marposs M1 Star MBG User manual

Instruction Manual
CONGRATULATIONS TO HAVE CHOSEN
Marposs M1 Star MBG (Mechanical Bore Ga ge)
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.

WARNINGS
In order to protract the correct operation and high quality standards of the bore
gauge, it is advisable to comply with the warnings below.
FOREWORD
The M1Star MBG mechanical bore gauge is a new-concept product, designed to
measure the inside diameter of blind or through bores in a quick and reliable way.
This product is innovative in its contents: the pioneering technology employed in its
construction ensures the utmost reliability and accuracy.
The concepts of extreme modularity on which the MBG system is based makes it possible
to meet the manifold application needs present in a normal work-shop environment.
This User Manual is supplied only for information purposes. Marposs SpA reserves the
right to change the contents of the manual without being obliged to give advance notice
of it and/or not to notify any possible modification 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 inside the plug gauge (see Fig. 1);
any operation that may be carried out inside it is authorized only if the appropriate tools (mentioned
in this manual) are used; otherwise the transmission system might get damaged.
WARNING:
Do not use solvents: the maintenance and/or cleaning of the plug gauge must be carried
out following the instructions contained in this manual.
WARNING:
The bore gauge must not be dropped
and/or hit: this might damage the
measurement detection system, particularly in
plug gauges for small diameters.
NOTE:
Any damage on the product and/or
relevant components due to an improper
use of the product void the Marposs SpA warranty
terms.
1

CONTENTSCONTENTS
CONTENTSCONTENTS
CONTENTS
CHAPTER 1. DESCRIPTION OF MAIN PARTS 5
CHAPTER 2. ASSEMBLY AND ZERO-SETTING OF INDICATOR 6
PENCIL PROBE 6
MARPOSS MECHANICAL/ELECTRONIC INDICATORS 8
NON-MARPOSS INDICATORS 9
CHAPTER 3. REPLACEMENT OF PARTS AND COMPONENTS 10
3.1 PLUG GAUGE 10
3.1.1 REPLACEMENT OF PLUG GAUGE 11
3.1.2 CAP REMOVAL 13
3.1.3 CONTACTS REPLACEMENT 15
3.1.4 DISASSEMBLY OF NOSEPIECE/ARMSET 19
3.1.5 DISASSEMBLY OF BUSHING, ROD AND SPRING 23
3.2 HANDLE 25
3.2.1 PENCIL PROBE HOLDER 26
3.2.2 INDICATOR HOLDER HANDLES 28
CHAPTER 4. OPTIONAL ACCESSORIES 29
4.1 THREAD ADAPTORS 29
4.2 ANGLE 30
4.3 DEPTH STOPS 31
4.3.1 ASSEMBLY OF DEPTH STOPS FOR DEPTH EXTENSIONS 32
4.3.2 ASSEMBLY OF NOSEPIECES DEPTH STOPS 33
4.4 HOOKS 34
4.5 DEPTH EXTENSIONS 35
4.6 ROTARY SPACER 36
CHAPTER 5. TROUBLESHOOTING 37
5.1 REPEATABILITY 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 46
7.4.2.1 COMPONENTS 3 - Ø< 5,5 46
7.4.2.2 COMPONENTS 5,5 - Ø< 7,5 46
7.4.2.3 COMPONENTS 7,5 - Ø< 9,5 47
7.4.2.4 COMPONENTS 9,5 - Ø< 26 47
7.4.2.5 COMPONENTS 26 - Ø- 300 48
7.4.3 CONTACTS 48
7.5 ACCESSORIES 50
7.5.1 THREAD ADAPTORS 50
7.5.2 ANGLE ADAPTOR 50
7.5.3 CAPS 50
7.5.4 DEPTH STOPS 51
7.5.4.1 DEPTH STOPS FOR EXTENSIONS 51
7.5.4.2 DEPTH STOPS FOR NOSEPIECE 52
7.5.5 HOOKSHOOKS
HOOKSHOOKS
HOOKS 52
7.5.6 EXTENSIONS 52
7.5.7 ROTARY SPACER 53
7.6 INDICATORS 53
7.6.1 PENCIL PROBES 53
7.6.2 MECHANICAL INDICATOR 54
7.6.3 ELECTRONIC INDICATOR 54
7.7 WRENCHES FOR RETOOLING/RECONFIGURATION/MAINTENANCE 55
7.7.1 WRENCHES FOR CONTACTS 55

5
DESCRIPTION OF MAIN
PARTS 1
Chapter 1 - DESCRIPTION OF MAIN PARTS
Thanks to the extreme flexibility of the MBG bore gauge, it 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

2ASSEMBLY AND
ZERO-SETTING OF
INDICATOR
6
Chapter 2 - ASSEMBLY AND ZERO-SETTING OF INDICATOR
There are two procedures for the assembly and zero-setting of the indicator:
Procedure for appliances where PENCIL PROBES are present;
Procedure for appliances where MECHANICAL or DIGITAL indicators are present.
PENCIL PROBE
The operations sequence varies according to the model purchased:
a) Bore gauge WITH Marposs pencil probe (or compatible) mechanically installed and
zero set (follow SET-UP A procedure)
b) Bore gauge WITHOUT pencil probe installed (follow SET-UP B procedure)
SET-UP A
1. Connect the bore gauge at the electronic indicator by means of the connector
2. Insert the bore gauge in the master (the displayed measure must be next to zero)
3. Perform the electrical zero setting of the bore gauge, following the procedure of the
electronic system in use. Please refer to the mechanical zero setting (SET-UP “B”;
from step 7 to step 12) in case 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 the 1.5 mm hexagonal-
end wrench (see fig. 2).
3. Manually loosen the ring nut “C” (if too tight use the 16mm A/F wrench), then unscrew
and disassemble the unit “E” + “B” from the probe holder “A” (see fig. 3).
4. Loose the tapered nut “D” and insert the probe in the relevant holder at a 14 mm
protrusion (see fig. 4). Manually screw the tapered nut “D” until its stopped.
5. Firmly apply the 10mm A/F wrench to the probe holder, and then permanently lock
the tapered nut “D” using the 15mm A/F wrench (see fig. 5).
6. Insert the connector in the handle then plug it in the electronic display.
7. IInsert the plug gauge “B” in the zero-setting master.
8. Insert the probe holder unit “A” in the group “E” +”B”. Firmly holding the unit “A”,
screw “E” + “B” turning them counterclockwise (see fig. 6).

7
ASSEMBLY AND
ZERO-SETTING OF
INDICATOR 2
9. Manually screw the ring nut “C” until its stopped, trying to maintain the zero-setting.
Firmly apply the 13mm A/F wrench to threaded connection “E”, and then lock the
ring nut “C” by means of the 16mm A/F wrench (see fig. 7).
10. Re-assemble the two semi-clamps to the relevant cable holder seats, inserting in-
between the cable (*) (see fig. 8).
11. Replace and screw the 2 nuts in the cable clamp, and lock 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 3,8 mm), it is required to use the specific tear-resistant gaiter included. Please
refer to fig. 8 for assembling.
NOTE:
The removal and/or replacement of the plug gauge may result in the loss of the zero-
setting of the bore gauge..
13A/F

2ASSEMBLY AND
ZERO-SETTING OF
INDICATOR
8
MARPOSS MECHANICAL/ELECTRONIC INDICATORS
In order to complete the bore gauge, it is necessary to assemble the display dial and to
follow the quick set-up procedure described below, which is suitable only for indicators
with Marposs characteristics.
SET-UP WITH TD1, TD10, TD1P AND QUICK DIGIT INDICATORS
1. By means of the A/F 16 mm wrench (fig. 1-A), or a 2 mm hexagonal wrench (fig. 1-
B) loose the ring nut “1” and manually unscrew the indicator-holder until extraction
from the handle.
2. By means of the hexagonal-end 2 mm wrench, insert and lock the indicator in the
relevant indicator-holder (*) at the following distances:
• 7 mm A-distance (fig. 2) in case of standard indicator holder-handle;
• until its stopped (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 means of the mechanical potentiometer.
5. Firmly apply the 27mm A/F wrench (**) to the seat of the plug gauge handle “2”,
and lock the ring nut “1” using the 16mm A/F wrench (see fig. 4) or the 2mm
hegagonal wrench.
NOTE:
The indicators, since they are not components of the plug gauge, are not assembled,
but placed within the package.
(*) The 3/8’’ indicator-holder require the extension “B” included, to be placed
between the indicator rod and the gauge contact (see fig. 6).
(**) If the mini handle is employed it is required to use the 15mm A/F wrench.
2 A/F
27 A/F
16 A/F

9
ASSEMBLY AND
ZERO-SETTING OF
INDICATOR 2
TAB 1
L max
20 mm
L min
16 mm
L1 max
16 mm
L1 min
14 mm
L
L1
ZERO-SETTING OF TD1; TD10; TD1P AND QUICK DIGIT INDICATORS
TD1 AND TD10:
Rotate the quadrant ring nut of the indicator, until have the ZERO corresponding to the
pointer.
TD1P:
On the upper part of the indicator unscrew 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 needs. Table 1 shows the maximum indicator
specifications with which the procedure described above can be followed.

3REPLACEMENT OF PARTS
AND COMPONENTS
10
CHAPTER 3 - REPLACEMENT OF PCHAPTER 3 - REPLACEMENT OF P
CHAPTER 3 - REPLACEMENT OF PCHAPTER 3 - REPLACEMENT OF P
CHAPTER 3 - REPLACEMENT OF PARTS AND COMPONENTSARTS AND COMPONENTS
ARTS AND COMPONENTSARTS AND COMPONENTS
ARTS AND COMPONENTS
The concept on which the bore gauge is based makes it possible to retool it via a
simple and direct replacement 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 gauge and that can be replaced
in case of wear.
COMPONENTS:
1. CAP
2. CONTACTS
3. MEASURING ARMSET
4. NOSEPIECE
5. LOCKING NUT(*)
1
2
3
4
5
12
(*) A special ring nut is included for the 7,5 – 9,5 range.