ANRS TVED

BUREAU

Automotive Engine Servicing

Level II

Learning Guide #04

Unit of Competence: Calibrate and Maintain Basic Measuring/Testing

Devices
Module Title: Calibrating and Maintaining Basic Measuring/Testing
Devices
LG Code: AUM AES2 M04 LO1-3

TTLM Code: AUM AES2 TTLM 04 08 17V1

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 Instruction Sheet Learning Guide # 04

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics:–
 Prepare for work
 Calibrate measuring /testing device
 Maintain measuring / testing device
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
 Explain Preparing for work
 Observe OHS measures
 Make workstation ready for work activities
 Explain measuring and testing device calibration
 Adjust measuring device correctly
 Check measuring device for functionality
 Maintain measuring/testing device
 Clean measuring and testing device
Learning Instructions:

1. Read the specific objectives of this Learning Guide.

2. Follow the instructions described below
3. Read the information written in the “Information Sheets”. Try to understand what are being
discussed. Ask you teacher for assistance if you have hard time understanding them.
4. Accomplish the “Self-checks". In each information sheets.
5. Ask from your teacher the key to correction (key answers) or you can request your teacher to
correct your work. (You are to get the key answer only after you finished answering the Self-
checks).
6. If you earned a satisfactory evaluation proceed to “Operation sheets and LAP Tests if any”.
However, if your rating is unsatisfactory, Ask your teacher for further instructions or go back
to Learning Activity.
7. After You accomplish Operation sheets and LAP Tests, ensure you have a formative
assessment and get a satisfactory result;
8. Then proceed to the next information sheet

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 Information Sheet-1 Preparing for work

Making workstation ready for work activities

Making workstation took around a day and was well worth the effort. Even if you have only an
hour to spare you can still get out the workstation and do some useful modeling. Think about
what YOU need for to solve YOUR problems.

If you are considering making your own workstation then spend a little time planning ahead.
Make a note of what tools you use regularly and which therefore need to be on your
workstation. Remember that you need to be able to carry your workstation about, so you need to
keep the total weight to a minimum. If you need several journeys back and forth to set up your
modeling then one of the big advantages of the workstation is lost. Work out where you will do
your modeling and the requirements of light and power.

Automotive Workstations are a mechanic‟s workbench with integrated storage, providing a

location for all of the day-to-day tools, parts and consumables that a mechanic will require. Not
only are these units attractive and professional but they also increase the productivity in the
workshop.

It is true that the modern high-volume automotive service centre has become an extension to the
showroom with an increased focus on customer service.

answers to the following questions before you start any working activities.

 What are the objectives of preparing your workstation?

 How much can you afford to spend?
 How much time am you willing to invest in preparing?
 What tools and materials will you need to prepare it?
 Where will you store the workstation (this may limit the size)?
 How much can you comfortably carry (this may limit the weight and contents)?
 Where are the places you are likely to model?
 How will you hold the workstation when you are carrying it?
 What tools do you need to have regularly to hand?
 What lighting and magnification do you need?

If you have the answers to all of the above then you are well on the way to having your own
workstation and modeling heaven is within your grasp.

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 Observing OHS measures and warnings in relation to working with precision tooling

Safety means protecting yourself and others from possible danger and injuring in the shop, you
are ' Safe' when you protect your eyes, your fingers, your hands all of yourself from danger as
well as others.

The preparation of work shop to supply equipment helps to -

 Keep environment well being

 Finish with specified our time pre-summing
 Identify the work and its implementing tools and equipment
 Decide the work procedure
 Keep tools, equipment and resource prevent ourselves from injury
 Done the work with quality
Employers have a duty of care to provide for the health, safety and welfare of all employees and
visitors in the workplace. Employer responsibilities include ensuring the safe handling, storage
and transport of machinery, equipment and substances; ensuring that all equipment and
machinery is well maintained and conforms to safety standards; and providing and maintaining
systems of work and work environments that are safe and pose no health risks to employees or
any visitors.

The employer must also make information instructions, training and supervision available and
guarantee the health and safety of employees by providing adequate facilities for the welfare of
employees, such as making sure work areas are well lit and well ventilated.

They must consult with employees about OHS matters to enable the employees to contribute to
decisions affecting their health, safety and welfare, while ensuring that employees do not pay
for any changes that need to be made under any OHS act or regulation.

So in order to prepare tools, equipments and work shop safely or comfortable before starting
work activity follow the following procedures.

1. Design/identify the work area used for practical activities

2. Identifying and selecting components, tooling and equipment in accordance with site
manufacturer instructions and site procedures
3. Assess the information/manufacturer manuals/specification for the activities to be done.
4. Observe safety rules
5. Ensure availability of fire extinguisher, wearing of working clothes

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 Tools and Equipment Safety

 Do not dump residue from steam cleaning in sewers.

 Wear protective gloves and a face shield.
 Use only approved cleaning solutions.
 Observe all environmental regulations.
 Keep tools in good condition.
 Use the proper tool for the job.
 Do not put tools in your pocket.
 Keep tools with cutting edges sharp.
 Keep tools clean and free from grease.
 Pull wrenches toward you, do not push.
 Do not use power equipment or tools on which you have not been trained.
 Keep power cords away from the path of vacuum cleaners, floor polishers and grinders.
 Do not carry plugged in equipment or tools with your finger on the switch.
 Do not carry equipment or tools by the cord.
 Disconnect the tool from the outlet by pulling on the plug, not the cord.
 Turn the tool off before plugging or unplugging it.
 Do not leave tools that are "On" unattended.
 Do not handle or operate electrical tools when your hands are wet or when you are
standing on wet floors.
 Turn off electrical tools and disconnect the power source from the outlet before
attempting repairs or service work. Tag the tool "Out of Service".
 Do not drive over, drag, step on or place objects on a cord

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 Self-Check -1 Written Test

Answer the following equation

1. what is Automotive Workstations? (3)

2. Mention at least 10 measuring/testing tools Safety. (5)

3. Mention advantages of preparation for work shop.(6)

7 points and above correct answered points are passed marks

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 OPERATION SHEET-1.1

OPERATION TITLE:- prepare work station

PURPOSE:- To increase work quality and safety reducing hazards

CONDITIONS OR SITUATIONS FOR THE OPERATIONS:-

 Bright / good visibility working area
 Hazard free work shop
 Cleaned and properly organized work shop /work bench
 Good ventilation working area
EQUIPMENT TOOLS AND MATERIALS : -
 Consumable materials like kerosene, sand paper, rag, penetrating oil, omo etc
 Measuring device like feeler gauge, Vernier caliper, micrometer, dial gauge, steel rule,
straight edge, etc

PROCEDURE,
1. Design/identify the work area used for practical activities
2. Identifying and selecting components, tooling and equipment in accordance with site
manufacturer instructions and site procedures
3. Assess the information/manufacturer manuals/specification for the activities to be done.
4. Observe safety rules
5. Ensure availability of fire extinguisher, wearing of working clothes
PRECAUTIONS:-

 Wear working cloths which properly fit with your body

 Make working area hazard free
QUALITY CRITERIA:

Preparing work station for quality work activities and improving productivity,

Check the preparation of workstation ready for the activities to be performed.

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 LAP Test -1.1

LAP Test 1.1 Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Instructions: Given necessary templates /guide , workshop, tools and materials you are
required to perform the following tasks within 1:00 hours.

Task 1. By using the given guide, Making workstation ready for work activities
with sourcing and supporting technical requirements for measuring/testing
device

Task 2. By using the given [Link] procedures and information

Task 3. By using the given guide Making workstation ready and safe for top
overhaul works

Task 4. By using the given guide Observing OHS measures and warnings
(standardize and sustain 3S)

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 Information Sheet-2 Calibrating measuring/ testing devices

Introduction to calibration

calibration is Set of operations that establish, under specified conditions, the relationship
between values of quantities indicated by a measuring instrument or measuring system, or
values represented by a material measure or a reference material, and the corresponding values
realized by standards. Calibration of an instrument involves comparing the measurements of
two instruments, one which has a known magnitude (also known as the standard) against the
instrument whose unit measure is under the test. The calibration standard must be more accurate
than the instrument under test.

Calibration establishes a relation between a) the quantity values with measurement uncertainties
provided by the measurement standards, and b) corresponding indications with associated
measurement uncertainties of the calibrated instrument or secondary standard. You can use this
information to establish a relation for obtaining a measurement result from an indication.

Importance of Regular Calibration

Regular calibration of instruments is necessary as the accuracy of their measurements start to
drop over time. You have to make sure the instruments don‟t get „out of calibration‟. You will
observe that the accuracy of major components of instruments like voltage references, current
shunts and input dividers will start to shift over time. However, this shift is minor and wouldn‟t
affect the measurements if you maintain a good calibration schedule as it will find and correct
the shift.
Here are some three major reasons why it is important to have your instruments calibrated:
 To ensure the accuracy of the readings
 To ensure that the readings are consistent with other measurements
 To ensure reliability of the instrument in terms
How Often Should You Calibrate
You are aware that you must calibrate the instruments regularly, but how often do you have to
calibrate them? You don‟t have a „one-size-fits-all‟ kind of an answer to this. Every instrument
has different calibration frequency requirement. Let us see how you can approach this aspect and
how you can send in the instruments for calibration services.
1. Follow the calibration interval recommended by the manufacturer
Every manufacturer recommends when you must calibrate their tools. Keep up with their
recommended frequency, but also remember that critical measurements may require
different intervals.
2. Before you start a major critical measuring project
If you have to carry out highly accurate measurements for a project, decide which
instruments you will be using for the testing. Once you have the list of instruments, send
them out for calibration and do not use them until the test. Keeping them on a „lock
down‟ till the testing begins will ensure that you get absolutely accurate results.

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 3. After a major critical measuring project ends

It is important to calibrate instruments before a major critical measuring project;

however, it is equally important to send the same instruments for calibration after the
project is finished. Once the calibration is done post project, you can confirm the
accuracy of your testing results for that project.

4. After an unforeseen accident

If your instruments took a hit, like a sharp physical impact or if something knocked out
the internal overload, you must send them out for calibration. At the same time, you must
have the safety integrity checked as well.

5. As per project requirements

Every project and measurement job has a different calibration requirement. Some may
require certified and calibrated test equipment regardless of the project size, and some
may not require stringent calibration standards. These requirements may not be explicitly
stated, which is why you must review the specs before the test.

6. Monthly, quarterly, or semiannually

If you use certain equipment for critical measurements often, it would be ideal to have a
shorter time span between calibrations. Depending on their usage, you have to calibrate
equipment on a monthly, quarterly or semiannually basis.

7. Annually and biannually

If you carry out a mix of critical and non-critical measurements, annual calibration would
be a good option to choose. Biannual calibration is ideal if you carry out critical
measurements and do not expose your meter to an event, as calibration at lengthy
frequencies can be cost-effective.

Don‟t consider calibration as an action that merely fine-tunes your test instruments. Calibration
ensures that you can use equipment safely and reliably. You will always get precise results when
you use calibrated test equipment. You can thus consider calibration as a form of quality
assurance.

What Factors Affect Calibration?

Just like with anything that is set, a torque wrench calibration will lose its accuracy over time.
With that being said, it is important to understand what factors have an effect on calibration and
how you can make a calibration last longer.
The average temperature at which the tool is used can tie in to how accurately the tool is
calibrated. Whether you‟re working with the tool in cool or warm conditions, it is important to

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 set the measurements of the tool to a comfortable setting in the climate in which the instrument
will be used. This will reduce the chance of errors in solution and provide more accurate results.
In calibration, mathematics is applied to determine the set measurements at which the tool will
be used. If a factor in the equation is incorrect, this can offset the calibration and cause major
errors in results and performance. It is important to properly measure the distance between the
square drive and the hand position in both measuring times to ensure a precise solution to the
equation.
Calibrators used for regulating precision in instruments (such as torque wrenches) must meet
specific requirements from a dependable manufacturer before being used in the process of
calibrating your work instrument. A defective calibrator can and will cause mistakes in
calibration results, thus leading to the misuse of your tool. It is important to inquire about a
calibrator‟s certainty before it is used in the process. This way, before any calculations are found,
you can rule out the defectiveness of the calibrator.
The Calibration of Measuring Equipment
Calibration entails documenting and ascertaining deviation of a measured value from a high
accurate standard that is retraceable. The value that is measured from the instrument that is used
is therefore compared to a known value of the test standards under the specified reference
conditions with the help of measuring procedures that are reproducible. Thus, it does not entail
any manipulation of the instrument that does not change.

Calibration ensures that the measuring instrument is retraceable to national standards. Most
importantly, it guarantees the quality of a given product in terms of internationally comparable
measurement results, thus offering legal security in terms of product liability, approval tests and
audits.
Calibration of instruments must be done at accredited laboratories. There are a number of risks of
not calibrating, some of which include
 Compliance and safety issues
 Wastage of resources and raw materials
 Low quality of the final products
 Increased downtimes
 Litigation issues
Why Calibrate?
Calibration ensures the accuracy of the tools, and inspection, measuring and test equipment used
to return aircraft, engines and components to service. Calibration minimizes measurement errors
and uncertainties to acceptable levels.
For calibration of tools, and inspection, measuring and test equipment, acceptable levels of
uncertainty are defined by the tolerance limits of the equipment‟s parameters established by the
manufacturer. The outcome is maintenance of the equipment within the defined accuracy of the
manufacturer‟s design tolerances.
What will happen if we measure wrong?
 Wrong decisions are made
 Bad product design
 Delayed Time To Market
 Unstable production test stations with low yield

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  Badly adjusted products–We scrap ”good” products unnecessary
 Delays in delivery
 Bad quality
 Field problems or breakdowns
 Bad reputation among our customers
 Or customers lose confidence in Ericsson
 We lose money –etc.
CALIBRATION PROCEDURES- CALIBRATION CERTIFICATES
The Laboratory shall use methods and procedures for the calibration of measuring equipment,
reference measurement standards (including reference materials) and test equipment used in
calibration and testing laboratories that comply with the requirements of ELOT EN ISO/IEC
17025. The methods and procedures shall include, but not be limited to:
A. Identification of the instrument, gauge or test equipment, or group of such items to which
the procedure is applicable
B. Identification of all measurement standards/reference materials and associated equipment
used to perform the calibration
C. The procedures to be adopted for handling, transporting, storing and using measuring
equipment and reference materials used for calibration, including details of lifetime and
measures to prevent contamination or loss of determinant
D. The procedures to be adopted for handling, transporting, storing and preparing items for
calibration
E. The environmental conditions that must be used, the limits applicable, the procedure for
any corrections that may have to be made as a result of the environmental conditions and,
where relevant, the minimum period of stabilization before calibration
F. The method or procedure for calibration in the form of written instructions and diagrams
where appropriate
G. Details of the measurement or calibration data to be recorded and the method for
presentation and analysis of this data
H. The limits of acceptance for the calibration data for the item or type of item being
calibrated
I. The estimation of the uncertainty of measurement of the calibration process (see
paragraph 4.2 of this guideline)
J. The procedures to be adopted for selecting calibration intervals when the
equipment/reference material is being used by the laboratory to perform calibration or
tests
K. The procedures for checking equipment and reference materials between calibrations
L. An identification number, number of pages, date of issue and name and person
authorizing issue and use of the procedure.
1. Calibration of Straight Edges
Straight edges are not readily calibrated in-house. However, if two straight edges of similar
lengths are available, a comparison can be done by placing them together and viewing any
gap. Any light indicates a gap of at least 0.0025 mm. Straight edges are available in four
forms: “I” section, bow shaped, rectangular (with or without bevel on one edge) and
toolmakers or knife edge straight edges.

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 A careful visual inspection of the working edge each time a straight edge is used is good
practice. Any evidence of wear or damage should prompt recalibration or replacement,
depending upon the extent of the problem.
2. Calibration of Feeler Gauges
Unless special levels of accuracy are required, feeler gauges can be calibrated in-house using
a properly calibrated micrometer. Visual inspection each time a gauge is used is good
practice and evidence of wear or damage should prompt recalibration or replacement.
3. Calibration of Steel Rules
The in-house calibration of steel rules is done by comparison with another rule and straight
edge. Suitable rules or graduated straight edges are available up to two meters long. A rigid,
flat surface is important for a reliable calibration, and an end-stop or other suitable fitting can
facilitate alignment of the zero graduations. A magnifying lens is useful in assessing small
discrepancies, especially on finely graduated rules.
The reference rule must not be used for any other purpose. It might have to be periodically
calibrated by an appropriate metrology laboratory. Careful visual inspection of the working
rule each time it is used is good practice. Evidence of wear or damage should prompt
recalibration or replacement.
4. Calibration of Steel Tapes
In common with steel rules, a tape is calibrated by direct comparison, usually with another
steel tape. However, a little more attention is needed to the procedure.
The more common tapes, usually referred to as “tape rules”, are available in lengths up to
about ten meters. They are usually provided with end fittings, which compensate for “end-
on” or “hook over” measurements. While some are marked with etched graduations, most
modern varieties are epoxy coated over printed graduations.
Steel measuring tapes available in lengths up to 100 meters are provided with engraved,
etched or printed scales. For all except tapes of the highest quality, however, the
manufacturing trend is towards epoxy coated, printed scales. End fittings are usually of the
“hook over” variety but special end fittings for particular applications are available.
In general, in-house calibration of tapes more than ten meters long is not recommended. Above
this length, the facilities needed become rather specialized and external calibration services
should be sought. It is always important to know the accuracy to which the tape needs to
conform.
For tape rules, no special precautions are necessary and calibration can be carried out on a flat,
rigid bed against a steel rule or steel tape scale, usually depending upon the length. Suitable end
fittings to provide a datum for “end on” and “hook over” checks are needed.
The accuracy of the higher quality tapes is normally specified with the tape fully supported along
its length under a specific tension at 20 °C. The applied tension is typically 50 N but this can
vary and the manufacturer‟s specification must be checked. Calibration procedures should
include instructions for applying the correct tension to both reference and test tapes. Means for
ensuring correct zero alignment will be needed, depending upon the type of end fitting provided.
Reference tapes should be used for no other purpose and should be calibrated periodically by an
appropriate metrology laboratory.

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 5. Calibration of Vernier Calipers
Vernier calipers are a form of highly accurate measuring device that gauges to the thousandth of
an inch the distance between two symmetrical sides opposing one another on an object. What
makes a Vernier caliper unique from other types of calipers is the inclusion of a Vernier scale
which enables these calipers to be even more precise.
In-house Calibration
Vernier calipers differ from most other measuring instruments in that the line of the scale is
offset from the line of measurement. Accuracy, therefore, is very sensitive to consistency in the
geometry of an instrument. This is influenced by the straightness of the beam, the sureness of the
jaws to the beam and the alignment of the sliding unit.
Scales are normally designed to be read directly to 0.05 mm, with the exception of some dial or
electronic calipers which read in 0.02 mm or 0.01 mm.
To get the best performance from a Vernier caliper:
a. Learn to acquire the correct “feel” to ensure that the measuring faces are square to the line
of measurement and make firm contact without straining
b. Avoid “springing” the measuring jaws since errors induced in this way are enhanced by the
displacement of the line of measurement from the line of the scale
c. Always use the locking screw on the sliding unit before taking a reading. This prevents
inadvertent movement and, more importantly, ensures consistent alignment with the beam
d. Do not hold an instrument in the hand any longer than is necessary. Hand heat is sufficient
to cause thermal expansion, adding to the inaccuracies inherent in the system
e. Get into the habit of doing routine checks regularly, perhaps even each time the instrument
is used, as follows:
i. Check that the sliding unit is a good sliding fit on the beam. Any build-up of dirt on the
slide should be cleaned off. The clamp should be in working order
ii. Check that the beam is straight and that the measuring jaws line up properly. Upper and
lower jaws should lie in the same plane and the measuring faces should show no evidence
of irregular gaps when they are brought together. Visual inspection is sufficient
iii. Check the measuring faces for burrs and wear
iv. When the jaws are closed, check that the Vernier indicates correct zero
v. Check several points in the working range of the Vernier against reference gauge blocks
or length bars.

Features of Vernier Calipers examined by Metrology Laboratories

1. Flatness and straightness of the beam. Determined by comparison with a calibrated
straight edge for straightness and a calibrated surface plate for flatness.
2. Co-planar relationship of the jaws. Determined using a calibrated straight edge and
feeler gauges.
3. Flatness and parallelism of the measuring faces. Parallelism can be assessed visually
with the jaws brought together against a strong light source. Flatness of each jaw can be
checked against a calibrated straight edge or against optical flats.
4. Squareness of the measuring faces to the inner edge of the beam. Determined by
comparison with a calibrated square.

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 5. Combined width of jaws. This feature is applicable only to instruments manufactured in
accordance with British Standards with jaws suited to both internal and external
measurements. It may be measured with a calibrated micrometer. Other calipers should
have the internal measurement facility calibrated separately, similar to the external, by
comparison with gauge blocks.
In order to ensure precision of measurements, it is important the calipers be maintained by
calibrating them regularly and carefully.
Step 1. Clear the caliper jaws and track of grease, dirt or any other foreign matter by wiping
them completely clean with a cloth.
Step 2. Ensure that the gear glides smoothly across the tracks by moving it back and forth.
Step 3. Close the jaws together and note the reading at this time. The dial should read zero.
If it doesn't, manually adjust the dial to zero.
Step 4. Check the OD jaws first by inserting a .500-inch (12.7 mm) gauge block in between
the caliper jaws. Close the caliper so that both jaws are touching the block. Record
the reading.
Step 5. Repeat step 4 with a 1-inch (25.4 mm) gauge block and then a 4-inch (101.6 mm)
block. Record both readings.
Step 6. Repeat step 4 using the appropriate size micrometer standard (150, 200 or 300) as
well. Record this reading.
Step 7. Check the ID jaws by setting the calipers to 12.7mm and locking them into place.
Measure the jaw width with another pair of calibrated calipers. Record the reading.
Step 8. Repeat step 7 for 25.4 mm and 101.6 mm settings as well as for the appropriate
length of caliper, either 150, 200 or 300. Record these readings.
Step 9. Perform a height check by setting a 12.7 mm gauge block onto the surface plate.
Extend the caliper above the block and then close it until it is just touching the block.
Record this reading.
Step 10. Repeat step 9 for both 25.4 and 101.6mm gauge blocks. Next place the correct size
micrometer standard onto the surface plate and extend the caliper above it, then close
the caliper until it is just touching it. Record all of the readings
6. Calibration of Digital Caliper
. When working with systems on a car such as the brake system, you need an absolutely accurate
digital caliper. Digital calipers can be checked for accuracy by calibrating them. This process of
calibration is quite easy to accomplish. The following paragraphs describe the steps that you will
need to follow to properly calibrate a digital caliper. There is also a short paragraph describing
the proper use of a digital caliper.
Step 1 - Clean Caliper Pads
Calipers are designed to measure to extreme degrees of accuracy. Some calipers will measure to
an accuracy of up to five decimal digits, or one hundred thousandth of an inch. Having clean
contact surfaces when measuring or calibrating to this degree of accuracy is imperative. Use a
clean and lint free cloth to wipe off the contact pads.

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 Step 2 - Unlock the Calibration Slide
On the fixed portion of the digital caliper is a locking lever that locks the fixed contact pad. This
needs to be unlocked in order to calibrate the digital caliper.
Step 3 - Close the Caliper Completely
Screw down on the adjustment knob until the moving portion of the digital caliper is as far as it
will go.
Step 4 - Press Fixed Pad against Moving Pad and Lock
Press down on the movable portion of the locking fixed pad until it makes firm contact with the
moving pad portion. While keeping pressure against the moving pad, swivel the locking lever to
lock the stationary pad in place.
Step 5 - Set Indicator to Zero
With the moving and stationary contact pads making firm contact and firmly locked in place,
rotate the knob or press the reset button until all digital readout digits are at 0.
Step 6 - Verify Digital Caliper Calibration
Most professional digital calipers come with two or three calibration rods. The sizes that these
rods come in will depend on the range that the digital caliper is capable of reading. Digital
calipers in the automotive industry will read from 0 to 6-inches. Smaller digital calipers, such as
ones that only read to 1-inch, may only have one calibration rod, which will normally be 0.5-
inches long, to an accuracy of how many decimal points that the digital caliper is capable of.
Larger digital calipers may also have a half inch calibration rod, plus an additional one or two
inch calibration rod.

7. Calibration of Micrometers
In-house Calibration
The micrometer is among the most commonly used measuring instruments. Direct readings to
0.01 mm (0.001 inch) are normal, with the addition of a Vernier scale readings to 0.001 mm
(0.0001 inch) are possible.

To get the best performance from a micrometer in use:

A. Never use undue force
B. Use the ratchet if fitted, or learn to acquire the correct “feel” to give constant measuring force
C. Make sure the measuring faces are square to the object being measured
D. Always check that the anvil faces are clean
E. Do not hold in the hand longer than necessary as hand heat will cause expansion, adding to
the inaccuracies inherent in the system
F. Get into the habit of doing routine checks regularly, perhaps even each time an instrument is
used as follows:
i. Check that the spindle runs freely and smoothly throughout the length of its travel. There
should be no perceptible backlash between the spindle screw and nut. Provided wear is

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 relatively uniform along the screw, the accuracy can be restored by adjusting the wear
compensating mechanism and re-setting the zero
ii. Clean the anvils carefully and examine for burrs
iii. Check that the micrometer indicates correct zero
iv. Examine for accumulated dirt, especially on the screw. Clean the instrument if necessary and
keep the screw very lightly lubricated
v. Check several points in the working range of the micrometer using appropriate reference
gauge blocks.

Features of Micrometers examined by Metrology Laboratories

a. Flatness of the anvils. Determined by using optical flats
b. Parallelism of the anvils. Determined by using optical parallels
c. Zero reading, range of error for traverse, error of alignment and measuring force. The
length of the setting rod is also calibrated if included.
Errors
“Progressive error” is the cumulative error over the total travel of the micrometer. These arise as
the thimble is rotated from the zero through variations in the pitch of the thread. They add
cumulatively as rotation progresses.
“Periodic error” is an error which occurs through a single revolution of the thimble and does not
add up progressively. The usual causes are “drunkenness” of the screw thread or eccentricity of
the thimble or its graduations.
The error at any setting of the micrometer is the sum of the progressive and periodic errors found
at that setting. These errors can only be determined using reference gauge blocks of selected
known sizes.
Outside micrometer calibration
Purpose
The purpose of this procedure is to provide general instructions for the calibration of outside
micrometers with Vernier, digital, or combination scales.
Scope
This general procedure shall be used in the absence of any specific calibration procedure for
outside micrometers.

Procedure
Preliminary Instructions and Notes

1. Read this entire procedure before beginning the calibration.

2. Calibration shall be performed in an environment that conforms to Manufacturer
Specifications.
3. The outside micrometer will hereafter be referred to as the Instrument Under Test (IUT).

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 4. Verify that the IUT is clean.
5. Visually examine the IUT for any condition that could cause errors in the calibration.
6. When adjusting micrometer do not retract spindle without carefully stoning the spindle
O.D. to remove burrs or nicks (if needed).
7. Whenever necessary to disassemble for adjustment, use care and cleanliness to assure no
damage to the threads.
8. If any of the requirements cannot be met, refer to the applicable manufacturer manual.
9. If a malfunction occurs or a defect is observed while calibration is in progress, the
calibration shall be discontinued and necessary corrective action taken; if corrective
action affects a measurement function previously calibrated, the function shall be
recalibrated before the remainder of the procedure implemented.

Specifications
The specifications of the IUT are determined by the applicable manufacturer's documentation. If
the manufacturer's documentation is not available, then the specifications identified in this
procedure are used.
 Micrometers with 0.0001" graduations shall be within 0.0001".
 Micrometers with 0.001" graduations shall be within 0.001".

 Reference Material
 Applicable Manufacturers Manual or Brochures.

Equipment Required
The Standards listed below should be selected on the basis of their higher accuracy level when
compared to the unit under test. Equivalent Standards must be equal to or better than the
Minimum-Use-Specification.
Minimum-Use-Specifications for Standards listed are 1/4 the accuracy required by the IUT.

 Cleaning solution
 Hard Arkansas stone
 Lint free cloth
 Gage oil
 Gage block set

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 Detailed Procedures

1. Clean faces and all exterior surfaces with lint free cloth, dampened with cleaning
solution.
2. Close IUT using ratchet or friction stop.
3. Hold IUT to light source and visually examine for light showing between faces. If faces
are not parallel, light will show between them.
4. Remove spindle assembly.
5. Clean then oil spindle and measuring screw.
6. Clean and oil fixed nut in barrel.
7. Reassemble IUT.
8. Check measuring screw for wear by pushing thimble to and fro in direction of measuring
screw axis. There should be no movement.
9. Adjust for wear by tightening fixed nut on barrel to a smooth, tight, (no shake) fit for the
full thread length. A smooth tight fit must be achieved for acceptance.
10. Close IUT using ratchet or friction stop to check zero setting.
11. Check accuracy with gage block(s) having accuracy not less than 0.00001 inch. Block
sizes must test the IUT not only at complete turns of the thimble scale, but also at
intermediate positions. This is required as a check on the accuracy of the scale around the
thimble as well as the measuring screw.
12. Place block or block combinations between anvil and spindle of the IUT and close the
IUT using ratchet or friction stop. Use block combinations to check the accuracy of the
instrument in three positions of total thimble range (zero, midway & full length).
Regular calibration intervals help ensure micrometer accuracy.

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 The standard used in calibrating measuring gages must possess an accuracy greater than a 4:1
ratio over the accuracy of the gage being calibrated. The accuracy of a gage block is typically
±0.000002 inch, and the accuracy of a micrometer is typically ±0.0001 inch. This exceeds the
4:1 ratio.

The inventor of the modern micrometer, Jean Laurent Palmer, introduced the basic principles of
magnification based on screw threads. His design is based on a 1-millimeter, single-pitch open
screw thread. One rotation, or 1 millimeter, was divided into 20 equal parts, bringing the smallest
resolution to 0.05 millimeter. His design was so advanced and complete, that nothing has been
added to or subtracted from his original concept in terms of the principles of operation. To
ensure accuracy, micrometers must be calibrated at regular intervals.

The 4 to 1 rule
 The standard used in calibrating measuring gages must possess an accuracy greater than a
4 to 1 ratio over the accuracy of a gage being calibrated. This common rule of thumb
originated some 40 years ago from MIL-STD-45662A, which was first published in 1960. A
gage block is used to calibrate an unknown micrometer. The "unknown" is the micrometer
and the "known" is the gage block being used. This gage block must have a certificate of
traceability to the National Institute of Standards and Technology (NIST).
 The use of gage blocks is always the best, because no other standards are more accurate
than the gage blocks, and they are the highest in the hierarchy of precision.
 There is a dedicated standard for large micrometers called "standard bar." Often, the bar is
supplied with large-size micrometers, and its end is either spherical or flat.
 It is suggested that the bar without certificate be compared against a traceable gage block
or immediately compared against a traceable gage block. This can be done on top of the
granite surface plate.
Calibration guidelines for micrometers using a five-point calibration method

1. Look at the frame, for signs of damage, such as indications that it was dropped on the
floor.
2. Observe both spindle and anvil faces. They must be flat, free of pinholes and clean.
Frosted surfaces may indicate wear.
3. If the micrometer needs repairs, they must be done first. Calibration may proceed only
when the gage is in good working order. Move the micrometer from 0 to 25 millimeters (0

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 to 1 inch) or the entire range and check if the spindle feels continuously smooth
throughout the range. In short, check if it is good enough for its intended use. A hard to
turn spindle is a sign of age or damage. Do not force it to rotate and have someone look
into the cause of malfunction.
4. The micrometer should turn smoothly and freely throughout the entire range, and it should
not bind or freeze during the check.
5. Check five points. In inch micrometers check 1.000, 0.500, 0.250, 0.125 and 0.0625 with
traceable gage blocks. The zero point is repeatedly checked but never reported. The check
points presented here are one suggestion: take the entire range, split it in half, split it in
half, split it in half again and split it for the last time. The points checked may be even
better if they are replaced by 0.997, 0.502, 0.246, 0.128, 0.611 or any other number for
that matter.
6. If 18.5 millimeters is checked on a daily basis, by all means include that number in the
calibration procedure to safeguard the system.

8. Calibration of Dial Gauges

In-house Calibration
Dial gauges are easy to use, accurate and relatively inexpensive instruments. However, because
of their mechanical complexity, they need particular care in their use and maintenance. The
mechanism consists of a rack on a plunger extension which actuates, through gears, a pinion
carrying a pointer.
Means for eliminating backlash are incorporated in the mechanism. A tension spring is provided
to keep the plunger tip in contact with the work piece. A revolution counter is fitted when the
pointer movement exceeds a single revolution. The plunger of a dial gauge is intended to work
dry in its close fitting bush and should never be lubricated. Even light oil will pick up dust which
can cause the plunger to stick.
A dial gauge can be used as:
a. A comparator for the measurement of small differences in dimension
b. A direct measuring instrument
c. A stable indicator
d. A component of a gauge or gauging fixture (dial calipers).
To get the best performance from a dial gauge:
A. Ensure that the dial gauge mounting is sufficiently rigid. Lack of rigidity in mountings is
a very common fault and seriously detracts from the accuracy of the system
B. Ensure that the dial gauge is square to the axis of measurement
C. Never release the plunger so that the contact point impacts on the work piece. This can
damage the rack
D. Avoid sideways force on the plunger
E. Avoid excessive plunger movement
F. When clamping a dial gauge over the cylindrically ground stem provided, exercise care
not to distort the stem causing the plunger to stick or jam in its bearing
G. Get into the habit of doing routine checks regularly, perhaps even each time an
instrument is used as follows:
 Check that the instrument is clean, with no obvious signs of damage

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  Check that the plunger moves smoothly. Be careful not to damage the spring loading
 Set the adjustable zero and ensure that the pointer returns properly to zero when a
displacement is applied to the plunger and released gently.

Features of Dial Gauges examined by Metrology Laboratories

The pointer is checked for position, whether it is firmly attached, whether it suffers from parallax
error and whether the spindle is visibly bent.
The plunger is checked for freedom of movement and for the existence of any shake, including
rotational. The measuring force of the dial gauge is also measured.
The dial gauge is checked for repeatability of reading by rolling a suitably sized roller under the
dial gauge from several different directions. The dial gauge is also checked by making repeat
readings of a flat surface with the spindle being lowered both rapidly and slowly. A dial gauge
should repeat readings to better than 1/5th division.
Discrimination is the ability of an instrument to resolve small gradual changes of readings. This
is done on dial gauges to BS using an eccentric mandrel having a known run out. The dial gauge
should indicate the run out (2½ divisions to British Standards) to within 1/3 division.
Errors of indication are checked over several intervals for compliance to British Standards: these
are any ten divisions, any half turn, any one turn, any two turns and over the total travel. This is
intended to determine any errors due to a bent needle spindle, eccentric face, damaged gears, etc.
This is done by gauge blocks, micrometers or, lastly, by an interferometer.
In order to calibrate the dial gauge the environment must be relatively dust free. Clean surrounding
inspection area with clean, clean all inspection tools.

A. VISUAL INSPECTION

1. Visually inspect the crystal for readability, nicks and general appearance.
a) Inspect the body, point, spindle and backing plate.
b) Inspect for missing components.
2. Clean the instrument with a clean lint free cloth
3. Visually inspect the indicator for evidence of damage, inspect the point, spindle, main body,
bezel/crystal assembly, spindle stop and backing plate.
4. Inspect the function of the indicator:
a) Does the bezel rotate smoothly? Does it seat properly?
b) Does the dial face turn with bezel? Does it slip?
c) Is there any play between spindle/spindle guides?
d) Does the condition of the crystal impair the ability to read?
e) Does the spindle travel smoothly in both directions?

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 B. CALIBRATION

1. Clean the granite surface plate with clean, dry, lint free cloth.
2. Clean magnetic base with clean, dry, lint free cloth. Check magnetic base for burrs. If
evident smooth with a fine file and emery cloth.
3. Lightly tighten the dial indicator to magnetic stand.
4. Check magnetic base against top of surface plate for flatness. Try to wobble magnetic base
from side to side and corner to corner, only 0 wobble is acceptable.
5. Adjust the dial so that the dial spindle is 90 o to surface plate in all directions.
6. Clean spindle point.
a) Lower dial until spindle point makes contact with surface plate. When long and short
needles are on “0” tighten clamps.
C. CONSISTENCY AND ACCURACY TEST

1. Move the spindle from “0” - .990”, five times slowly and smoothly. Note: Do not
bottom out the spindle in either direction. Allow point to touch surface plate record
needle placing. Repeat this procedure three times with .250”, .500”, and .750” gauge
blocks. Record readings on Inspection Report.
9. Height gauge calibration procedure
Standards and Equipment

The following equipment is required:

 Granite Plate
 Master Gauge Block Set
NOTE: Standards and equipment used must have a valid calibration certificate

Calibration Procedure

Height Gauge Calibration Record Sheet” must be used Clean the Height Gauge‟s measuring
surfaces, the granite plate, and the gauge blocks to be used

1. Digital Height Gauges only need one scale to be verified

2. Zero the Height Gauge at the start and adjust as required by the manufacturers‟
specifications. If you cannot zero it then mark it as a fail
3. When testing the Height Gauge, one of the points must be near the lower limit that the
instrument can measure, another somewhere in the middle, and the third near the upper
limit
4. Use a conversion factor of 25.40 mm/in to convert gauge block lengths to Metric from
Imperial

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 Step 1. Measure the ambient temperature and record it. If the temperature is <18oC or
o
>24 C,
Step 2. Test Characteristic: Inspect the anvils and the Sliding Scale
Test Method: Visual, Touch

Acceptable Limit: No damage, nicks, or burrs. Should have straight and parallel
faces, smooth movement over the whole length with no free play

Step 3. Test Characteristic: Measuring Scale

Test Method: Using gauge blocks, measure and record 5 different heights, stack
and wring blocks as necessary. Use the inspection grade granite plate Acceptable
Limit: +/- 0.002" or 0.05mm

Step 4. Test Characteristic: Anvils

Test Method: If different anvils are available for the height gauge, make and record
one measurement for each Acceptable Limit: +/- 0.002" or 0.05mm

10. Calibrating Torque Wrenches

Torque wrenches used on aircraft need to be calibrated at least once a year. For personal torque
wrenches that are used on non-aircraft applications, depending on the amount of use of the
torque wrench, a calibration could wait a little while.

The torque wrench is a key instrument in precision work, so even the smallest obstacle could
offset a calibration enough to break a stud, loosen a nut or leave a stripped thread. A torque
wrench that is prepped before use will guarantee the most accurate result.

Clean and undamaged threads specifically define torque values on this type of wrench. This is
critical when knowing the settings for each torque wrench job for your aircraft.

How To Calibrate A Torque Wrench

While professional torque wrench calibrations are required for aviation applications, you can
always learn a do-it-yourself calibration technique that can be used when professional
calibrations are not applicable.
In order to understand how a calibration is done, it is critical to know the mathematics behind it.
The formula used in this adjustment is for a straight, non-spinning object such as a lever: torque
(T) = force (weight) x distance (T = F x D). You can also use the formula Ta = Ts x (D1/D2), in
which applied torque (Ta) = torque setting (Ts) x (distance one/distance two).

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 The load on the bolt will depend upon such a factor as the friction of the thread. If applying a
torque load to an oiled bolt, the amount of an applied load will increase, excluding a regular,
lightly oiled cylinder head bolt. Any other oiled bolt will increase the load as well as increase the
risk of overloading and breaking the bolt and crushing a gasket.
Tools & Supplies to Calibrate Torque Wrench DIY

A torque wrench

A bench vise

20lbs (pound) weight

A piece of thin rope or string

Marker

Calculator

Measuring tape
Step 1. Measure the length from the square drive to the point of the torque wrench on which
your hand rests when using the tool.
Step 2. Place the square drive of the wrench in the vise and secure it. No other part of the
wrench should be locked in the vise.
Step 3. Align the torque wrench to the value of the settings you got in step one (the distance
from the square drive to your hand) and multiply it by 20 pounds.
Step 4. From the position your hand rests, tie the 20-pound weight with the thin rope or string
to the wrench.
Step 5. If you hear a click from the wrench, lift the weight and move it towards the head of the
wrench until the clicking stops. If you don‟t hear a click at first, move the weight
farther from the head of the wrench and try again. You can make a definitive mark
after two or three stops in the same location of the wrench. IMPORTANT: Make sure
the wrench is horizontal when conducting this step.
Step 6. Measure the distance from the square drive to the location in which the rope is located
after step five. Multiply your finding distance by 20 pounds.
Step 7. With the formula Ta = Ts x (D1/D2), you can calculate the applied torque with
your findings. Applied torque (Ta) = torque setting (Ts) x (distance in step one/distance
in step five).

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 11. Calibrating Torque screwdrivers

Calibrating a torque screwdriver insures that it performs within its technical specification. Most
torque screwdrivers have a min and max torque value along with a % standard torque deviation.
When you have a screwdriver calibrated, you ensure that a screwdriver maintains its % standard
torque deviation at its min, max, and several torque values between the min and the max. All of
our torque screwdrivers come with a manufacturer's certification stating that the screwdriver
operates within its specification.
Adjusting the Torque Setting for a Preset Torque Screwdriver
 Connect the screwdriver to the testing instrument and use appropriate adapters if needed.
 Check the current setting of the screwdriver. Apply torque clockwise slowly until the
screwdriver slips over.
 To adjust torque setting remove the end cap.
 To increase the torque setting, loosen the lock screw. Insert the hex key into the internal
adjuster and turn clockwise.
 To decrease the setting, rotate counterclockwise below your desired setting. Then turn
clockwise to increase torque to the desired value.
 Do not adjust settings above or below the recommended torque range of a tool.
 Check the screwdriver and continue adjusting until the desired torque is reached.
 Once the setting seems consistent, then record the final torque readings.
 Apply calibration label and seal.

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 Self-Check -2.1 Written Test

Answer the following equation

1. What is calibration? (3)

2. Why calibration is important? (3)

3. How Often Should You Calibrate measuring/testing device/instruments? (6)

6 points and above correct answered points are passed marks

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 OPERATION SHEET-2.1

OPERATION TITLE:- Calibration of Vernier Calipers

PURPOSE:- to ensure accurate reading.
CONDITIONS OR SITUATIONS FOR THE OPERATIONS:-
 Bright / good visibility working area
 Hazard free work shop
 Cleaned and properly organized work shop /work bench
 Good ventilation working area
EQUIPMENT TOOLS AND MATERIALS : -
Consumable material = cloth, kerosene, etc
Tools = Different size Gauge block, Vernier caliper
PROCEDURE,
1. Clear the caliper jaws and track of grease, dirt or any other foreign matter by wiping them
completely clean with a cloth.
2. Ensure that the gear glides smoothly across the tracks by moving it back and forth.
3. Close the jaws together and note the reading at this time. The dial should read zero. If it doesn't,
manually adjust the dial to zero.
4. Check the OD jaws first by inserting a .500-inch (12.7 mm) gauge block in between the caliper
jaws. Close the caliper so that both jaws are touching the block. Record the reading.
5. Repeat step 4 with a 1-inch (25.4 mm) gauge block and then a 4-inch (101.6 mm) block. Record
both readings.
6. Repeat step 4 using the appropriate size micrometer standard (150, 200 or 300) as well. Record
this reading.
7. Check the ID jaws by setting the calipers to 12.7mm and locking them into place. Measure the jaw
width with another pair of calibrated calipers. Record the reading.
8. Repeat step 7 for 25.4 mm and 101.6 mm settings as well as for the appropriate length of caliper,
either 150, 200 or 300. Record these readings.
9. Perform a height check by setting a 12.7 mm gauge block onto the surface plate. Extend the
caliper above the block and then close it until it is just touching the block. Record this reading.
10. Repeat step 9 for both 25.4 and 101.6mm gauge blocks. Next place the correct size micrometer
standard onto the surface plate and extend the caliper above it, then close the caliper until it is just
touching it. Record all of the readings
PRECAUTIONS:-
 Wear working cloths which properly fit with your body
 Make working area hazard free
 Read and interpret manual which guide you how to disassemble and tag engine system
components.
QUALITY CRITERIA:
Calibrate Vernier calipers properly and check the visibility of the graduation
Check proper operation of Vernier caliper

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 OPERATION SHEET-2.2

OPERATION TITLE:- Height gauge calibration

PURPOSE:- To read accurate measurement .

CONDITIONS OR SITUATIONS FOR THE OPERATIONS:-
 Wear appropriate clothes, shoe ...
 Ensure the work shop hazard free
 Ensure the working area is bright / good visibility
 Make workstation comfortable
 Use rages ,kerosene clearing purpose
EQUIPMENT TOOLS AND MATERIALS : -
 Granite Plate
 Master Gauge Block Set
 height gauge
PROCEDURE,
o
1. Measure the ambient temperature and record it. If the temperature is <18oC or >24 C,
2. Test Characteristic: Inspect the anvils and the Sliding Scale
3. Test Characteristic: Measuring Scale
4. Test Characteristic: Anvils
PRECAUTIONS:-
 Wear working cloths which properly fit with your body
 Make working area hazard free
 Read and interpret manual which guide you how to disassemble and tag engine system
components.
QUALITY CRITERIA:
Check the calibration height gauge is properly calibrated
Check the proper operation of height gauge to assure the proper calibration of height gauge.

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 LAP Test -2.1

LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Instructions: Given necessary templates /guide , Remove, Inspect and perform the
following tasks within 4 hours.

Tassk 1. By using the given guide, identifying object or component to be measured and

Obtaining correct specifications from relevant source

Tassk 2. By using the given guide, Selecting appropriate measuring instrument

Tassk 3. By using the given guide Checking measuring devices for functionality and

Adjusting measuring devices correctly

Tassk 4. Observing OHS throughout the process (standardize and sustain 3s)

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 Information Sheet-2 Maintaining measuring / testing devices

Accessing Information required for maintenance

measuring/testing device Maintenance

All measuring/testing device and vehicles must be properly maintained so that workers are not
endangered. Construction regulations require inspections of vehicles, measuring/testing device
tools, machines and equipment before use.

components of maintenance program

A maintenance strategy includes procedures as well as corrective and preventive maintenance

 Inspections ensure that measuring/testing device, tools and equipments are operating
correctly. Safety inspections ensure the tools/equipments are safe for both patients and
operators.
 Corrective maintenance (cm) restores the function of a failed device and allows it to be
put back in to service.
 Preventive maintenance (pm) aims to extend the life of the tools/equipment and reduce
failure rates.
Preventive maintenance is the systematic care and protection of tools, equipment,
machines and vehicles in order to keep them in a safe, usable condition, limit downtime
and extend productivity. We must always be aware that maintenance tasks themselves are
potentially hazardous and can result in injury. The successful maintenance program is:

 well organized and scheduled,

 controls hazards,
 defines operational procedures, and
 trains key personnel.
How to Maintain a Precision Measuring Tool
Proper use of precision measuring tools is one of the most important preconditions to ensure
product quality. To maintain the accuracy and reliability of a precision measuring tool, one has

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 to do a good job in taking good care of it besides using it properly according to reasonable
operation instructions

Step 1. Be sure that the work pieces have stopped. Measuring work pieces on lathes should be
carried out only after the work pieces have stopped; otherwise, the accuracy of the tool may be
negatively impaired due to wear of the measuring faces and accidents may occur.

Step 2 Wipe the measuring faces of a precision measuring tool and the to-be-measured
surface of the work piece so as to prevent the measuring accuracy from being negatively
affected by dirt or dust. It is not advisable to use such precision measuring tools as Vernier
caliper, micrometer and dial indicators to measure those forged roughcasts or abrasive-bearing
pieces (like carborundum), because the measuring faces will be abraded and accuracy will fall.

Step3. Never put precision measuring tools together with hand tools, such as cutting tools,
files, hammers and drills for the fear of bumping the precision measuring tools. Never put
them on lathes either to prevent them from dropping from lathes and breaking down due to

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 vibration of lathes, especially in the case of Vernier calipers which should be laid flat in specific
cases to avoid distortion

Step 4 Use your tools for their purpose. Precision measuring tools should not be used as
substitutes for other tools. So it is not advisable to use vernier caliper as line markers,
micrometers as small hammers or steel linear as screw drivers and cutting scrap wipers. It is not
proper either to take precision measuring tools as toys, take flinging a micrometer with hands for
example. These behaviors will lead to the falling of accuracy of precision measuring tools.

Step 5. Maintain temperature. Temperature does have a substantial impact on the measuring
results. Precise measurement of work pieces should be carried out only under the condition that
the temperature is around 20 °C (68 °F). Generally, measurements can be carried out under room
temperature, but the work pieces and the measuring tools should share the same temperature.
Otherwise, the result of measurements will not be accurate due to the characteristic of distortion
of metals subject to temperature changes. Precision measuring tools are subject to the changes of
temperature, too. They should not be put under direct sunshine, because measurements will not
be achieved when the temperature rises. Never put precision measuring tools near heat sources
such as electric cooker and heat transmitter to protect the tools from being distorted by heat thus
disabling accuracy.

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 Step 6 Be aware of the immediate area. Precision measuring tools should never be put near
magnetic area, such as magnetic worktable, to avoid being magnetized.

Step 7 When having discovered some abnormal phenomena on a precision measuring tool, such
as rough surface, burr, rusts, distortion of the body or ineffective movements, users should not be
allowed to fix it on their own, not to mention fix it with hammers, files or emery cloth for the
fear of augmenting errors. Users should send the flawed tool to the repair depot and use it after it
is repaired right!

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 Step 8 Users should clean the tools after use. Tools except those made of stainless steel or
framed by protective materials should be daubed with anti-rust oil, put in a specific case and kept
in dry places to be free from being rusted.

Step 9 Periodic maintenance should be applied to precision measuring tools. Long-used

precision tools should be sent to authorized calibration facilities periodically for test and
calibration to avoid product quality problems caused by unreasonable reading errors of the tools.

Carrying out routine maintenance and storage of measuring and testing devices

Routine Care of measuring device/Instruments.

ROUTINE MAINTENANCE is a small scale activity to keep a piece of machinery or equipment
in good working order. Routine maintenance are the upkeep practices that an organization
performs on a regular basis with an eye towards preventing harm to workers and large-scale,
expensive repairs. According to Business Dictionary, routine maintenance commonly demands
less skilled labor and involves tasks that protect a building, equipment, machines, a plant or a
system against normal wear and tear.

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 Routine maintenance, also called planned maintenance, often involves scheduling, at which time
machines, including computer systems, or other assets are examined, updated or tuned up. This
scheduled effort may require ordering spare parts or running diagnostics. Regular maintenance
like this avoids catastrophic breakdowns in equipment and allays the greater costs associated
with those repairs. Additionally, these precautions enhance worker safety, especially for those
operating the equipment in question.
Before making the first set up of the day, visually inspect the instrument for cracks, bumps, and
dents. Check the machined surfaces and the polished faces of the lenses and mirrors. Try the
clamps and motions for smooth operation (absence of binding or gritty sound).

Frequently clean the instrument externally. Any accumulation of dirt and dust can scratch
the machined or polished surface and cause friction or sticking in the motions.
Dirt and dust should be removed only with a clean soft cloth or with a camel hair brush.
Non-optical parts may be cleaned with a soft cloth or clean chamois.
Clean the external surfaces of lenses with a fine lens brush and , if necessary, use a dry
lens tissue. Do not use silicon treated tissues, as they can damage the coated optics. It is
permissible to breath on the lens before wiping it, but liquids, such as oil, benzene, water,
etc., should never be used for cleaning purposes. DO NOT loosens or attempt to clean
the internal surface of any lens.
Cover an instrument whenever it is uncased and not being used for any length of time,
particularly if there is dust or moisture in the air. After an instrument has been used in
damp or extremely cold situation, special precautions must be taken to prevent
condensation of moisture inside of the instrument. When working with the instrument in
cold weather, it should be left in the carrying case in the vehicle overnight. If stored in a
heated room overnight, the instrument must be removed from the carrying case. If the
instrument is wet or frost covered it should be remove it from its case, and leave it at
room temperature to dry out.
apply 5S as work regulation.
Cleaning measuring and testing devices

Solvent Degreasing/cleaning
Solvent degreasing (or solvent cleaning) is the physical process of using organic solvents to
remove grease, fats, oils, wax or soil from various metal, glass, or plastic items. The types of
equipment used in this method are categorized as cold cleaners, open top vapor degreasers, or
conveyor zed degreasers. non aqueous solvents such as petroleum distillates, chlorinated
hydrocarbons, ketenes, and alcohols are used. Solvent selection is based on the solubility of the
substance to be removed and on the toxicity, flammability, flash point, evaporation rate, boiling
point, cost, and several other properties of the solvent.
The metalworking industries are the major users of solvent degreasing, i. e., automotive,
electronics, plumbing, aircraft, refrigeration, and business machine industries. Solvent cleaning
is also used in industries such as printing, chemicals, plastics, rubber, textiles, glass, paper, and

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 electric power. Most repair stations for transportation vehicles and electric tools use solvent
cleaning at least part of the time

Clean up procedures

 Clean up every time whenever you leave an area, including sweeping the floor.
 Clean and return all tools to where you got them.
 Use compressed air sparingly; never aim it at another person or use it to clean hair or
clothes.
 Shut off and unplug machines when cleaning, repairing, or oiling.
 Never use a rag near moving machinery.
 Use a brush, hook, or a special tool to remove chips, shavings, scraps etc. from the work
area. Never use the hands.
 Keep fingers clear of the point of operation of machines by using special tools or devices,
such as, push sticks, hooks, pliers, etc.
 Keep the floor around machines clean, dry, and free from trip hazards. Do not allow chips
to accumulate.
 Mop up spills immediately and put a chair or cone over them if they are wet enough to
cause someone to slip.
Carry out storing of measuring and testing device

After cleaning the work area, store tools and equipments on its proper place/storage shelf. which
have the following procedures.

 store reused materials, tools and equipments in a proper place.

 Design place for each kind of tools.
 Label the storage cabinet or place correctly.
 Store them near the point of use.
 Wash and dry properly before storing.
 Store sharp edge materials properly when not in use with sharp edge down.
 Put frequently used items in conveniently accessible conditions.
 Gather and secure electrical chord to prevent entanglement or snagging.
 Cutting boards should be stored vertically to avoid moisture collection
 Metal equipments can be stacked on one another after drying.

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  Make sure the areas where you are storing the equipment are clean, dry and not
overcrowded.
Importance of proper storage of tools and equipments
 It is important factor for safety and health as well as good business.
 Improves appearance of general-shop and construction areas.
 Reduce overall tool cost through maintenance.
 This also ensures that tools are in good repair at hand.
 Teaches workers principles of tool accountability.

Pointers to follow in storing measuring and testing devices

 Have a designated place for each kind of tools.
 Label the storage cabinet or place correctly.
 Store them near the point of use.
 Wash and dry properly before storing.
 store sharp edge materials properly when not in use with sharp edge down.
 Put frequently used items in conveniently accessible conditions.
 Gather and secure electrical chord to prevent entanglement or snagging.
 Cutting boards should be stored vertically to avoid moisture collection
 Metal equipments can be stacked on one another after drying.
 Make sure the areas where you are storing the equipment are clean, dry and not
overcrowded
,. Completing necessary documentation and reports
Documentation is a set of documents provided on paper, or online, or on digital or analog
media, such as audio tape or CDs. Examples are user guides, white papers, on-line help, quick-
reference guides. It is becoming less common to see paper (hard-copy) documentation.
Documentation is distributed via websites, software products, and other on-line applications.
Procedures and techniques
The procedures of documentation vary from one sector, or one type, to another. In
general, these may involve document drafting, formatting, submitting, reviewing, approving,
distributing, reposting and tracking, etc., and are convened by associated A standard operating
procedure (SOPs) in a regulatory industry. It could also involve creating content from scratch.
Documentation should be easy to read and understand. If it's too long and too wordy, it may be
misunderstood or ignored. Clear, Short, Familiar words should be used to a maximum of 15
words to a sentence. Only gender hyper neutral word should be used and cultural biases should
be avoided. Procedures should be numbered when they are to be performed
Documentation should be prepared by qualified specialists. The key to good documentation is to
correctly identify the problem to be solved, and hence to specify an appropriate solution. The
nature and extent of the work must then be clearly conveyed to those who will do it. This
information sheet discusses firstly what to document and secondly how.

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 Most documents contain lists (known as schedules) of components such as windows or floor
finishes. For conservation work, schedules of repairs are commonly prepared for each room or
other element. Schedules are an effective way to summarise the works to be done. Poorly
documented repair works could result in the work making matters worse rather than better.
The Need to Document
Documenting maintenance and renewal information enables repair and maintenance work to be
conducted efficiently and effectively. It also provides key information to the owners, supervisors
and depreciation report providers. These documents are also important in order to provide
proper maintenance to ensure home warranty insurance coverage.

Follow these three general principles to develop records and documents:

1. Keep it short and simple. Use bullet points and flow diagrams instead of long sentences
and lengthy paragraphs.
2. Clarity is important. Step-by-step instructions are easily understood.
3. Use a standardized, consistent format. Although different programs may need different
documents and records, using a similar approach will help staff learn quickly.
Problem reporting procedures
 Inspect/test the vehicle accordance with manufacturer procedure
 Record/ capture the problem with the necessary information
 Order the recorded problems in accordance with their damaging area
 Report to the assigned person for these problems
 Maintain damaging parts according to maintenance procedure
 Preparing reports have no error/discrepancy

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 Self-Check -2.1 Written Test

Answer the following question

1. How to Maintain a Precision Measuring Tool? list the procedures. (5)

2. mention Pointers to follow in storing measuring and testing devices. (5)

3. What are three general principles to develop records and documents? (6)

8 points and above correct answered points are passed marks

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 OPERATION SHEET-3.1

OPERATION TITLE:- Maintain a Precision Measuring Tool

PURPOSE:- To reduce failure rate .

CONDITIONS OR SITUATIONS FOR THE OPERATIONS:-
 Wear appropriate clothes, shoe ...
 Ensure the work shop hazard free
 Ensure the working area is bright / good visibility
 Make workstation comfortable
 Use rages ,kerosene clearing purpose
EQUIPMENT TOOLS AND MATERIALS : -
Consumable materials = Smooth cloth, , cleaning solvent
Tools = tools to be maintained
PROCEDURE,
1. Be sure that the work pieces have stopped.
2. Wipe the measuring faces of a precision measuring tool and the to-be-measured surface of the
work piece so as to prevent the measuring accuracy from being negatively affected by dirt or
dust.
3. Never put precision measuring tools together with hand tools, such as cutting tools, files,
hammers and drills for the fear of bumping the precision measuring tools.
4. Use your tools for their purpose
5. Maintain temperature
6. Be aware of the immediate area
7. When having discovered some abnormal phenomena on a precision measuring tool, such as
rough surface, burr, rusts, distortion of the body or ineffective movements, users should not be
allowed to fix it on their own, not to mention fix it with hammers, files or emery cloth for the
fear of augmenting errors
8. Users should clean the tools after use.
9. Periodic maintenance should be applied to precision measuring tools.
PRECAUTIONS:-
 Wear working cloths which properly fit with your body
 Make working area hazard free
 Read and interpret manual which guide you how to disassemble and tag engine system
components.
QUALITY CRITERIA:
Inspect Precision Measuring Tool Maintenance quality and proper operation of maintained
measuring tool.

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 LAP Test -

LAP Test 3.1 Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Instructions: Given necessary templates /guide , perform the following tasks within 2 hours.

Tassk 5. By using the given guide Carry out routine maintenance and storage of measuring

and testing devices

Tassk 6. By using the given guide, Clean measuring and testing devices

Tassk 7. By using the given guide Complete necessary documentation and reports

Tassk 8. Observe OHS throughout the process (standardize and sustain 3s)

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 Annex I

Answer keys for learning guide -04

Answer key

Self check 1
1. Automotive Workstations are a mechanic‟s workbench with integrated storage,
providing a location for all of the day-to-day tools, parts and consumables that a
mechanic will require.
2. Measuring/testing tools Safety
 Wear protective gloves and a face shield.
 Use only approved cleaning solutions.
 Observe all environmental regulations.
 Keep tools in good condition.
 Use the proper tool for the job.
 Keep tools clean and free from grease.
 Do not use power equipment or tools on which you have not been trained.
 Keep power cords away from the path of vacuum cleaners, floor polishers and
grinders.
 Do not carry plugged in equipment or tools with your finger on the switch.
 Turn the tool off before plugging or unplugging it.
 Do not leave tools that are "On" unattended.
 Do not drive over, drag, step on or place objects on a cord

3. The preparation of work shop to supply equipment helps to -

[Link] environment well being
[Link] with specified our time pre-summing
[Link] the work and its implementing tools and equipment
[Link] the work procedure
[Link] tools, equipment and resource prevent ourselves from injury
[Link] the work with quality
Self check 2
1. calibration is Set of operations that establish, under specified conditions, the relationship
between values of quantities indicated by a measuring instrument or measuring system,
[Link] is important:
 To ensure the accuracy of the readings
 To ensure that the readings are consistent with other measurements
 To ensure reliability of the instrument in terms

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 3.
1. Follow the calibration interval recommended by the manufacturer
2. Before you start a major critical measuring project
3. After a major critical measuring project ends
4. After an unforeseen accident
5. As per project requirements
6. Monthly, quarterly, or semiannually
7. Annually and biannually

Self check 3
1. A Precision Measuring Tool maintenance procedures are
1. Be sure that the work pieces have stopped.
2. Wipe the measuring faces of a precision measuring tool and the to-be-measured
surface of the work piece so as to prevent the measuring accuracy from being
negatively affected by dirt or dust
3. Never put precision measuring tools together with hand tools, such as cutting tools,
files, hammers and drills for the fear of bumping the precision measuring tools.
4. Use your tools for their purpose.
5. Maintain temperature
6. Be aware of the immediate area
7. When having discovered some abnormal phenomena on a precision measuring tool,
such as rough surface, burr, rusts, distortion of the body or ineffective movements,
users should not be allowed to fix it on their own, not to mention fix it with hammers,
files or emery cloth for the fear of augmenting errors.
8. Users should clean the tools after use.
9. Periodic maintenance should be applied to precision measuring tools

2. Pointers to follow in storing measuring and testing devices

 Have a designated place for each kind of tools.
 Label the storage cabinet or place correctly.
 Store them near the point of use.
 Wash and dry properly before storing.
 store sharp edge materials properly when not in use with sharp edge down.
 Put frequently used items in conveniently accessible conditions.
 Gather and secure electrical chord to prevent entanglement or snagging.
 Cutting boards should be stored vertically to avoid moisture collection
 Metal equipments can be stacked on one another after drying.
 Make sure the areas where you are storing the equipment are clean, dry and not
overcrowded

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 3. The three general principles to develop records and documents are:
1. Keep it short and simple. Use bullet points and flow diagrams instead of long
sentences and lengthy paragraphs.
2. Clarity is important. Step-by-step instructions are easily understood.
3. Use a standardized, consistent format. Although different programs may need
different documents and records, using a similar approach will help staff learn
quickly.

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 Annex II

References
1. Auto mechanics books

2. Technical guide for Simple Linear Measurement Instruments Published by: International

Accreditation New Zealand

3. LABORATORY FOR PRODUCTION MEASUREMENT Faculty of Mechanical

Engineering Smetanova 17, 2000 Maribor, Slovenia

4. [Link]

+measuring+devices&aqs=chrome..69i57j0l5.44271j0j8&sourceid=chrome&ie=UTF-8

5. [Link]

6. Vernier Caliper Calibration Procedure Memorial University Technical Services

Document No.: TS-0048 Revision: 3

7. Height Gauge Calibration Procedure Memorial University Technical Services Document

No.: TS-0050 Revision: 3

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 Annex III
For further communication about TTLM
Prepared by:-

No Trainer’s Institute Qualification Address

Name Phone Email

1 Tefera Finote Damot Msc in 0913013347 Gtefera19@[Link]

Getachew TVET Automotive
Collage Technology

2 Adamu Injibara PT Msc in 0918049889 Adamukassa03@[Link]

Kassa collage Automotive
Technology

Coordinators

1. Ato Mulaw Limenh Lulie ---------------------------- ANRS TVED Bureau

2. Ato Andargachew

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