even death Check that the lifting and load suspension gear has sufficient load bearing capacity and that it is in perfect condition Observe the accident prevention regulations issued by your Employers Liability Insur ance Association or other competent supervisory authority responsible for your com pany Fasten the loads ...

Page 26: ... register a complaint Examine the complete machine carefully and check whether all materials such as shipping documents instructions and accessories have been delivered with the machine 3 2 1 Standard accessories 1 x Oil bottle for oil cups 1x grease gun for grease nipple 3 x Open ended spanner 2 1 set Allen key 3 1 x Hand lever for spindle sleeve feed 4 1 x Philips and flat screwdriver 5 1 x ISO ...

Page 27: ...Dimensions Installation plan on page 24 3 5 1 Requirements regarding the installation site Keep a work area of at least one metre around the machine free for operation and main tenance In order to achieve sufficient safety against falls by slipping the accessible area in the mechani cal machining zone of the machine must be equipped with a slip resistance The slip resistant mat and or the slip res...

Page 28: ... be prepared in such a way that any coolant used cannot penetrate into the ground Any parts sticking out such as stops handles etc have to be secured by measures taken by the customer if necessary in order to avoid endangering persons Provide enough space for set up and operating personnel and material transport Also bear in mind accessibility for installation and maintenance works Ensure adequate...

Page 29: ...NTION All four corners of the machine foot must lie flat The maximum height difference of the bearing surfaces after tightening the anchor screws should not exceed 0 05mm per 1000mm We recommend using a machine spirit level to align the milling machine The the anchor screw nuts Check the alignment of the milling machine again Re check the alignment after a few days of use 3 7 First commissioning W...

Page 30: ...period before commissioning Remove all wrappings and clean all surfaces with a degreaser to soften and remove protective greases and coatings Wipe all surfaces with a clean cotton cloth and lubricate the milling machine in accordance with the maintenance section Inspection and maintenance on page 57 before switching on the power and putting the machine into service 3 9 1 Lubrication and oil levels...

Page 31: ...nding 2 5mm2 Electric connected load 5 4 KVA Permissible voltage fluctuations in normal operation 6 10 Volt Permissible frequency fluctuations 1Hz 50 60 Hz Permissible phase imbalance 3 or less ATTENTION Ensure that all 3 phases L1 L2 L3 and the ground wire are connected correctly The neutral conductor N of its power supply is not connected ATTENTION Check if the drive motor is turning in the corr...

Page 32: ... occur 3 12 2 Protection from Dangerous Shock Currents use of ELCBs To achieve increased safety in all installation systems and in power supply ranges for which the installation provisions stipulate or recommend the ELCB devices Measure for Protection from Dangerous Shock Currents as regulated in DIN VDE 0100 Part 410 All measures are to be mentioned Protection from indirect contact as protection ...

Page 33: ...pe A they are therefore suitable for all the circuits mentioned ELCBs of this series therefore detect all types of fault current according to the triggering characteristic B i e both smooth DC fault currents and also all AC fault currents of all frequencies and mixed frequencies up to 1 MHz are detected and switched off reliably in the event of a fault Alternating current sensitive ELCBs of type A...

Page 34: ...10 13 11 Pos Designation Item Designation 1 Control panel with Newall DP700 position display DP700 Quick start guide on page 51 8 Tool clamping device for horizontal milling 2 Chip and spray guard 10 Emergency stop 3 Hand crank table motion manual 11 Spindle gear 4 Hand crank milling head 12 Spindle vertical milling 5 Drive motor spindle drive 12 Spindle horizontal milling Clamping the tool on pag...

Page 35: ...rol panel Pos Designation Item Designation 1 Rev counter 6 Push button table feed On Off 2 Push button Rapid traverse X Y Z axis 7 Emergency stop button 3 Coolant pump On Off 8 stepless feed speed Z axis 4 Rotational direction spindle 9 stepless feed speed X Y axis 5 Push button spindle drive On Off 10 Feed direction lever with detent position 1 2 4 3 5 9 6 7 8 10 10 ...

Page 36: ...p the tool to rotate the spindle as this may engage a gear setting Img 4 2 Speed table ATTENTION Only change speeds and gear settings when the machine is at a stop Use the torque button to facilitate the engaging of gear settings Optionally the handwheel on the rear of the spindle can be used to facilitate engagement in gear positions 5I MZ 4IJMT UQV ...

Page 37: ...lowing conditions During operation The milling machine is in proper working order The milling machine is used as intended The operating instructions are followed All safety devices are installed and activated WARNING Stop the machine immediately in the event of any abnormality in operation and make sure it cannot be started up accidentally or without authorisation Notify the person responsible imm...

Page 38: ...tch of the spindle drive to the required position The spindle starts to rotate CAUTION When drilling with the spindle sleeve lever on the milling head the spindle guard on the milling head must be set and closed When milling with the automatic feed the chip and spray guard around the milling table must be closed When using the cooling lubricant pump the chip and spray guard must always be closed 4...

Page 39: ...he correct rotation speed Use upcut milling if at all possible In upcut milling the direction of feed is opposite to the direc tion of rotation Please refer to a table reference book e g Tabellenbuch Metall Europa Lehrmittel ISBN 3808517220 or the following diagrams to determine the correct cutting speed for your tool and the material to be machined 4 9 1 Diagram for determining speeds 4 9 2 Setti...

Page 40: ... 31 40 Translation of the original instructions MZ4S GB MZ4S_GB_4 fm 4 9 3 Diagram for determining feed rate mm min mm Ø n 80 n 160 n 245 n 360 n 490 n 720 n 1100 n 2200 0 01 0 02 0 05 0 1 0 2 0 5 1 2 20 30 40 50 60 70 80 100 150 200 ...

Page 41: ...and the feed rate for each mill diameter Example Ø 50 mm t 8 mm Result Feed rate 50 mm min Example Ø 50 mm Feed rate 70 mm min Result t 6 mm The values refer to low carbon unalloyed steel e g ST37 S235JR For softer or harder mate rials the values must be adjusted accordingly 2 3 4 5 6 7 8 9 10 15 20 20 30 40 50 60 70 80 90 100 150 200 mm min t mm t Ø Ø 32 Ø 25 Ø 20 Ø 40 Ø 50 Ø 80 V ...

Page 42: ...he X Y Z axis feed on ATTENTION Loosen clamping lever on the cross table Loosen clamping lever on the milling head Set feed rate to 0 Switch on drive motor for the feed Set the direction lever X Z or Y in the desired feed direction and engage Slowly increase the feed rate 4 11 2 Switching the X Y Z axis feed off Set the feed direction lever to the neutral position Switch off drive motor for the fe...

Page 43: ...cally Loosen clamping screws and rotate milling head to 90 Re tighten clamping bolts 4 12 1 Aligning the milling head INFORMATION The milling head should be aligned after resetting to the initial position with a dial indicator so that holes can be produced with the spindle sleeve at a right angle Clamping bolts Scale angle of rota tion ...

Page 44: ... table the machine operator must take additional precautions to ensure safe operation We recommend mounting e g a dividing apparatus on the horizontal table and adjusting the milling spindle to horizontal milling in order to maintain the same machining method The milling table is fixed to the vertical table with four T slot screws DIN 787 M14 x 50 The T slots are executed similar to DIN 650 14 4 5...

Page 45: ...ase and dirt ISO 40 tool holder M16 tie rod When vertical milling and horizontal milling the tool is clamped with a tie rod Dismantle protective cap tie rod Vertical milling clamp tool from above via the drawbar with a 22mm wrench Refit protective cap drawbar Horizontal milling clamp tool via the drawbar with the rotating device 4 15 Adjusting spindle guard When drilling adjust the spindle guard t...

Page 46: ... of the tool holder The compressed air tool clamp for turning the tightening rod in and out can only be operated when the spindle guard is open Shift the morse taper fixture into the spindle of the milling machine Press the clamp or release button 2 to clamp or unclamp the tool INFORMATION If necessary the tightening torque of the air motor can be reduced This adjustment option 3 is located under ...

Page 47: ...Operation Version 1 0 4 2020 07 31 47 Translation of the original instructions MZ4S GB MZ4S_GB_4 fm 4 3 1 2 ...

Page 48: ... eyebolt into the counter bearing lift with a crane or other lifting device Push the counter bearing onto the centring alignment on the milling head and mount and tighten the counter bearing on the mil ling head Img 4 4 Counter bearing side milling cutter Recommended threshold values when lifting and carrying loads Reasonable load in kg and frequency of lifting and carrying Occasionally More frequ...

Page 49: ...off switch The central lubrication system supplies functionally important components on your milling machine If the on off switch is per manently switched off important parts cannot be supplied with lubricant Zentralschmierung Lubrication System on page 92 1 Arbor ISO 40 with counter bearing 16mm external diameter 2 Arbor ISO 40 with counter bearing 22mm external diameter 3 Arbor ISO 40 with count...

Page 50: ... Swivel the vertical milling head on the spindle drive 3 Tighten the hexagon screws and hexagon socket screws 4 19 Coolant WARNING Ejection and overflowing of coolants and lubricants Make sure you do not get the cooling lubricants on the floor Spilled on the floor cooling agents must be removed immediately The flow of cooling agent is activated and deactivated by means of a selector with on the co...

Page 51: ...ut Voltage to DP700 15 24VDC 10 Conforms to Low Voltage Directive External PSU Input Note Newall Measurements Systems reserves the right to change specifications without notice Warnings The mains supply is connected into a switch mode power supply separate from your DP700 via a detachable supply cord supplied If another supply cord is used it must have fitted a C5 10A EARTHED mains connector with ...

Page 52: ... Digifind Reference Switches between Zero and Axis Preset modes Switches between Absolute and Incremental modes Information selection scrolls through options on Message display Function Menu Key Function Navigation Keys Switches between Inch and mm display Zero an Axis in Zero Mode Ensure DP700 is in Zero Mode of Axis 1 2 or 3 Zero an Axis in Set Mode Ensure DP700 is in Set Mode of Axis 1 2 or 3 E...

Page 53: ...se numeric keypad to enter value value is in whole minutes of axis 1 to scroll through functions to return to main menu See full manual on website for more details to exit setup of axis 1 e S P A N O L D A N S K i T A L L I A N O c Z E C H D E U T S C H P O R T U G U E R U S S I A N T U R K I S H s e t u p T Y P E G E N E R I C M I L L L A T H E s e t u p E N C O D E R S P H 2 G U S N 1 0 U S N 5 ...

Page 54: ...electing your cooling lubricant Optimum Maschinen Germany GmbH does not accept any liability for subsequent damages due to unsuitable cooling lubricants The flashpoint of the emulsion must be higher than 140 C When using non water miscible cooling lubricants oil content 15 with a flashpoint ignitable aerosol air mixtures might develop There is a potential danger of explosion ATTENTION Only the cor...

Page 55: ...to VKIS sheet 9 Sticking and residue beha viour It should not attack the varnish of the machine according to VDI 3035 It should not attack any machine elements metals elastomers Low foaming behaviour of the emulsion It should be as finely dispersed as possible in order to avoid clogging in the needle slot screen 5 2 Safety WARNING The consequences of incorrect maintenance and repair work may inclu...

Page 56: ...rmer Maschinen GmbH Dr Robert Pfleger Str 26 D 96103 Hallstadt can provide a customer service technician however the request for a customer service techni cian can only be made via your specialist dealer If the repairs are carried out by qualified technical personnel they must follow the indications given in these operating instructions Optimum Maschinen Germany GmbH accepts no liability nor does ...

Page 57: ...indows on page 60 Start of work Daily after every maintenance or Repair Lubricant tank Slideway oil Fill level control Check the quantity and refill the lubricant tank of the central lubrication system Refilling the oil in the central lubrication system on page 61 Cooling lubricants on page 54 Lubricant on page 108 weekly Cooling lubricant lubricant Fill level status control CAUTION The cooling lu...

Page 58: ...hecking oil tank main gear on page 64 Every 1000 operating hours Wipers on the slides Check Replace Check the wipers on the slides Maintenance and replacement of the wiper on page 69 Electrical cabinet Cleaning Cleaning the electrical cabinet on page 61 Empirical value of the operator Chip collection tray Cleaning Cleaning the chip tray on page 60 60 months Protective covers Where necessary replac...

Page 59: ...ructions MZ4S GB MZ4S_GB_5 1 fm based on operator s historic values in accordance with German DGUV BGV A3 Electronics Electrical inspection Obligations of the operating company on page 12 Electronics on page 18 Validation on page 55 Interval Where What How Check ...

Page 60: ...ur milling machine Damaged scratched or even broken polycarbonate sight windows must be replaced immediately A soft cloth should be used to clean the machine safety glass The following detergents have been tested and approved by us Hahnerol glass cleaner Hahnerol Sidolin Streak Free Henkel Active Window Cleaner Neu mann We recommend replacing the polycarbonate inspection windows 60 months after co...

Page 61: ...mend that the electrical cabinet is cleaned every 1000 operating hours The illustrated control cabinet key is included in the accessories 5 4 4 Refilling the oil in the central lubrication system The central lubrication system lubricates important functional parts of the milling machine The maximum fill amount is 2 litres If levels drop below the minimum fill amount an audible alarm is triggered T...

Page 62: ...ap base e g Mobilux 3 Check the smooth running of the bearings after lubrication Adjusting the spindle bearing on page 68 Abb 5 3 Lubricating nipple vertical milling head 5 4 6 Ball screw X axis Using a grease gun lubricate the lubricating nipple monthly with about 50ml of grease with a lit hium soap base e g Mobilux 3 Check the smooth running of the ball screw after lubrication Abb 5 4 Spindle X ...

Page 63: ...n Abb 5 5 Spindle Y axis 5 4 8 Ball screw Z axis Using a grease gun lubricate the lubricating nipple monthly with about 50ml of grease with a lit hium soap base e g Mobilux 3 Check the smooth running of the ball screw after lubrication If the table moves downwards independently due to the smooth running of the ball screw when the clamping levers are open the friction must be increased Play adjustm...

Page 64: ... oil inspection glass is dirty or the oil level is not visible the oil must be changed ATTENTION Do not overfill total fill amount 0 9 litres Abb 5 7 Oil main gear 5 4 10 Checking filling oil tank horizontal spindle Dismantle the cover plate Check the oil level The fill level should be approximately 0 15 litres If the oil is visibly contaminated the oil must be changed ATTENTION Do not overfill to...

Page 65: ...measurement at the top If possible use a dial gauge with drag pointer Position the dial gauge at the height of the top V ledge Press the machine stand down on the left and the vertical table on the right side and release Read the dial gauge the deviation must be less than 0 01mm In the event of a larger deviation push the V ledge with the adjusting screw slightly Position the dial gauge on the und...

Page 66: ...Fix dial gauge as shown Press the vertical milling table down on the left side and release Read the dial gauge Press the vertical milling table up on the left side and release Read the dial gauge the total deviation must be less than 0 01mm In the event of a larger deviation push the V ledge with the adjusting screw slightly Perform measurement on the right Position the dial gauge on the right sid...

Page 67: ...ent Perform measurement on the front If possible use a dial gauge with drag pointer Fix dial gauge as shown Move the milling head to the left and right Read the dial gauge the total deviation must be less than 0 01mm In the event of a larger deviation push the V ledge with the adjusting screw slightly Perform measurement at the rear Position the dial gauge on the rear and proceed using the same me...

Page 68: ...stud screws on the bearing nut Slightly adjust the play in the bearing with the bearing nut Abb 5 12 Adjust vertical spindle bearing Horizontal spindle Remove the top cover Remove the transmission of the upper drive shaft Loosen the stud screws on the bearing nut Slightly adjust the play in the bearing with the bearing nut Abb 5 13 Adjust horizontal spindle bearing Draw bar cover Bearing nut Beari...

Page 69: ...arefully check for unusual wear scratches or damage caused by chips Damaged wipers negatively impact machine accuracy Replace damaged wipers immediately It is recommended to check the wipers at least every 1000 operating hours 5 4 16 Cleaning the cooling lubricant tank Cooling lubricants and tanks on page 70 Remove the cover plate on the machine toot Abb 5 14 Tank with coolant pump 5 5 Recommended...

Page 70: ... is an increase in nitrite content to more than 20 ppm mg 1 or nitrate content to more than 50 ppm mg 1 there is an increase in the N nitrosodiethanolamine NDELA to more than 5 ppm mg a CAUTION Comply with the manufacturer s specifications for mixture ratios hazardous substances e g system cleaners including their permissible minimum use times CAUTION Since the cooling lubricant escapes under high...

Page 71: ...initial filing Measures in accordance manufacturer s recommendations 1 0 based on initial filing Replace cooling lubricant clean cooling lubricant circulation system Usage concentration Manual refractometer weekly 1 Method results in incorrect values with tramp oil content Base reserve Acid titration in accordance with Manufacturer s recommendation as required Method is independent of tramp oil co...

Page 72: ...he article no is located in the spare parts list Die Seriennummer befindet sich am Typschild The serial no is on the rating plate 6 2 Hotline Ersatzteile Spare parts Hotline 49 0 951 96555 118 ersatzteile stuermer maschinen de 6 3 Service Hotline 49 0 951 96555 100 service stuermer maschinen de 6 4 Elektrische Ersatzteile Electrical spare parts 6 5 Schaltplan Wiring diagram Der aktuelle Schaltplan...

Page 73: ...Version 1 0 4 2020 7 31 73 Originalbetriebsanleitung MZ4S DE EN MZ4S_parts fm 6 6 Getriebe allgemein General gear box ...

Page 74: ...Öldeckel Oil Cap 1 UM41060 03346245135 36 Nadellager Needle Bearing 2 K20x26x20 03346245136 37 Kugellager Ball Bearing 1 6007ZZ 03346245137 38 Haltering Retaining Ring 3 STW45 03346245138 39 Haltering Retaining Ring 3 STW35 03346245139 40 Haltering Retaining Ring 1 RTW55 03346245140 41 Passfder Key 1 8x7x32L 03346245141 42 O Ring O Ring 1 G50 03346245142 43 Welle Shaft 1 M2x20T 03346245143 44 Abst...

Page 75: ...is Ball Screw 1 Tr25xP5 LT 03346235204 5 Schwenkkopf Swivel Head Body 1 UM41005 03346235205 6 Linearführung Linear Guide 2 BGXH25FN BGR25 03346235206 7 Platte Slide Plate 1 UM41008 01 03346235207 8 Welle Shaft 1 UM41012 03346235208 9 Abstandshalter Spacer 1 036x6t 03346235209 10 Platte Connecting Seat 1 UM41014 01 03346235210 11 Motorriemenscheibe Motor Pulley 1 UM41082 03346245211 12 Hülse Sleeve...

Page 76: ...03346245224 25 Stift Solid Taper Pin 1 6 03346245225 26 Motor Motor 1 3 75kW 2P 03346245226 27 Feder Spring 1 X404114 03346245227 28 Kugellager Ball Bearing 2 6002ZZ 03346245228 29 Schraube Screw 1 M6x16L 03346245229 30 Sechskantschraube Hex Bolt 2 M12x60L 03346245230 31 Ölschraube Oil Plug 1 3 8 PT 03346245231 32 Stopper Stopper 1 X504055 03346245232 33 Stahlstift Steel Pin 2 010x40L 03346245233 ...

Page 77: ... 02 03346245312 13 Welle Shaft 1 UM41111 03346245313 14 Ring Collar 1 UM41112 03346245314 15 Kegelradgetriebe Bevel Gear 1 UM41113 03346245315 16 Lagerring Bearing Spacer 1 UM41121 03346245316 17 Lagerring Bearing Spacer 1 UM41122 03346245317 18 Abstandshalter Spacer 1 UM41138 03346245318 19 Positionierstift Positioning Pin 2 UM41100 03346245319 20 Lagermutter Bearing Nut 1 AN02 03346245320 21 Sch...

Page 78: ...rösse Artikelnummer Qty Size Item no 1 Gehäuse Housing 1 UM41095 03346245401 2 Welle Shaft 1 UM41096 03346245402 3 Kegelradgetriebe Bevel Gear 1 UM41117 03346245403 4 Abstandshalter Spacer 1 UM41097 03346245404 5 Winkellager Angular Bearing 1 7011C 03346245405 6 Winkellager Angular Bearing 1 7013C 03346245406 7 Lagermutter Bearing Nut 1 M40X1 5P 03346245407 8 Scheibe Star Washer 1 AW08 03346245408...

Page 79: ...amping nut 1 UM41110 03346245603 4 Stahlstift Steel Pin 7 5x16 03346245604 5 Kegelradgetriebe Bevel Gear 1 UM41116 03346245605 6 Abdeckung Cover 1 UM41091 03346245606 7 Sicherungsstift Lock Pin 1 UM41120 03346245607 8 Feder Quill 1 UM41098 03346245608 9 Vertikale Spindel Vertical Spindle 1 UM41102 03346245609 10 Abdeckung Cover 2 UM41099 03346245610 11 Positionierstift Positioning Pin 2 X002169 03...

Page 80: ...ng Retaining Ring 1 STW48 03346245625 26 Spindelvorschub Spindle Handle System 1 600VL 2GA S01 03346245626 Werkzeugspannung horizontal Horizontal tool clamping system Pos Bezeichnung Designation Menge Grösse Artikelnummer Qty Size Item no 1 Getriebewelle Transmission Shaft 1 UM41107 01 03346245701 2 Skalenring Dial Plate 1 UM41105 03346245702 3 Abstandshalter Spacer 1 UM41108 03346245703 4 Hülse O...

Page 81: ...nummer Qty Size Item no 1 Ring Protecting Spacer 2 UM33060 03346245901 2 Netz Net 2 UM33068 03346245902 3 Abdeckung Cover 1 UM37007 03346245903 4 Motorplatte Motor Seat 1 UM37060 03346245904 5 Hülse Sleeve 1 UM37010 03346245905 6 Stange Rod 1 UM37011 03346245906 7 Riemenscheibe Motor Pulley 1 5Mx18Tx20W 03346245907 8 Riemenscheibe Motor Pulley 1 5Mx54Tx20W 03346245908 9 Abstandshalter Spacer 1 20x...

Page 82: ...links Bracket Left 1 UM47006 03346245919 20 Abdeckung Cover 1 UM47009 03346245920 21 Riemen Belt 1 HTD 5M 20 450L 03346245921 22 Ring Dial Seat 1 X5W04096 03346245922 23 T Nut T Nut 6 M14xP2 0 03346245923 24 Drucklager Thrust Bearing 2 51104 04051140 25 Lagermutter Bearing Nut 2 YSR M20x1 0 03346245925 26 Motor Motor 1 PF22 0400 7 5S4 40N 03346245926 27 Kugellager Ball Bearing 4 6004ZZ 0406004 28 ...

Page 83: ...Qty Size Item no 1 Rundes Griffrad Round Handle Wheel 2 0200 M10 033462451001 2 Abdeckung Cover 2 W1 1 4 20 033462451002 3 Sicherungsring Lock Ring 2 X204065 033462451003 4 Skalenring X Y Achse Dial Ring for X Y axis 2 0 02 5 mm 033462451004 5 Kupplung Clutch 2 X204064 033462451005 6 Nadellager Needle Bearing 2 TLA 1622 033462451006 7 Griff Grip 2 X504098 033462451007 8 Feder Spring 2 X404114 0334...

Page 84: ...1 UM44012 033462451108 9 Maschinenbasis Machine Base 1 UM9001 033462451109 10 Riemenscheibe Z Achse Motor Pulley Z axis 1 UM9071 28F 033462451110 11 Wischer Wiper 2 UM72007AS 033462451111 12 Wischer Wiper 2 UM72008AS 033462451112 13 Nivellierbolzen Leveling Bolt 4 M20xP2x80L 033462451113 14 Flexibler Griff Flexible Handle 2 M12x40L 033462451114 15 Einstellschraube Adjusting Screw 2 M8x37L 03346245...

Page 85: ... Bearing Bracket 1 UM9105 033462451206 7 Lagerbock Bearing Bracket 1 UM9106 033462451207 8 Kegelradgetriebe Bevel Gear 1 UM9107 033462451208 9 Getriebewelle Transmission Shaft 1 UM9108 033462451209 10 Getriebewelle Transmission Shaft 1 UM9109 033462451210 11 Universelle Kurbel Universal Crank 1 SJS16 ST 390 410 033462451211 12 Skalenhalter Dial Holder 1 UM9111 033462451212 13 Zahnradhalterung Gear...

Page 86: ...51305 6 Halterung Bracket 1 UM37021 033462451306 7 Abstandshalter Spacer 1 UM42011 033462451307 8 Kegelradgetriebe Bevel Gear 1 M2x30T RH 033462451308 9 Halterung Bracket 1 UM42028 033462451309 10 Abstandshalter Spacer 1 UM42032 033462451310 11 Abstandshalter Spacer 4 UM47010 033462451311 12 Teller Plate 1 UM47019 033462451312 13 Motorplatte Servo Motor Seat 1 UM47018 033462451313 14 Lagermutter B...

Page 87: ...2351401 2 Abdeckung Cover 1 UM37028SL 033462351402 3 Top Schutzhülle Top Protecting Cover 1 UM41124 033462351403 4 Messingstück Brass Piece 2 012 7x10 033462351404 5 Sattel Saddle 1 UM43001S 033462351405 6 Trägerplatte R Support Plate R 1 UM43002 02 033462351406 7 Stützplatte L Support Plate L 1 UM43002 02MR 033462351407 8 Gib Gib 2 29x580L 033462351408 9 Gib Gib 1 29x580L 033462351409 10 Block Lo...

Page 88: ...451419 20 Ring Protect Ring 1 040x5t 033462451420 21 Bodenschutzhülle Bottom Protecting Cover 1 UM9149SL 033462451421 22 Endschalterplatte Limit Switch Plate 1 UM9242SL 033462451422 24 Flexibler Griff Flexible Handle 2 M10x85L 033462451424 25 Flexibler Griff Flexible Handle 2 M16x40L 033462451425 26 Einstellschraube Adjusting Screw 7 M8x37L 033462451426 27 Lagermutter Bearing Nut 1 YSR M55x2 0 033...

Page 89: ...tikelnummer Qty Size Item no 1 Horizontales Gerät Horizontal Steady Device 1 UM41131 033462452301 2 Keilleiste Gib 1 20x82 033462452302 3 Halterung Bracket 1 UM41132 033462452303 4 Teller Plate 2 UM41129 033462452304 5 Buchse Bushing 2 UM41128 033462452305 6 Nadellager Needle Bearing 1 KT303818 033462452306 7 Ölbuchse Oil Bushing 2 SPB303815 033462452307 8 Innensechskantschraube Hex Socket Cap Scr...

Page 90: ...kelnummer Qty Size Item no 1 Langer Fräsdorn Longer Cutter Arbor 1 Ø16mm ISO40 033462452401 2 Langer Fräsdorn Longer Cutter Arbor 1 Ø22mm ISO40 033462452402 3 Langer Fräsdorn Longer Cutter Arbor 1 Ø27mm ISO40 033462452403 4 Langer Fräsdorn Longer Cutter Arbor 1 Ø32mm ISO40 033462452404 5 MK3 Adapter MT 3 Adapter 1 ISO40 MT3 033462452405 6 MK2 Adapter MT 2 Adapter 1 MT3 MT2 033462452406 7 MK1 Adapt...

Page 91: ...l Box 1 UM41149 033462352506 7 Rahmenabdeckung R Frame Cover R 1 UM42002 033462452507 8 Rahmenabdeckung L Frame Cover L 3 UM42049 033462452508 9 Rückseite Back Cover 2 UM42052 1 033462452509 10 Obere Abdeckung Top Cover 1 UM42053 033462452510 11 Schutzhülle Protecting Cover 1 UM42056 01 033462452511 12 Tube Tube 1 UM42059 033462452512 13 Halterung Bracket 1 UM43109 033462452513 14 Abdeckung Cover ...

Page 92: ... Automatic Lubricator 1 2L Optional 033462452601 2 Innensechskantschraube Hex Socket Cap Screw 4 M6x25L 033462452602 3 Flexibles Stahlrohr Flexible Steel Tube 1 d4x1800L 033462452603 4 Winkeladapter Elbow Adaptor 3 AL 013 033462452604 5 Gerader Adapter Plane Straight Adapter 3 AL 020 033462452605 6 Aluminiumrohr Aluminum Pipe 6 d4 033462452606 7 Innensechskantschraube Hex Socket Cap Screw 2 M5x25L...

Page 93: ...anne Tub 1 M6x40 033462452703 4 Scheibe Washer 4 06 033462452704 5 Innensechskantschraube Hex Socket Cap Screw 2 M6x12 033462452705 6 Schlauch Hose 1 1 2 033462452706 7 Schlauchanschluss Hose Fitting 2 PT 3 8 x 1 2 90 033462452707 8 Schlauchschelle Hose Clamp 2 5 6 11 20 033462452708 9 Kühlmittelpumpe Coolant pump 1 1 8HP 033462452709 10 Halogenlampe Halogen Lamp 1 24V 500L 033462452710 LED Lampe ...

Page 94: ...Version 1 0 4 2020 7 31 94 Originalbetriebsanleitung MZ4S DE EN MZ4S_parts fm 6 23 Dreharm Bedienfeld Rotate Arm Operation Panel ...

Page 95: ...1 E VR002 033462453216 17 Schalter für Kühlmittelpumpe Coolant Pump Switch 1 E SA002 033462453217 18 Not Halt Schlagschalter Emergency Switch 1 E SB001 033462453218 19 Spindel F R Auswahlschalter Spindle F R Select Switch 1 E SA001 033462453219 20 Geschwindigkeitsregler Speed Adjuster 1 E VR003 033462453220 21 Haltegrif Curve Grab Handle 1 ES 121300B 033462453221 22 Steuerkastensitz Control Box Se...

Page 96: ...Version 1 0 4 2020 7 31 96 Originalbetriebsanleitung MZ4S DE EN MZ4S_parts fm 6 24 Schaltplan Wiring diagram ...

Page 97: ...Version 1 0 4 2020 7 31 97 Originalbetriebsanleitung MZ4S DE EN MZ4S_parts fm ...

Page 98: ...Version 1 0 4 2020 7 31 98 Originalbetriebsanleitung MZ4S DE EN MZ4S_parts fm ...

Page 99: ...Version 1 0 4 2020 7 31 99 Originalbetriebsanleitung MZ4S DE EN MZ4S_parts fm ...

Page 100: ...Version 1 0 4 2020 7 31 100 Originalbetriebsanleitung MZ4S DE EN MZ4S_parts fm ...

Page 101: ...Version 1 0 4 2020 7 31 101 Originalbetriebsanleitung MZ4S DE EN MZ4S_parts fm ...

Page 102: ...Version 1 0 4 2020 7 31 102 Kopie Original PD150 PD200 3346225 DE EN PD150 PD200 tool spanner_parts fm 6 25 Option Druckluft Werkzeugspanner Compressed air tool spanner option ...

Page 103: ... 18 Zylinder Cylinder S45C 03346225P02019 19 Vordere EBT Platte Front EBT plate ADC12 03346225P02020 20 Öldichtung Oil seal Ø6 Ø10 Ø16 03346225Q20001 21 Lager Bearing 628z 040628z 22 Dichtung Schlagschrauberkäfig Hammer gage gasket Ø3 5 x Ø37 7 x Ø44 7 03346225P02078 23 Schlagbolzen Hammer pin Ø3 5 x Ø39 7 x Ø46 7 03346225P02076 24 Hammerkäfig Hammer cage Ø10 x Ø34 x T 0 3 03346225P02075 25 Anschl...

Page 104: ...x T1 03346225W12030 67 Halbmondring Crescent ring IRTW 32 03346225F00032 68 Untere Abdeckung Bottom cover 03346225P02034A 69 Innenring Inner ring Ø32 x Ø18 x T13 03346225P02035 70 Kopf Anzugsstange Drawbar head 03346225P02036 70 Anzugsstange Drawbar 03346225P02037 71 Ring Anzugsstange Drawbar ring 03346225P02038 72 Schlagschrauber Bolzen Hammer cage pin Ø5 9 x 32L 03346225U46032 73 Schlagschrauber...

Page 105: ...Version 1 0 4 2020 7 31 105 Kopie Original PD150 PD200 3346225 DE EN PD150 PD200 tool spanner_parts fm 6 26 Zubehör Accessories ...

Page 106: ...006 Luftschlauch Air pipe 03346225A00001 15 Gelenkbaugruppe Joint assy 3 8 x 2 5M 03346225P02908 16 Mutter Nut 03346225P02043 17 Kappe Cap 03346225P02041 18 Gelenk Joint 03346225P02042 19 Mutter Nut 03346225P02044 20 Mutter Nut 03346225P02045 21 Mutter Nut 03346225P02046 26 Lampe Light 03346225P02056 27 Sicherungshalter Fuse holder 03346225E50901 28 Sicherung Fuse 4A 03346225E50051 29 Anschlusskab...

Page 107: ... PM 20 03346225P02063 53 Druckanzeige Pressure gauge 03346225P02064 54 Schraube Screw M6 x 20 03346225T36020 55 Schraube Screw M6 x 16 03346225T36016 56 Schraube Screw M5 x 10 03346225T15010 57 Schraube Screw M4 x 10 03346225T14010 58 Unterlegscheibe Washer Ø5 x 12 x 1mm 03346225W10050 59 Federscheibe Spring washer Ø5 03346225W20050 60 Federscheibe Spring washer Ø6 03346225W20060 61 Steuerbox Baug...

Page 108: ...la 150 Meropa 150 VG 100 CLP 100 Aral Degol BG 100 BP Energol GR XP 100 SPARTAN EP 100 Klüberoil GEM 1 100 Mobilgear 627 Shell Omala 100 Meropa 100 VG 68 CLP 68 Aral Degol BG 68 BP Energol GR XP 68 SPARTAN EP 68 Klüberoil GEM 1 68 Mobilgear 626 Shell Omala 68 Meropa 68 VG 46 CLP 46 Aral Degol BG 46 BP Bartran 46 NUTO H 46 HLP 46 Klüberoil GEM 1 46 Mobil DTE 25 Shell Tellus S 46 Anubia EP 46 VG 32 ...

Page 109: ...r broches à haute vitesse VG 68 Deol BG 68 Emergol HLP D68 Spartan EP 68 Drucköl KLP 68 C Shell Omala 68 Fett für Zentralschmierung Fließfett Grease for central lubrica tion Graisse pour lubrification centrale NLGI Klasse 000 NLGI class 000 ARALUB BAB 000 Grease EP 000 Shell Gadus S4 V45AC CENTO PLEX GLP 500 Mobilux EP 023 Multifak 264 EP 000 Fett für Hochfrequenzspin deln Grease for Built in spin...

Page 110: ...e the clamping chuck Taper cannot be inserted in quill Remove any dirt grease or oil from the internal conical surface of the spindle sleeve or the taper Clean surfaces well Keep surfaces free from grease Motor does not start Motor is wrongly connected Defective fuse Have it checked by qualified personnel Motor is overheating and there is no power Motor overloaded Insufficient mains voltage Motor ...

Page 111: ...oose Tool is blunt The workpiece is not fastened Readjust the bearing slack or replace the bearing Readjust bearing slack fixed bearing Adjust strip to the correct slack using the adjusting screw Check re tighten Sharpen or renew the tool Clamp the workpiece firmly Earth leakage circuit breaker trips Smooth DC residual currents Current in the protective earth conductor Leakage current on page 32 M...

Page 112: ...rt Pfleger Straße 26 D 96103 Hallstadt does not grant any further warranties unless they are listed below or were promised as part of a single contractual provision Liability or warranty claims are processed at OPTIMUM GmbH s discretion either directly or through one of its dealers Any defective products or components of such products will either be repaired or replaced by components which are fre...

Page 113: ...h nearest approaches the intent of the guarantor and remains within the fra mework of the limits of liability and warranty which are specified by this contract is deemed agreed 8 5 Storage ATTENTION Incorrect and improper storage might result in damage or destruction of electrical and mechanical machine components Store packed and unpacked parts only under the intended environmental conditions Fol...

Page 114: ...supplied to the waste paper collection The films are made of polyethylene PE and the cushion parts are made of polystyrene PS These materials can be reused after reconditioning if they are passed to a collection station or to the appropriate waste management enterprise Only forward the packaging materials correctly sorted to allow direct reuse 8 6 3 Disposal of the machine INFORMATION Please take ...

Page 115: ... Union and other European countries with a sepa rate collecting system for those devices The sign on the product or on its packing indicates that the product must not be handled as common household waste but that is needs to be disposed of at a central collection point for recycling Your contribution to the correct disposal of this product will protect the environment and the public health Incorre...

Page 116: ...n Drill chuck Drill bit adapter can be fixed by hand Tool Milling cutter drill bit etc Term Explanation Chapter Short summary new version number 2 3 Machine foot dimension 1 0 1 4 1 Note on manual movement with the hand cranks on the milling table in de energised condition 1 0 2 2 Spare parts 4 16 Tool spanner option 1 0 3 3 Interdepartmental transport 1 0 4 ...

Page 117: ...machines EN 60204 1 2014 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 13849 1 2015 Safety of machinery Safety related parts of controls Part 1 General design principles EN 13849 2 2012 Safety of machinery Safety related parts of controls Part 2 Validation EN ISO 12100 2013 Safety of machinery General principles for design Risk assessment and risk reduction EN...

Page 118: ... of the original instructions MZ4S GB MZ4S_GB_7 accuracy example report fm 8 10 Example accuracy report The accuracy report is enclosed with the machine The values to be observed correspond to the German industrial standard from 1979 DIN 8515 ...

Page 119: ...Version 1 0 4 2020 07 31 119 Translation of the original instructions MZ4S GB MZ4S_GB_7 accuracy example report fm ...

Page 120: ...Lubrication 30 M Main switch 14 17 Maintenance work 18 Maintenance Inspection 54 Malfunctions 110 118 Mounting anchored 29 O Obligations of the operating company 12 of the operator 13 Operating material 54 Operation 34 operator s log 55 P Panels 34 36 37 Personal protective equipment 25 Power failure 38 Prohibition warning and mandatory signs 15 Protective equipment 16 Q Qualification of personnel...

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