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Use and maintain basic

mechanical

measuring devices

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CONTENTS Page 4 Measuring tools

Page 5 Venier calipers

Page 8 Digital calipers

Page 8 Calipers

Page 9 Micrometers

Page 12 Depth micrometers

Page 14 Steel rules

Page 15 Straight edges

Page 15 Measuring tapes

Page 16 Engineers squares

Page 17 Combination squares

Page 18 T-square and

Page 18 Bevel protractors

Page 19 Spirit level

Page 19 Section overview

Page 20 Review questions

RELEVANT VOCABULARY What is the objective of this unit?

Use and maintain basic mechanical measuring devices. What is this unit about?

 Select and use basic mechanical measuring devices  Maintain devices

 Complete work processes How will I be assessed?

Assessment will take place when you are confident that you have acquired the skills and the underpinning knowledge necessary to successfully complete the unit. Practical skill assessment will take place only after a period of supervised practiced and repetitive experience. You must be able to meet all the requirements of this unit without direct supervision.

Where can I find the Elements and Performance Criteria? At the back of this workbook.

It is recommended that you are familiar with the following words and their definitions to help your understanding of the material contained in this workbook.

Accurate: Without errors Drag: Pull with force Chafed: To wear away by rubbing Efficiently: With minimum waste or effort Precision: Highly accurate or exact Leverage: Ability to move or lift Pivoting: The act of turning Tensioned: To tighten

Coarse: Rough

Bevelled: Cut to form an angle other than 90° degrees Calibrated: To adjust to meet the standard

Graduation: Division into stages or degrees Increments: Increasing in number or size Tolerance: Acceptable range

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Start Reading

Safety when using measuring tools

 Some measuring tools have sharp edges so take care to avoid cuts.  Never carry tools in pockets or throw tools to colleagues.

 Only use tools for their intended purpose.

 Steel measuring tools are conductive so avoid using near live wires or sources of heat.

Various kinds of measuring tools are used in automotive workshops and their main purpose is to enable safe, accurate and speedy measurement of work. To achieve this you must select the most appropriate tools and know how to use them correctly.

General rules for using measuring tools:

1. Select the most suitable tool to carry out the job safely and effectively. The tool must be in good working condition and free from fracture and jagged edges. Repair or replace as necessary.

2. Carry out regular tool maintenance to maximise the service life and to ensure ongoing accuracy of the tool.

3. Read the tool manufacturer’s operating instructions. Tools can vary from manufacturer to manufacturer.

4. To reduce down time in searching for tools always return the tools to their correct position on the shadow board or in their container.

5. Ensure that tools are kept clean and free from grease or oil. This will prevent the grease or oil from being transferred to the customer’s vehicle and will also assist the technician to maintain a firm grip of the tool.

6. Ensure that the tool is correctly calibrated before use. A faulty measuring tool will provide inaccurate readings which could prove to be expensive if relied upon. 7. Tools that are faulty, damaged or in need of calibration should be removed from

service, tagged and reported to the workshop supervisor.

8. Only use tools for their intended purpose. Measuring tools are precision instruments that have been designed for specific purposes. Using them outside specifications may cause damage, premature wear or give unreliable results. 9. Always double check measurements. Refer to conversion charts for imperial and

metric measurements.

Common measuring tools used in automotive workshops include:

 Calipers: Vernier calipers, digital calipers, internal and external calipers  Micrometers: inside, outside and depth

 Steel rules  Straight edges  Measuring tapes

 Squares: engineer’s, combination, T-squares and bevel protractors  Spirit levels

MEASURING TOOLS

Correct tool for the job

Tag faulty tools Common tools Very Important Safety Points

Main Scale Vernier Scale Main scale Vernier scale 1st _{Alignment point} VERNIER CALIPERS

The Vernier calipers are a hand held tool that allow an object to be measured in inches/mm to the second decimal place.

Vernier calipers measure inside, outside and depth measurements. Verniers are made from stress relieved stainless steel and have precisely ground measuring surfaces to give an accurate reading on the scale. The scale is precisely etched onto the caliper bar and a standard set of Vernier calipers measure from zero millimetres to 152 millimetres. To understand the operation of Vernier calipers it is important to appreciate their construction. They are constructed of two scales:

 Main scale, which is measured in millimetres or inches.

 Vernier scale, which is measured in fractions of a millimetre or an inch. The most common scale used today is the metric scale.

A Vernier caliper consists of: 1. Metric scale

2. Imperial scale 3. Main scale

4. Sliding Vernier scale 5. Outside measuring jaw 6. Inside measuring jaw 7. Depth gauge

8. Vernier scale lock screw 9. Thumb slide

10. Vernier scale size (1/50)

The three main applications of a Vernier scale are to measure outside diameters, inside diameters and depth.

Reading the Vernier scale

Step 1

From the main scale (top row) take the reading in whole millimetres up to the zero point on the Vernier scale.

Step 2

Using the Vernier scale (bottom row) locate the first point at which the Vernier scale is in alignment with the main scale.

Step 3

Add the readings together.

A thumb lock is used to clamp the caliper sliding bars to enable the user to inspect closely when measuring in awkward places. Calipers are also available with a dial indicator gauge. It is recommended that eye protection be worn when operating a Vernier caliper.

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Correct use of Vernier calipers

Ensure that both of the internal jaws are placed deep into the object to be measured.

When measuring outside diameter the work must be placed fully into the Vernier jaws.

To measure depth, ensure that the Vernier measuring scale is flush against the side of the work Internal Reading External Reading Depth Reading

Storage and handling of Vernier calipers

 Handle calipers carefully. Avoid dropping or bumping. Calipers are precision tools and any damage will affect the accuracy of readings taken.  After use, the calipers should be cleaned and dried thoroughly. Wipe the

sliding surfaces and measuring faces. If lubrication is required apply oil lightly to each part of the caliper.

 Check the slider moves free and smoothly. Adjust the set screw as required.  Store calipers in their container. Do not expose to direct sunlight

 Ensure top pivot is secure and thread not damaged Reading the Vernier scale

Example One

The main scale reading = 71.00 millimetres

The Vernier scale reading =0.34 millimetres Total reading = 71.00 + 0.34 = 71.34 millimetres Example Two

The main scale reading = 11.00 millimetres

The Vernier scale reading =0.24 millimetres Total reading = 11.00 + 0.24 = 11.24 millimetres Main scale = 11.00 mm Vernier scale = 0.20 mm Inline point = 0.04 mm Total = 11.24 mm 10mm divisions 1mm divisions 0.02mm divisions 0.1mm divisions Inline point Take Note *

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Digital Calipers

Digital calipers can also be used to take internal, external and depth measurements. They provide accurate measurements and can be switched between imperial and metric. A zero function allows for display to be reset at any point along the slide.

Calipers

Calipers can be used for measuring distances and scribing parallel lines, arcs and circles. The main types of calipers used in automotive workshops include:

Internal calipers

 Internal calipers are used for measuring inside diameters.  The measuring points of the internal calipers point away

from each other. Using internal calipers

1. Position the calipers centrally between the edges to be measured.

2. Adjust the calipers until both measuring points are in contact with the inner edges with slight drag.

3. Remove the calipers and measure the distance between the measuring points using a steel rule or a micrometer.

External caliper

 External calipers are used for measuring outside diameters.

 The measuring points of the external calipers point towards each other.

 Can be used to compare the sizes of two parts. Using external calipers

1. Position the calipers centrally between the outside edges to be measured.

2. Adjust the calipers until both measuring points are in contact with the outer edges with a slight resistance. 3. Remove the calipers and measure the distance between

the measuring points using a steel rule or a micrometer. Inside diameters Outside diameters Locking screw External Internal LCD screen Slider Depth measure

Centralise the Work

Storage and handling of calipers

 Handle calipers carefully. Avoid dropping or bumping. Calipers are precision tools and any damage will affect the accuracy of readings taken.  After use the calipers should be cleaned and dried thoroughly.

 Store calipers in their container  Never store calipers with loose tools. MICROMETERS

Micrometers are precision made tools designed to measure inside, outside, and depth measurements to 0.01 mm. They are mainly used to determine the serviceability of components and are generally used on engine components such as:

Crankshafts Bearing surfaces Cylinder bores Camshafts

Construction of an outside Micrometer 1. Thimble

2. Sleeve 3. Frame 4. Fixed anvil 5. Ratchet

6. Thimble locking mechanism 7. Datum line

8. Spindle

Reading the Outside Micrometer

The work to be measured is placed squarely between the spindle and the fixed anvil.

Turn the ratchet clockwise until the ratchet clicks, (two or three attempts are required to ensure the work is centralised).

Apply the thimble locking mechanism and remove the work to allow a close inspection of the measuring scale.

The first reading is taken from the lower scale of the sleeve. Read the whole millimetre figure.

The upper scale on the sleeve shows measurements in 0.5mm graduations.

The next reading is taking from the scale on the thimble (this scale is measured in 0.01mm graduations). Engine Components Hole depths Pin sizes Valve stems Pistons Take Note *

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11 Outside Micrometer Reading

 The lower scale on the sleeve indicates the distance in whole millimetres.  The upper scale on the sleeve indicates the distance in 0.5mm graduations.  The upper and lower scales are read from left to right.

 The thimble scale indicates the distance in 0.01mm graduations and is read from bottom to top.

Example One:

Lower scale reading = 11.00 millimetres Upper scale reading = 0.50 millimetres Thimble scale reading = 0.47 millimetres Outside micrometer reading =11.97 millimetres

Example Two:

Lower scale reading = 8.00 millimetres Upper scale reading = 0.00 millimetres Thimble scale reading = 0.18 millimetres Outside Micrometer reading = 8.18 millimetres

11 0.5 All lines = 0.5mm 47 All lines = 0.01mm

The inside micrometer is a precision tool designed to measure the inside diameter of an object.

An inside micrometer consists of:  Spindle

 Thimble  Anvils

 Extension piece (if required). Reading the inside micrometer

Select an appropriate sized micrometer and anvil attachment for the hole to be measured.

Place the inside micrometer into the hole and turn the thimble until both anvils are touching the surfaces.

Adjust the inside micrometer to centralise in the hole.

Remove the inside micrometer to allow a close inspection of the measuring scale. The reading is taken in the same way as an outside micrometer reading.

Internal Micrometer Reading

1. The upper scale on the sleeve indicates the distance in whole millimetres.

2. The lower scale on the sleeve indicates the distance in 0.5mm graduations. The upper and lower scales are read from left to right.

3. The thimble scale indicates the distance in 0.01 millimetre graduations and is read from bottom to top.

Example One:

Upper scale reading = 3.00 millimetres Lower scale reading = 0.00 millimetres Thimble scale reading = 0.15 millimetres Internal micrometer scale reading = 3.15 millimetres

Using an inside micrometer

Inside Diameters

2 1

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Measures hole depths

Right to Left

Using a Depth Micrometer Example Two:

Upper scale reading = 9.00 millimetres Lower scale reading = 0.00 millimetres Thimble scale reading = 0.40 millimetres Internal Micrometer Reading = 9.40 millimetres

DEPTH MICROMETERS

Depth micrometer is a precision tool used to measure the depth of a hole or a step. Construction of a Depth Micrometer

1. Sleeve 2. Thimble 3. Ratchet

4. Adjustable anvil 5. Frame

Reading a Depth Micrometer

Select an appropriate sized depth micrometer for the hole or step to be measured. Adjust the sleeve until the zero line on the thimble lines up with index line on the sleeve.

Ensure that the frame is sitting flat on top of the work. Adjust the ratchet until the anvil reaches the bottom of the hole or step.

The measuring scale on the sleeve is read from right to left and the measuring scale on the thimble is read anti-clockwise. 3 2 1 5 4

The upper scale on the sleeve indicates the distance in whole millimetres. 1. The lower scale indicates the distance in 0.5 millimetre graduations. The upper and lower scales are read from right to left.

2. The thimble scale indicates the distance in 0.01 millimetre graduations as in read from top to bottom.

Example One:

Upper scale reading = 10.00 millimetres Lower scale reading = 0.00 millimetres Thimble scale reading = 0.48 millimetres Depth Micrometer Reading =10.48 millimetres Example Two:

Upper scale reading = 13.00 millimetres Lower scale reading = 0.00 millimetres Thimble scale reading = 0.38 millimetres Depth Micrometer Reading = 13.38 millimetres

1

2

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Take Note *

STEEL RULES

A standard steel rule is 30 cm long and is precision machined from steel with two straight edges with a metric and imperial measuring scale. It is used for general purpose measuring of components and metal measuring, scribing, marking and aligning.

It is important that the steel rule is perfectly flat and straight with straight edges. Using a steel rule

1. Position the steel rule straight across and flush with the surface to be measured. The rule should be held at an angle of 90° to the surface of the work and at 90° to both edges of the work.

2. Align the zero graduation on the steel rule with the work and measure the distance between the two points to determine the length of the work.

Steel rules should be oiled to prevent rusting when not in use.

Using a Steel Rule to measure work. General

Measuring

Flush with surface

Storage and handling of Micrometers

 Handle micrometers carefully. Avoid dropping or bumping. Micrometers are precision tools and any damage will affect the accuracy of readings taken.

 Before use wipe off any dust from the spindle, anvil and measuring faces.  Allow the micrometer some time to adjust to room temperature.

 After use, the calipers should be cleaned and dried thoroughly. Wipe the sliding surfaces and measuring faces. If lubrication is required apply oil lightly to each part of the caliper.

 Check the slider moves free and smoothly. Adjust the set screw as required.  Store calipers in their container. Do not expose to direct sunlight

Take Note *

STRAIGHT EDGES

A standard straight edge is approximately one metre long. It is constructed from precision machined steel and has two straight edges and a measuring scale on one edge. The straight edge is used with a feeler gauge to determine warp in cylinder heads, engine blocks and manifolds.

MEASURING TAPES

Retractable measuring tapes are used in the automotive industry for a variety of measuring activities such as measuring panels, suspension heights, lamp positions and wheel base dimensions. Measuring tape scales can be metric, imperial or a both.

Measuring tapes have a measuring scale stamped onto a curved metallic strip that retracts into a container. They are spring loaded so as soon as the tape is released it will return to the container. A stop mechanism on the container allows the tape to be held into position when extended.

A metal tab at the start of the ribbon allows for the tape to be attached at the start end so that measurements can be taken single-handedly.

Measuring tape sizes range from 2m to 10m. After use measuring tapes should be wiped with a clean rag to remove oil and grease and then stored in a tool box.

Storage and handling of steel rules and straight edges

 Handle rules and edges carefully. Avoid dropping or bumping. Remember these are precision tools and any damage will affect the accuracy of readings taken.

 Rules and edges must never be exposed to an electrical supply.

 After use, rules and edges should be cleaned and dried thoroughly.

 Steel rules should be stored in their protective plastic covering provided by the manufacturer when not in use.

 Store rules and edges their protective cover and hang on a shadow board.

 Never store rules or edges with loose tools. Determine

Warpage

Using a Straight Edge with a Feeler Gauge to measure warp on a cylinder head.

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Storage and handling of engineer’s squares Store by hanging in its original container. Check blade and rest for security and damage

Wipe clean and dry with a rag. To prevent rusting is important to remove any moisture from the surface of the square.

Apply a thin layer of oil before storing. Store in original case away from other tools. Take Note *

SQUARES

Squares are commonly used in panelbeating, fabrication and engineering workshops for measuring work where specific angles are required. Squares that may be used include:  Engineer’s square

 Combination square  T-square

 Bevel protractor ENGINEER’S SQUARE

An engineer’s square is a precision tool made of carbon steel and is used for measuring and checking angles of 90°, for marking out lines at right angles to the datum line and for squaring two pieces of work.

The engineer’s square consists of two straight edges (marking blade, stock rest) joined together at an angle of 90°. It is important that the engineer’s square is regularly calibrated.

Using an engineer’s square

1. Before using the engineer’s square ensure that the work surface is clean and free of burrs.

2. Position the edge of the stock rest firmly against the work surface.

3. Move the stock rest until the marking blade is flat onto the surface of the work. 4. Evidence of clearance between the work surface and the marking blade indicates

that the work surface is warped.

5. To square two pieces of work, position the stock rest flat on one surface and align the marking blade with the side of the second work piece. To ensure the accuracy of alignment reposition the engineer’s square 90° from the initial position and recheck.

An engineer’s square should be handled and stored in the same manner as a steel rule. Datum lines

Stock rest

Blade

Take Note *

COMBINATION SQUARES

A combination square is a hand held tool that is precision made and is designed as a multipurpose measure and level. It has a 30cm steel rule blade with metric and imperial measurements, a groove through the centre of the blade and a spirit level attachment that travels along the groove.

The spirit level attachment has a precision machined surface that runs at 90 degrees to the steel rule blade and a thumb screw to lock the spirit level attachment to the steel rule blade. A combination square can be used to measure:

Distance Depths Levels

Inside right angles Outside right angles 45 degree angles

Construction

1. 12 inch steel rule. 2. Sliding frame.

3. 90 degree face to the rule. 4. 45 degree face to the rule. 5. Spirit level bubble. 6. Sliding frame lock nut.

7. Sliding frame groove in the centre of the steel rule.

8. Hanging hole for storage.

Scribing a 45O_{angle on a}

piece of work.

Storage and handling of combination squares

Wipe clean and dry with a rag. To prevent rusting it is important to remove any moisture from the surface of the square.

Ensure that the work is securely held.

Do not over-tighten locking thread for blade. Apply a thin layer of oil before storing.

Hang on a shadow board or store in original case away from other tools. Multipurpose

Measure and Level

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Take Note *

T-SQUARES

The T-square is a good option when looking to draw and cut in a straight line.

Its name comes from its resemblance to the letter T. T-squares come in varying sizes.

A T-square has two components - the long shaft called the "blade" and the short shaft called the "stock" or "head".

The T-square edge should be free of nicks and cracks in order to provide smooth, straight lines.

Most T-squares have a hole towards the end of the blade for hanging the tool up.

After use wipe the blade and stock with a clean rag and hang on a shadow board or store in its original container.

BEVEL PROTRACTORS

A bevel protractor is a graduated circular protractor with one pivoted arm used for measuring or marking off angles. Sometimes Vernier scales are attached to give more precise readings.

The bevel protractor is used to establish and test angles to very close tolerances and can measure any angle from 0° to 360°.

The bevel protractor consists of a base, a graduated dial and a blade which is connected to a swivel plate (with Vernier scale) by a thumb nut and clamp.

The base is placed on the bottom side of the angle to be measured while the blade is placed on the opposite side. To measure the angle adjust the nut to release the blade and protractor which allows the protractor to be moved along the blade to fit an angle. When the edges of the base and blade are parallel, a small mark on the swivel plate coincides with the zero line on the graduated dial.

Since the spaces, both on the main scale and the Vernier scale, are numbered both to the right and to the left from zero, any angle can be measured.

Safety and Storage: Store by hanging.

Keep free from oil and grease. Wipe clean with rag. Ensure that the work is securely held.

Loosen securing bolts for the swivel plate before adjustments Do not over-tighten locking thread for blade or swivel plate.

SPIRIT LEVELS

A spirit level is an instrument designed to indicate whether a surface is horizontal or vertical. Used in the motor industry to check and calibrate workshop equipment.

The level has a machined true edge and contains a sealed glass tube partially filled with alcohol or other liquid, containing an air bubble whose position reveals whether a surface is perfectly level.

To use, place the level's frame on the object to be checked. Move the object until the bubble is in the centre of the vial within the indicator lines. This indicates the surface is flat.

The spirit levels edge should be free of nicks, dents and warpage in order to provide the most accurate reading when flat against an object. Make sure that the vials are not damaged. If broken, replace the entire level rather than just the vial. Longer levels typically have a hole on the end so they can be stored on a shadow board. Wipe with a clean rag after use.

CALIBRATION

Measuring tools should be calibrated on a regular basis to ensure that they are measuring accurately. Usually a known measured standard device is used to test the accuracy of the tools. Measuring tools will lose some accuracy over time due to wear or tear, or may suffer immediate loss due to sudden electrical or mechanical impact. During the calibration process the tool may be reset to its factory settings.

SECTION OVERVIEW

Measuring tools are precision tools that measure: Distance

Size

Straightness Angles

All measuring tools should be handled with care, well-maintained and stored in the original containers.

Calibration checks are required to ensure the measuring tools are accurate. The tool must be operated in accordance with manufacturer’s specifications. It may be necessary to wear protective clothing when using measuring equipment. Read manufacturer’s guidelines for advice.

Faulty tools must be tagged and reported to the workshop supervisor. Tools must only be used for their intended purposes.

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REVIEW QUESTIONS

Q1 Record the readings displayed on each of the following: Upper scale ____________ Lower scale ____________ Thimble ____________ Reading ____________ Upper scale ____________ Lower scale ____________ Thimble ____________ Reading ____________ Upper scale ____________ Lower scale ____________ Thimble ____________ Reading ____________ Upper scale ____________ Lower scale ____________ Thimble ____________ Reading ____________ Reading ____________________ Reading ____________________

Q2 List 5 general rules to be considered when using measuring tools: ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

Q3 Name the 2 scales on a Vernier Calipers:

________________________________________________________________ ________________________________________________________________

Q4 Name the tool that is designed for measuring the inside diameter of an object. ________________________________________________________________

Q5 List 3 precautions to be observed when handling and storing Vernier Calipers: ________________________________________________________________ ________________________________________________________________

________________________________________________________________ ________________________________________________________________

________________________________________________________________

Q6 Name the tool that is designed for measuring the depth of a hole.

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Q7 Provide an automotive use for a straight edge.

________________________________________________________________ ________________________________________________________________

Q8 Provide an automotive use for a measuring tape.

________________________________________________________________ ________________________________________________________________

Q9 What measurements can be taken using a combination square?

________________________________________________________________ ________________________________________________________________

________________________________________________________________

Q10 Why is it important to remove moisture from measuring tools before storing? ________________________________________________________________ ________________________________________________________________

Q11 What action should be taken if a measuring tool is damaged?

________________________________________________________________ ________________________________________________________________

Q12 How can a spirit level help to determine whether a surface is flat?

________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

ELEMENTS AND PERFORMANCE CRITERIA – UNIT AURTTA003

ELEMENT NAME

Select and use basic mechanical measuring devices AURTTA003.1 1.1 Task instructions are interpreted and vehicle to be worked on is identified

1.2 Measuring device information is sourced and interpreted

1.3 Potential hazards and risks associated with the task are identified and reported to workplace supervisor

1.4 Measuring devices are selected to meet job requirements, and checked for serviceability and calibration according to manufacturer specifications and workplace procedures

1.5 Measuring devices are used according to manufacturer specifications, workplace procedures andsafety requirements

ELEMENT NAME

Maintain devices AURTTA003.2

2.1 Measuring devices are maintained and stored according to manufacturer specifications and workplace procedures

2.2 Faulty devices are tagged and reported according to workplace procedures as required

ELEMENT NAME

Complete work processes AURTTA003.3

3.1 Final inspection is made to ensure work meets task instructions and workplace standards

3.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected and stored

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