Mira Bb-86 mini User manual

Instruction manual

English (EN)

Unit for precise sleeve

counterbore operations

Table of Contents

Safety Regulations...................................................................................................................................2

Basic Safety Guidelines...........................................................................................................................3

Non-liability...............................................................................................................................................8

Warranty....................................................................................................................................................8

Declaration of conformity BB-86 Standard.............................................................................................9

Declaration of conformity BB-86 Mini...................................................................................................10

Declaration of conformity BB-86 Giant................................................................................................11

1Description of parts.........................................................................................................................13

2Performance system of the BB-86 unit..........................................................................................14

3Working method..............................................................................................................................16

3.1 Example A.....................................................................................................................................16

3.2 Example B.....................................................................................................................................17

4Turning tools and their application................................................................................................18

5Working process .............................................................................................................................21

6Special applications........................................................................................................................28

7Service and maintenance................................................................................................................29

7.1 Grinding of the turning tools...........................................................................................................29

7.2 Quick precision check....................................................................................................................29

7.3 Lubrication of the main spindle and the advancing mechanism......................................................30

8Spare parts BB-86 main spindle.....................................................................................................31

9Spare parts BB-86 units..................................................................................................................32

10 Assembly drawing BB-86 units ......................................................................................................34

11 Schematic diagram..........................................................................................................................35

12 Special accessories ........................................................................................................................36

Safety Regulations

For safe operation of this electro-magnetic device, please pay close attention to the safety notices whenever

these warning symbols are shown.

We would like to inform you about potential dangers whichmay occur. It is therefore imperative that you read

the following instructions carefully, and proceed accordingly.

DO NOT use the device in a dusty, humid or explosive environment => Danger of short circuit!

The BB-86 must not be used with an open handgrip!

DO NOT bypass or tape-over the handgrip tumbler-switch because this can be very dangerous!

Safety goggles or approved eye protection and must be worn during setup and working with the unit!

Persons with long hair must also wear a hairnet!

There is a risk of injury by the cutting bit which is attached to the rotating spindle!

Unplug the device before working on electronic components!

In all cases, repairs to the tool are only allowed to be performed by the local MIRA-dealer or the

manufacturer => (MINELLICorporation)!

Only use genuine MIRA spare parts, which are listed in the respective instruction manual!

DO NOT touch the electric circuits of the device. Contact with these circuits can be life threatening!

Modification of the electric elements of this device could cause severe damage!

Repairs of the BB-86 can be performed ONLY by authorised personnel or the MINELLI Corporation.

Safety guidelines for the BB-86

Thefollowing safetyguidelinesmust be observedduring everystepwhenworking withthisdevice. Thisincludes

set-up, during the processing of the counterbores and when performing maintenance or repairs. Disregard for

these guidelines is an incorrect use of the device.

Grounding of the device

The device must be properly grounded to prevent electrical shock. Therefore, the ground-clamp must be

connected to the ground of the main circuit.

Do not use in an explosive environment!

The use of the device in an explosive environment (i.e. flammable gases, vapours or dust) may induce the

ignition of these materials and is strictly prohibited.

ATTENTION!

1. To avoid the risk of partial overheating, the device must not be used in a dusty or steamy atmosphere.

2. The device must not be used ina wet environment. In addition the device must not be exposed to rain or dew.

This may induce an electric arc between electronic elements in the device.

3. Service and maintenance of the unit by authorised personnel only. Servicing the electronic components

of the device is dangerous because there can be a high risk of an electric shock. Components can

continue to hold a latent electrical charge for a short time after the device has been switched off. Before

beginning service-operations on the device, make sure that the capacitors of the device have been

discharged and do not hold any latent electrical charge.It is prohibited to work on the connectors of the

device if the device is connected to an electric power source. In addition, operating the device without a

mechanical shut-off switch or fuse in the power supply is strictly forbidden.

4. Service and adjustment operations must always be performed by a minimum of 2 people. In an

emergency, there must be a person that can cut off the electric circuit to administer first aid.

5. This device must not be used for emergency or safety tests.

6. Any contact with the electric circuits must be avoided. During the operation of the device, any contact with

these circuits can be life threatening. In addition, the device can be damaged by careless contact with

sensitive elements.

7. To avoid further risks, you must receive permission from the manufacturer, MINELLI Corporation, if you

want to add, change, replace and/or manipulate any parts of the device by yourself.

8. If any repair or replacement work needs to be performed, the BB-86 must always be disconnected from

the electrical outlet. For information about service and repair, please read the respective chapters in the

Instruction manual.

Basic Safety Guidelines

Important information about the instruction manual

•A thorough knowledge and understanding of the basic safety guidelines and safety regulations

(shown on page 2) are key conditions for the safe operation of this device.

•This instruction manual contains important guidelines how to safely use this device.

•All persons who use this device must carefully follow the steps as outlined in this instruction

manual.

•In addition, local regulations related to safety and accident prevention must also be followed.

Responsibility of the tool owner

The tool owner will only allow employees to use the tool if they:

•have an intimate understanding ofthe basic guidelines for workingsafety and accident prevention.

•have been instructed about the proper device application.

•have read and understood the safety guidelines and warning notices in the instruction manual.

In addition, the tool owner will follow up with tool users at regular intervals to ensure tool safety

awareness.

Responsibility of the employees

The employees who use the device must commit to the following before they begin using the tool:

•that they will observe the basic safety guidelines for work safety and accident prevention.

•that they have read, understood, and signed the safety guidelines and warning notices in the

instruction manual.

Operating risks

The devices, BB-86, BB-86 Giant and BB-86 Mini, have been developed based on the latest state-

of-the-art technology, and were manufactured in accordance with the governing safety regulations.

However, it is possible by using these devices that some risks could appear for the user or third

persons if the devices are not operated according to the MIRA instruction manual, or if they are

misused. These tools should be used only:

•for its designated use.

•in good working order.

Breakdowns or malfunctions need to be corrected immediately if they deviate from the safety

guidelines.

Conventional utilisation

The MIRA BB-86 device is designed exclusively for processing sleeve counterbores on combustion

engines, and is not intended for any other use. The Minelli Corporation will not be liable for damages

which occur from unintended uses.

The intended utilisation also includes the following points:

•the user must comply with all the safety guidelines shown in the instruction manual, and

•the device owner must keep a record of the service work performed on the device.

Warranty and liability

Warranty issues are described in MIRA‘s terms of sales and return policy conditions, and are an

integral part of any sales contract between MIRA and the customer. Warranty and liability claims are

void if the injuries or damages resulted from any of the following causes:

➢Non-designated use of the device

➢Incorrect mounting and operation

➢Failure to follow the guidelines in the instruction manual with regard to the transport, storage,

assembly, initial start-up operation and servicing of the device

➢Unauthorized manipulation of the device

➢Unauthorized alteration of the BB-86 (for example: modifications to the magnetic plate or

switches, mechanical components, electrical components or circuitry)

➢Poor monitoring of the device components which are wear out

➢Incorrectly executed repairs

➢Unforseen disasters by external-material influence and force majeure

Symbols and advisory notations

The following symbols and descriptions are usedto emphasize safety risks in this instruction manual:

Warning notice –General danger: Indicates a potentially dangerous situation which can

result in minor to severe injuries including death if the safety guidelines are not followed.

Warning notice –Danger of an electrical shock: Indicates a dangerous situation which can

result in an electrical shock and severe burns or death if the safety guidelines are not followed.

Warning notice –Danger of pinching fingers and hands: Indicates a potentially dangerous

situation which can result in minor to severe injuries to fingers and hands if the safety

guidelines are not followed.

Info –notice: Shows Information and/or comments which are important for the appropriate

use of the machine and its functionality.

Application –notice: Shows accessories and additional application features of the machine.

Organisational provisions

•The operator must ensure the required safety-equipment is set-up properly.

•All safety devices must be checked at regular intervals.

Protection-apparatus

•Before initial start-up of the device, all protection-apparatus must be correctly installed and

functioning.

•Protection devices may be removed only

- after shutdown and

- after steps have been taken to prevent the device from re-starting

•Replacement of protection-devices by the operator must be installed in accordance with the

regulations.

Informative safety provisions

•The instruction manual must be always kept together with the device.

•In addition to the instruction manual, local regulations covering accident prevention and pollution

control must also be observed.

•All safety and warning signs on the device must be kept in a readable condition.

Training of the users

•Only persons who have been instructed and properly trained may use the BB-86.

•All users must be fully trained with all aspects of the device including how to mount, start-up,

handle, service, and repair the BB-86.

•Beginners may only work with the BB-86 under the supervision of an experienced user.

Device- magnet and switches

•Do not manipulate the magnetic plate and do not modify the switches under any circumstances.

•Only trained users are allowed to work with the BB-86 device.

Safety provisions in the standard mode

•All protection apparatus must be absolutely functioning whenever the device is in operation.

•Before switching-on the device, the operator must make sure that nobody is exposed to any risks

when the device is started.

•The device should be checked for external damage and that it is functioning safely at least one

time during each shift.

Risks of electrical power

•Service work conducted on the electrical supply must be done by an expert (i.e. Certified

Electrician, etc.)

•Inspection of the electrical components of the device must be performed at regular intervals.

Loose connections and damaged cables/wires must be repaired immediately.

•If it is necessary to do work on electric components, a second person must be present who can

remove the power cord from the main power outlet in case of an emergency.

Especially dangerous areas

•The magnetic base of the BB-86 poses a risk of pinching fingers and hands when clamping down

on the motor block surface. Exercise caution when activating the magnet.

•The rotary cutting bit has very sharp and jagged edges and can cause severe lacerations or

others injures. Exercise caution when processing the counterbore sleeves!

•The BB-86, BB-86 Giant and BB-86 Mini have rotating machine parts which present a risk for

(long) hair, hands and fingers. Wear suitable personal safety protection equipment (e.g. hairnet,

gloves etc.).

Leaking of hazardous dust and vapours

•During the processing of the counterbore sleeve, metal dust, particles, and vapour from the cutting

oil can occur. These fine particles can irritate and injure the lungs and eyes. Wear suitable

personal safety protection equipment (e.g. safety goggles, mask etc.). Ensure sufficient

ventilation during processing. For added safety, an eyeflushing device should be available.

Service and repairs, trouble shooting

•All users must be informed about imminent service and repairs for the device.

•All of the device’s pre- or post- switched machine parts and operating mediums, e.g. electricity,

must be disengaged to prevent accidental start-up.

•Whenever inspection, service, or repair work is done, the device must be disconnected from the

main power supply and the main switch must be locked to prevent unexpected re-starting.

- Lock and remove the key from the main power switch, if possible.

- Attach a sign to the device indicating the device cannot be switched on.

•Larger devices must be carefully mounted and secured on lifting gears during replacement.

•Check loosened screw connections for a compact seat.

•Upon completion of the service work, the safety apparatus of the device must be checked and

verified.

Constructive modifications on the BB-86

•It is forbidden toadd components ormake modifications to the device without written authorisation

from the manufacturer, Minelli Corp. (MIRA®). This also applies to welded components.

•All constructive modifications require a written approval from the Minelli Corp. (MIRA®)

Switzerland

•Faulty device parts may only be replaced by original replacement parts.

•Only use original genuine MIRA® replacement parts.

- By using replacement parts from third party suppliers, there is no guarantee that the parts are

constructed for the required operational demands and the required safety functions.

Cleaning of the BB-86 and disposal of wastes

•Waste materials and by-products must be correctly handled and removed especially when:

- working on greasy systems- and devices

- cleaning with solvents

•The external surface of the BB-86 must be cleaned on a regular basis with a dry flannel cloth.

Only use industrial cleaner if the device is necessary polluted

•Further cleaning per grade of using and grade of pollution of the device.

•The packaging material used to ship the BB-86 must be disposed of correctly in the respective

waste container and/or according to local environmental regulations!

Noise emission of the device

•The sound pressure level emitted by the BB-86, BB-86 Giant and BB-86 Mini, is rated at 30dB(A)

•When the BB-86 is used in combination with the Vario Drive System, there is a sound pressure

level up to 70dB(A) emitted from the Vario Drive.

Safety advisory for transporting the device

•When transporting the BB-86, the device must be shipped in the original carrying case that it

arrived in when it was delivered from the Minelli Corporation.

•The BB-86 must be protected against damages by the transportation company.

•Typical transportation damages such as dropping or crushing can be avoided by appropriately

packing and securing the shipment.

•The MINELLI Corporation will not be liable for inadequate precautions to secure the shipment.

The exclusive copyright of this instruction manual belongs to the MINELLI Corporation (MIRA).

This instruction manual is provided to the operator and his personnel.

Minelli Corporation

MIRA Division

Mattenstrasse 3

8330 Pfäffikon ZH

Switzerland CH

For the provided technical documentation see the authorised person in chapter „Declaration of conformity”

on page 9

Non-liability

The BB-86 turning device for sleeve counterbore procedures may only be operated according to the

Operating Instructions. The manufacturer refuses to accept any liability for accidents and damages caused

by incorrect operation. He also refuses any liability for unintended use of the device.

Warranty

In case of manufacturing or material defects, Minelli Corporation will replace the defective part or parts at no

charge, within 24 months of the date of purchase. No further claims will be covered under the warranty.

Defective parts must be returned along with proof of purchase. The warranty does not cover any subsequent

damage caused by these defective parts. The warranty does not cover unprofessional handling, the use of

incorrect electronic parts or deliberate damage, nor does it cover shipping and packing costs.

Declaration of conformity BB-86 Standard

Declaration of conformity BB-86 Mini

Declaration of conformity BB-86 Giant

BB-86 Sleeve counterbore tooling

After a diesel engine block has been re-surfaced, the height of the counterbores must be re-adapted to the

size of the liner rims, minus the amount of the protrusion. Also in the case of leaking liners, the counterbores

must be refaced, preferably on the vehicle, without having to remove the engine. The portable MIRA BB-

unit performs both applications in a simple, quick and extremely precise operation. Figure 2

Processing of counterbore seats

The MIRA BB-device is simple to operate and the procedure is very fast and precise. After insertion of the

correct cutting tool, the device is placed onto the clean cylinderblock surface. The centering is done by

means of a roller device which is on the backside of the cutting tool, and guides the cross feed. A powerful

electro-magnet holds the device firmly in place. Figure 1 and Figure 3

The exact depth of the tool is set on the micrometric vertical feed. By turning the handle and simlutaneously

holding the crossfeed ring with the other hand, the carbide tip tool advances horizontally and cuts the

counterbore to its exact depth.

Figure 2

Figure 1

Figure 3

1 Description of parts

1To avoid accidents from an electrical

shock, unplug the power cord from the

electrical outlet first! After that, repairs

can be safely performed on the

electrical components.

It is recommended that the magnetic

base be deactivated when the device is

not in use.

Crank handle

Vernier

Locking

screw

Main spindle

Bow

Turning tool with

hard carbide tip

Cover

plate

Advancing

mechanism

Specification

label

Worm screw

Gear bushing

Centering roll

1Tumbler switch

1Power cord

1Handle

1Magnetic base

(220V/110V)

2 Performance system of the BB-86 unit

The BB-86 Standard as well as the BB-86 Giant are made for processing counterbore sleeves, and offer

the following features and functions:

Mini Standard Giant

1. Electro-magnetic base BB-86:

•Attaches directly onto the engine block (See page 22)

•or onto the intercostal plate (See page 28)

•or onto the MIRA Repair ring (See page 36)

2. Tumbler switch

Pos. 1 Magnet on

ON-Position

Pos. 0 Magnet off (Residual magnetism remains)

(Mid-position) Figure 4

Pos. 2 Polarity is reversed

(short tap) (Removes any residual magnetic field from the engine block)

Figure 4

Ø154

Ø197

Ø170

Ø212

Ø198

Ø239

3. Vertical feed with advancing mechanism

Adjusts the depth of the turning tool. Figure 5

Vernier is adjustable to 0 (See step 14 on page 25)

1 Revolution = 1mm

1 Graduation mark = 0.01mm (1/100mm)

4. Bow

For inserting, removing and quick setting of the turning

tool. Figure 6 and Figure 7

5. Horizontal feed with gear bushing

By firmly holding the gear bushing and simultaneously

turning the crank handle, a horizontal feed of 0.15mm

per revolution is achieved by means of a planetary

gear and a plano-thread. A reduced cross feed speed

can be obtained by pressing the fingers against the

gear bushing. Figure 8

Figure 5

Figure 6

Figure 7

Figure 8

3 Working method

3.1 Example A

This example applies to a dismounted engine where the block has been re-surfaced and new sleeves have

been inserted. In this case, the counterbore depth will have been reduced by the re-surfacing of the block,

and needs to be adjusted. Proceed as follows: Clean the sleeves and accurately measure the collar

thickness of each sleeve with the micrometer. Write the measurement onto each sleeve, and number them

in accordance with the cylinder. Subtract the amount of the protrusion specified by the manufacturer from

the collar thickness and write the result onto the surface of the block of each counterbore.

There are 2 different methods for working with the tool:

1. If the same turning tool is frequently used, it is recommended that the vernier be set to 0 (See step

14 on page 25). This can be accomplished after centering of the unit by means of the advancing

mechanism. The required depth can be set and blocked in this position. Now the proper surfacing of

the seat can be started (see „Turning tools and their application“ on page 18).

2. If the same turning tool is not used everytime, there is no advantage to be gained by setting the

vernier to 0. In this case proceed as follows: for each counterbore, the existing depth must be

measured and compared with the nominal value and the difference must be written down. After

centering of the unit, the tip of the turning tool must be set above the seat at the precise location

where the measurement was taken. By slightly turning the crank handle and simultaneously

advancing the vertical feed, the turning tool will come in contact with the seat (see steps 11 and 12

on the pages 24 and 25). Thereafter, the turning tool needs to be pushed back into the free area

with the hard metal tip positioned just above of the counterbore seat. Following that, the previously

measured depth difference needs to be set. Finally, the advancing mechanism locking screw must

be blocked and then the seat surfacing can be started.

Depth of the counterbore

Thickness of sleeve rim

Protrusion

Counterbore-Ø

Rim groove-Ø

Engine

block

Engine

block

This picture shows the important working

surfaces. These are the sealing surface of the

block and the sealing and bearing surface of

the sleeve collar.

Depending on the specifications of the engine

manufacturer, the inserted sleeve can be

protruding or recessed.

3.2 Example B

If an engine is only partially dismounted or only one counterbore needs work, the situation changes. In such

a case the block is not re-surfaced. Instead, the leaky sleeve has to be replaced by an oversized sleeve, or

a sealing sheet needs to be applied to the standard sleeve. The correct counterbore depth must be

determined by either the thickness of the sealing sheet, or the oversized collar.

If only one counterbore needs to be repaired, a repair centering ring is available to simplify the procedure.

The repair centering ring compensates for the protrusion of the neighboring sleeves (see „Special

accessories“ on page 36). The picture shows the important surfaces to be worked on. These include the

sealing surface for the cylinderhead and also the sealing and bearing surface for the sleeve collar. The

sleeve should be setaccording to the specifications of the engine manufacturer. Thesleeve canbe recessed

instead of protruding.

Depth of the counterbore

Counterbore-Ø

Protrusion

Thickness of sleeve rim

Sealing shim

Engine

block

4 Turning tools and their application

Order-No.:

Center-Ø

d (mm)

Working-Ø

D (mm)

Remarks

MB-85

73-86

67-86

MB-86

85-104

77-104

MB-87

97-126

87-126

MB-88

123-160

111-160

MB-89

158-194

146-196

MB-90*

192-224

178-224

Order-

No.:

Center-Ø

d (mm)

Working-Ø

D (mm)

Remarks

MB-136

105-130

MB-137

130-160

130-174

CAT 3304,

3306, D343

MB-138

160-190

160-200

CAT D379,

D398, D399

MB-139

190-220

190-240

CAT 3500-

3508

Order-No.:

Center-Ø

d (mm)

Working-Ø

D (mm)

Remarks

MB-96

73-84

59-84

MB-97

84-102

70-102

MB-98

95-122

81-122

MB-99

123-158

109-154

Order-No.:

Center-Ø

d (mm)

Working-Ø

D (mm)

Remarks

MB-100

98-126

MB-101

120-164

MB-102

152-192

Standard counterbore seat turning tool

Turning tool for engines with intercoastal

plate or with interrupted counterbore wall

Chamfering tool 45°

Bestell-

Nr.:

Zentrier-

d (mm)

Bearbeitungs-

D (mm)

Bem.

MB-85

73-86

67-86

MB-86

85-104

77-104

MB-87

97-126

87-126

MB-88

123-160

111-160

MB-89

158-194

146-196

MB-90*

192-224

178-224

Chamfering tool 75°

Order-No.:

Center-Ø

d (mm)

Working-Ø

D (mm)

Remarks

MB-91/1

120-150

154-150

Deutz

MB-108

106-122

100-122

KHD

Order-No.:

Center-Ø

d (mm)

Working-Ø

D (mm)

Remarks

MB-92

90-124

84-124

Deutz,

Daf,

Güldner

MB-93

73-88

67-88

VW,

Porsche

Order-No.:

Center-Ø

d (mm)

Working-Ø

D (mm)

Remarks

MB-113

127-158

127-166

Saurer

Order-No.:

Center-Ø

d (mm)

Working-Ø

D (mm)

Remarks

MB-119

158-194

144-194

Henschel

1516

Order-No.:

Center-Ø

d (mm)

Working-Ø

D (mm)

Remarks

MB-94

123-150

123-154

Mercedes

MB-109

114-146

Perkins

Order-No.:

Center-Ø

d (mm)

Working-Ø

D (mm)

Remarks

MB-88AD

130-166

122-166

Mercedes

Special tools for aluminium cylinderheads

Special tools for counterbore seat

corresponding to construction specifications

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