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Instruction Manual

CONGRATULATIONS TO HAVE CHOSEN

Marposs M1 Star MBG (Mechanical Bore Gauge)

Reading this manual will enable you to use the product in the best way,
and to become acquainted with all the system characteristics that mark

it out and make it unique of its kind.

Summary of Contents for M1 Star MBG

Page 1: ...TO HAVE CHOSEN Marposs M1 Star MBG Mechanical Bore Gauge Reading this manual will enable you to use the product in the best way and to become acquainted with all the system characteristics that mark it out and make it unique of its kind ...

Page 2: ......

Page 3: ... of the product The descriptions contained in this manual may not be tampered with or altered by unauthorized personnel For further information we invite you to visit our website www testar com where you can download the updated versions of the individual instruction manuals All the products company names and logos are protected by copyright WARNING Do not manipulate or twist the measuring armset ...

Page 4: ...Y TEST 38 CHAPTER 6 MAINTENANCE 39 6 1 ORDINARY MAINTENANCE 39 6 1 1 THREE MONTHS MAINTENANCE 39 6 1 2 SIX MONTHS MAINTENANCE 39 6 2 SPECIAL MAINTENANCE 40 CHAPTER 7 LIST OF SPARE PARTS 41 7 1 STANDARD INDICATOR HOLDER 41 7 1 1 COMPONENTS 41 7 2 MINI INDICATOR HANDLE 42 7 2 1 COMPONENTS 42 7 3 PENCIL PROBE HOLDER 43 7 3 1 COMPONENTS 43 7 4 PLUG GAUGES 44 7 4 1 NOSEPIECES 45 7 4 2 MEASURING ARMSETS...

Page 5: ... is possible to achieve the configuration that is most suitable to any individual requirement The graphic representation below identifies the main parts of the bore gauge which will be analyzed in detail further on HANDLES THREAD ADAPTORS ANGLE ADAPTOR HOOKS DEPTH STOPS DEPTH EXTENSIONS ROTARY SPACER CONTACTS CAPS PLUG GAUGE ...

Page 6: ... the zero setting is not obtained by means of the SET UP A procedure SET UP B 1 Apply the 13 A F wrench to the threaded connection seat E see fig 1 unscrew and extract from the handle the measuring unit probe holder A threaded connection E plug gauge B see fig 1b 2 Unscrew and remove the nuts from the cable holder clamp unit using the 4 A F wrench and disassemble the two semi clamps by means of th...

Page 7: ... them using the 4mm A F wrench see fig 8 12 Screw the handle to the measuring unit see fig 9 and lock it by means of the 13mm A F wrench 13 Perform the electrical zero setting of the bore gauge through the electronic system in use The pencil probes for the M1 Star see page 53 have been manufactured with a 4 7 mm diameter cable In case the pencil probes in use have standard diameter cables 3 3 or 3...

Page 8: ...A 0 mm in case of mini indicator holder handle 3 Apply the bore gauge to the zero setting master see fig 3 4 Re insert in the handle the indicator holder unit manually screw it so as to notice at least a 500 mm shifting of the indicator pointer for models TD1 TD10 and Quick Digit For the TD1P model the indicator pointer has to be within the 30 mm range in order to be sure to retrieve the ZERO by m...

Page 9: ...screw the plastic plug and operate on the mechanical potentiometer in order to have the pointer set to ZERO see fig 5 It is possible to operate on the whole display range 50 µm Replace the plastic plug QUICK DIGIT Push the RESET button to zero the indicator NON MARPOSS INDICATORS Many indicator models are available on the market so it is difficult to determine a set up procedure that can meet all ...

Page 10: ...ent of some of its parts and or components Below all the procedures for a correct replacement of the components are described 3 1 PLUG GAUGE The plug gauge is the basic element of the bore gauge because it contains all the movement transduction technology It is supplied completely assembled see Fig 1 calibrated and tested at the Marposs center Figure 2 shows all the components that form the plug g...

Page 11: ...ROBE HOLDER use the 13mm A F wrench for a MINI INDICATOR HOLDER use the 15mm A F wrench 3 1 1 REPLACEMENT OF PLUG GAUGE The plug gauge can be replaced if its components are worn out or if a retooling is required in order to measure a different diameter For retooling procedures it is important to consider that the size of thread M for plug gauge and handle connection changes in relation to the meas...

Page 12: ...mstance may demage both the sensor and the plug gauge On Fig 6 are represented the instering distances of the plug gauges in the handle and the height of the thread adaptor if applied 1 Manually screw the plug gauge in the handle seat until stopped see Fig 4 2 Apply special wrench B to seat 1 see Fig 5 and lock the plug gauge to the handle The wrench B must be applied to seat 2 for plug gauges wit...

Page 13: ...assembly and or to replace some components within the plug gauge The assembly disassembly procedure of the cap differs according to the diameter range of the plug gauge as indicated below DISASSEMBLY OF CAP IN PLUG GAUGES FOR 12 Ø 120 1 Insert the bent circlip pliers in the holes A see Fig 1 2 Tighten the pliers and extract the cap see Fig 2 ASSEMBLY OF CAP IN PLUG GAUGES FOR 12 Ø 120 1 Take the c...

Page 14: ...w the 4 screws 2 Extract the 2 half clamps from the plug gauge 3 Disassemble the 4 spacers by means of the 8mm A F wrench see Fig 5 ASSEMBLY OF CAP IN PLUG GAUGES FOR 120 Ø 300 1 Assemble the 4 spacers by means of the 8mm A F wrench see Fig 5 2 Insert the two half clamps in the plug gauge so as to cause the holes on the half clamps to coincide with the spacers see Fig 6 3 Insert the 4 screws and s...

Page 15: ...BLIND BORES BC THROUGH BLIND BORES SUPERBLIND BORES BC THROUGH BLIND BORES 7 5 Ø 26 26 Ø 300 CONTACTS SCREWED SO AS TO TOUCH THE MEASURING ARMSET CONTACTS SCREWED IN AND POSITIONED ON THE MEASURING ARMSET AND LOCKED BY MEANS OF A SELF LOCKING THREAD CONTACTS SCREWED IN AND POSITIONED ON THE MEASURING ARMSET AND LOCKED BY MEANS OF A LOCK NUT CONTACTS SCREWED IN AND POSITIONED ON EXTENSIONS BY MEANS...

Page 16: ...4mm A F open wrench DESCRIPTION ORDER CODE Tungsten Carbide and DLC Diamond Diamond Contacts Extensions Tungsten Carbide and DLC Tungsten Carbide and DLC Tungsten Carbide and DLC with 2 5 mm radius Diamante Tungsten Carbide and DLC with 1 5 mm radius Diamond Tungsten Carbide Tungsten Carbide Lock nut contacts of Tungsten Carbide and DLC Lock nut contacts of extension CONTACTS TYPE APPLICATION SB B...

Page 17: ...ures a view of the entire bore gauge pretravel see Table of contacts 2 Screw in contacts T1 and T2 by means of the relevant wrench see CONTACTS WRENCH TABLE so as to fit them inside nosepiece A see Fig 1 3 With the bore gauge in vertical position unscrew contact T1 so as to protrude it out of the nosepiece see Fig 2 by an amount that ensures that when the plug gauge is inserted in the master and p...

Page 18: ... the master check for a shift of 50 µm on the display see Fig 7 6 Firmly holding the indicator turn the handle clockwise until 50 µm is visualized by the display see Fig 8 7 Repeatedly extract and insert the bore gauge in the master unscrewing contact T2 each time until the value ZERO is displayed In this way the excursion for each contact is 50 µm equal to a 100 µm application range If the applic...

Page 19: ... the contacts for the display device The versions developed are basically 2 one with FINGERS measuring range from 3 mm to 26 mm and one with PARALLELOGRAM measuring range from 26 mm to 300 mm Fig 2 shows the models in relation to their measuring range Fig 3 shows as example the measuring armset composition for a range between 9 5 and 26 A Armset B Rod C Spring D Sliding bushing E Nosepiece locking...

Page 20: ...the components the interchangeability is not possible DISASSEMBLY ASSEMBLY OF NOSEPIECE MEASURING ARMSET FOR RANGE 5 5 26 mm Special tools are required to disassemble and assemble these components in order to ensure the proper nosepiece measuring armset coupling Due to this reason it is strongly recommended to contact the nearest MARPOSS office ...

Page 21: ...to apply the wrenches specified in the relevant table 1 Disassemble the plug gauge from the handle see page 11 2 If present disassemble the cap see page 14 Remove the contacts see page 15 except nosepieces with open contacts seat see fig 2 3 Firmly apply the wrench A to the nosepiece seat then unscrew and remove the nut by means of the wrench B see fig 3 4 Extract the measuring armset from the nos...

Page 22: ...rench B see fig 3 4 Assemble the contacts see page 17 5 Assemble the cap if present see page 13 6 Assemble the plug gauge on the handle and lock it see page 11 On the table 1 is expressed the suggested torque to lock the nut ATTENTION in order to ensure the correct mutual position of the measuring armset and the nosepiece both components are equipped with a centering and mating reference 1 2 3 B A...

Page 23: ... Firmly apply wrench A to the spacer seat 1 see Fig 2 then unscrew bushing 2 by means of the wrench B 3 Extract the unit composed by rod C bushing A spring B see Fig 3 4 Extract the components drawing them off the rod ASSEMBLY OF BUSHING FOR RANGE 3 7 5 mm 1 Assemble the unit composed by rod C bushing A spring B see Fig 3 2 Insert and manually screw the rod unit to the measuring armset 3 Firmly ap...

Page 24: ...easuring armset see Fig 2 ASSEMBLY OF BUSHING FOR RANGE 7 5 300 mm 1 Insert the rod c the spring b and manually screw the bushing a so as to stop it see Fig 2 2 Lock the bushing 2 by means of the wrench B On the table 1 are expressed the suggested torques to lock the rod unit B Tab 1 S S S S SUGGESTED UGGESTED UGGESTED UGGESTED UGGESTED TORQUE TORQUE TORQUE TORQUE TORQUE Ø 7 5 9 5 Ø 9 5 26 ROD UNI...

Page 25: ...onforming to the anatomy of the hand is also the element that connects the indicator to the plug gauge It may be a pencil probe holder in electromechanical applications fig 1 or an indicator holder in the Standard or Mini version in mechanical applications fig 2 2 1 Standard Mini PENCIL PROBE HOLDER INDICATOR HOLDER ...

Page 26: ...peration ensure functionality A cable guide and cable clamp protect the pencil probe cable COMPONENTS See Fig 2 A CABLE GUIDE B THREADED BUSHING C HANDLE D REMOVABLE NUMBER PLATE E COLLET F CABLE CLAMP G TAPERED NUT H PENCIL PROBE HOLDER I ADJUSTING RING NUT L THREADED CONNECTION 1 2 A B C D F G I H L E ...

Page 27: ...disassemble the nuts on the clamp unit F Fig 5 by means of the 4mm A F wrench and disassemble the two half clamps by means of the 1 5 mm hexagonal end wrench 3 Loosen the adjusting ring nut I and unscrew the threaded connection L see Fig 6 4 Unscrew the cable guide A by means of the 30mm A F wrench and the threaded bushing B by means of the 28mm A F wrench see fig 2 page 26 4 A F L H G I F 1 5 13 ...

Page 28: ...means of the 27mm A F wrench see Fig 5 3 Unscrew and extract the plastic cap C for handle by means of the 30mm A F wrench see Fig 6 3 2 2 2 MINI INDICATOR HOLDER HANDLE COMPONENTS SEE FIG 7 A INDICATOR HOLDER B ADJUSTING RING NUT H HANDLE TRANSMISSION ASSEMBLY DISASSEMBLY MINI INDICATOR HOLDER COMPONENTS 1 Loosen adjusting ring nut B by means of the 16mm A F or with the 2mm hexagonal end wrench 2 ...

Page 29: ... the plug gauges and or accessories with the handle Three are the available manufactured models which can achieve any type of interfacing Figure 1 shows the thread adaptor and the relevant table indicates the sizes of the threaded connections ASSEMBLY 1 Manually screw the thread adaptor to the handle see Fig 2 2 Apply wrench C see table to the adaptor seat and lock it see Fig 2 1 2 A B M3 5 x 0 35...

Page 30: ...achine and where the bore is in a position that requires a 90 tilting of the measuring axis ASSEMBLY 1 Disassemble the plug gauge from the handle see page 11 2 Screw the angle to the handle see Fig 2 and tighten it by means of the 11 mm A F wrench 3 Screw the plug gauge to the angle see Fig 3 and lock it by means of the appropriate wrench see page 11 1 2 3 ...

Page 31: ...d depth stop position has been achieved lock the whole unit by means of the hexagonal end wrench 2 5 mm for the Ø 4 depth stop and 3 mm for the Ø 7 5 depth stop The depth stop locking position varies according to the depth in which the measurement needs to be detected As shown on Fig 6 if the depth stop rests on the plug gauge the measuring depth is zero because the touch takes place on the axis o...

Page 32: ... A by screwing the M5 dowel by means of the 2 5 mm hexagonal end wrench see Fig 2 3 By means of the 5 mm A F wrench screw and lock the stop spacers in the relevant seats see Fig 3 The choice of the seat is determined by the diameter class of the nosepiece see table below The depth stop locking position varies according to the depth in which the measurement needs to be detected As shown on Fig 2 if...

Page 33: ...g to the depth in which the measurement needs to be detected see Fig 1 To define the correct position it is sufficient to add A to C distance between the axis of the contacts and the top of the nosepiece by means of a slider gauge see Fig 2 2 By means of the 3 mm hexagonal end wrench see Fig 3 lock the depth stop at the required distance 3 A C A C NOTE In order to avoid mechanical stress of the no...

Page 34: ...ance to a hook avoiding the presence of the cable on the worktable ASSEMBLY 1 Unscrew the cable guide from the threaded bushing using the 30 mm A F wrench see Fig 2 2 As shown in Fig 3 insert the eye in the cable and position it on the threaded bushing 3 Screw the cable guide to the threaded bushing and lock it by means of the 30 mm A F wrench see Fig 4 2 3 4 1 ...

Page 35: ...2 Manually screw the depth extension to the handle see Fig 2 3 Lock it by means of the appropriate wrench see Fig 3 and 1 4 Manually screw the plug gauge to the other end of the extension see Fig 4 5 Firmly apply the appropriate wrench see Fig 1 to the extension seat then lock the plug gauge by means of the relevant wrench see page 11 1 2 3 4 20 30 40 50 65 80 100 125 AVAILABLE LENGHTS Ø 4 mm Ø 7 ...

Page 36: ...y spacer to the handle on threaded side B then apply 13 A F wrench and lock it 3 Manually screw the plug gauge to the rotary spacer until stop it 4 As shown in Fig 3 firmly apply the 13 A F wrench to the rotary spacer and lock the plug gauge by means of the appropriate wrench see page 11 A B M6 x 0 75 M10 x 1 13 A F C D 13 A F NOTE the table in Fig 1 will help you in the assembly indicating the si...

Page 37: ...or angle from the handle Measuring system pencil probe from the pencil probe holder or mechanical electronic indicator from the indicator holder Wearing of the nosepiece such situation increases the nosepiece workpiece clearance altering the technical metrological features of the bore gauge Residual dirt entered the movement transducer unit inside the measuring armset this instance requires a spec...

Page 38: ...ote down the value displayed on the indicator 5 Take out the bore gauge from the master 6 Repeat step 4 and 5 for 50 times in quick sequence 7 Calculate the standard deviation s of the 50 measurement and then multiply it for the factor 2 77 The achieved value represents the repeatability of the bore gauge with the applied indicator 8 Subtract from the calculated value the error of the applied indi...

Page 39: ...ed the first every three months and the second every six months 6 1 1 THREE MONTHS MAINTENANCE Clean the plug gauge using compressed air see fig 1 if it is the case disassemble the cap see page 14 6 1 2 SIX MONTHS MAINTENANCE Disassemble the plug gauge from the handle see page 12 Disassemble the rod unit see page 24 By means of compressed air clean the internal part of the plug gauge starting from...

Page 40: ...f the measuring armset special care for the V of movement transducing soaking the elements in a solvent solution isopropilic alcohol see fig 4 Dry the measuring armset by means of compressed air see fig 5 and lubricate it using a common workshop antioxidant lubricant Clean with a cloth the rod unit sphere see fig 40 and apply a thin layer of grease using common workshop lubricant grease Re assembl...

Page 41: ...2TCL6S0000 2TCLBS0000 2TCL7S0000 7 1 1 COMPONENTS Besides the complete indicator handle the individual components are supplied as well see the table and the relevant graphic representation DESCRIPTION Indicator holder assembly ø 8 Indicator holder assembly ø 3 8 Adjusting ring nut Plastic cap for indicator handle Handle label Removable number plate Collet Transmission assembly Extension for indica...

Page 42: ...tor handle ø 8 M6 Indicator handle ø 8 M3 5 Indicator handle ø 3 8 M10 Indicator handle ø 3 8 M6 Indicator handle ø 3 8 M3 5 CODE 2TCSAS0000 2TCS6S0000 2TCS3S0000 2TCSBS0000 2TCS7S0000 2TCS4S0000 The appropriate extensions to be installed on the indicator are supplied as standard equipment with the indicator handles Together with the spare part the extension to be installed on the indicator is sup...

Page 43: ...ide Threaded bushing Handle number plate Removable number plate Collet CODE REF 1 2 3 1T0CGS0994 1T0TBS0996 1T0HAS0993 1T0NPS0991 1T0CLS0995 DESCRIPTION Cable clamp assembly ø 8 Cable clamp assembly ø 3 8 Pencil probe holder ø 8 Pencil probe holder ø 3 8 Adjusting ring nut Threaded connection M10 Threaded connection M6 Complete penc pr holder ass y ø 8 M10 Complete penc pr holder ass y ø 8 M6 Comp...

Page 44: ...5 20 20 26 26 300 3 4 4 5 5 5 5 7 5 7 5 9 5 C D E F G H A B mm R 1 Plug Gauge type MBG T 0 2165 0 2953 0 2953 0 3740 0 3740 0 5905 0 5905 1 0236 1 0236 1 5748 1 5748 11 811 0 1181 0 1575 0 1575 0 2165 0 2165 0 2953 0 2953 0 3740 0 3740 0 5905 0 5905 1 0236 1 0236 11 811 MBG SB Dimension C ø MIN Bore Radius Contact 1 R 2 inch 6 0 2362 8 0 3150 1 0 0394 5 5 7 5 7 5 9 5 9 5 15 15 26 26 40 40 300 3 4 ...

Page 45: ... of an inch resolution Plug gauge type the last alphanumerical character indicates the specification of the distance between the axis of the contacts and the top of the nosepiece C 1 T M N Marking mm Minimum diameter of bore to be measured D expressed in mm α X X X X X X X X X X Inch Plug Gauge Type Minimum diameter of bore to be measured D expressed in inches Prefix 0 002 0 009 MEASURING RANGE PL...

Page 46: ... NOT supplied DESCRIPTION COMPONENTS 5 5 Ø 7 5 7 4 2 MEASURING ARMSETS On the following pages are listed all the spare part components for the measuring armsets 7 4 2 1 MEASURING ARMSET 3 Ø 5 5 DESCRIPTION Armset Locking nut Spring spacer Rod Spring Bushing CODE 1 2 3 4 NOT supplied 1TLM000081 1TGL000020 1TGN000000 1TGS000060 1TGLR00075 5 6 REF Complete measuring armset CODE NOT supplied DESCRIPTI...

Page 47: ...te measuring armset for superblind bores CODE not supplied not supplied DESCRIPTION COMPONENTS 7 5 Ø 9 5 7 4 2 4 MEASURING ARMSET 9 5 Ø 26 DESCRIPTION Armset Rod Spring Bushing Locking nut CODE 1 2 3 4 not supplied 1TGN000003 1TGS000062 1TGL000069 1TLM000023 5 REF Complete measuring armset for through and blind bores Complete measuring armset for superblind bores CODE not supplied not supplied DES...

Page 48: ...e contacts are supplied as spare parts Their coding is based on their technical specifications Below there is a representation of the coding pattern of the contact T C W C Material Prefix α Length of contact expressed in mm mm mm mm mm X X X X X X X X X X δ Prefix alphanumerical range that identifies the theme contacts with speaking code Material specifies the type of plug gauge and material coati...

Page 49: ...on Sundry these data depend by the diameter class of the plug gauge and are different in application B blind BC blind C 1 5mm T through or SB super blind bore and in contact tip radius R1 and R2 DIAMETER CLASS mm inch PLUG GAUGE TYPE BC BLIND BORES C 1 5mm C E G J DIAMETER CLASS mm inch PLUG GAUGE TYPE T THROUGH BORES TUNGSTEN CARBIDE OR DLC R1 mm R2 mm DIAMOND R1 mm R2 mm PLUG GAUGE TYPE SB SUPER...

Page 50: ... and all the plug gauges in the program 3 different thread adaptors are marketed see Fig 1 Their specifications and ordering codes are indicated in the table below 1 2 1 2TAS630000 2TAS660000 2TAS6A0000 2TASA30000 2TASA60000 2TASAA0000 7 5 3 CAPS The table below shows the caps with their ordering codes on the basis of the diameter class and or type of plug gauge for through blind bores or for supe...

Page 51: ...TDE0M150B0 2TDE0M150C0 2TDE0M150D0 2TDE0M150E0 56 91 129 189 68 103 141 201 153 213 Eight spacers are supplied as standard equipment with the caps for plug gauges with a range 120 mm Four of them are 29 mm long to be used in plug gauges for through bores while the other four are 24 5 mm long to be used in plug gauges for blind and super blind bores 1TC0000769 1TC0000770 1TC0000771 1TC0000772 1TC00...

Page 52: ...d dimension is expressed in inches with a thousandth of an inch resolution NOTE For the standard versions the minimum allowed diameter of the nosepiece is ø 8 mm 7 5 6 EXTENSIONS Three different models of extension are marketed Their technical specifications are shown in Fig 1 The table below will allow you to identify the commercial codes in relation to the type and or length of the extensions TY...

Page 53: ...10 LVDT cable length L 5 m and Lumberg connector SV50 6 3441553010 H10 HBT cable length L 2 m and Lumberg connector SV50 6 3441553011 H10 HBT cable length L 5 m and Lumberg connector SV50 6 3441562015 Compatible pencil probe with AIR GAGE electronics L 2 m 3441565019 Compatible pencil probe with ETAMIC ZDB electronics L 2 m 3441567013 Compatible pencil probe with FEINPRÜF MAHR electronics L 2 m 34...

Page 54: ...k Digit indicators can be found in the site www testar com B A 12 5 S A 65 9 B 2 59 53 4 2 10 mm inch mm inch M M M M MODEL ODEL ODEL ODEL ODEL S S S S S 7 6 2 MECHANICAL INDICATORS Three different models of mechanical indicators are marketed Their technical specifications are indicated in the table below TD10 TD1 TD1P Ø 8 3 8 Ø 8 3 8 Ø 8 3 8 0 010 mm 0 001 0 001 mm 0 0001 0 001 mm 0 0001 10 mm 0 ...

Page 55: ...ed only as an optional accessory and are used for all the retooling and or reconfiguration and or maintenance operations indicated in this manual EXAGONAL END WRENCH 2 mm EXAGONAL END WRENCH 1 5 mm SPECIAL AND OPEN WRENCHES SPECIFICATIONS SKETCH CODE WRENCH FOR NOSEPIECE FRON 3 TO 5 5 mm WRENCH FOR NOSEPIECE FROM 5 5 TO 7 5 mm WRENCH FOR NOSEPIECE FROM 7 5 TO 9 5 mm INDICATOR SET UP FOR ANTI ROTAT...

Page 56: ...56 7 LIST OF SPARE PARTS NOTES NOTES ...

Page 57: ...57 LIST OF SPARE PARTS 7 NOTES NOTES ...

Page 58: ... to Marposs products cited or showed in this document are registered marks or MARPOSS marks in the United Sta tes or in other countries Rights of third parties on marks or registered marks cited in the present document are acknowledged to the relevant owners Marposs has an integrated system to manage the Company quality the environ ment and safety attested by ISO 9001 ISO 14001 and OHSAS 18001 cer...

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