Automotive Measuring Tools

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EDUCATIONAL SERVICES LTD

"ccredited and registered provider

Use and maintain basic


mechanical measuring devices
 6OJU"63TTA3

Student Name _________________________________________ Date __/ __/201


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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

Page 23 Elements and performance criteria

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2
STANDARD AURTTA003

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.

RELEVANT VOCABULARY
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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3
MEASURING TOOLS

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
Start Reading 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
Correct tool manufacturer to manufacturer.
for the job
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.

Tag faulty 7. Tools that are faulty, damaged or in need of calibration should be removed from
tools 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.
Very Important
Safety Points 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.

Common measuring tools used in automotive workshops include:


 Calipers: Vernier calipers, digital calipers, internal and external calipers
 Micrometers: inside, outside and depth
Common  Steel rules
tools  Straight edges
 Measuring tapes
 Squares: engineer’s, combination, T-squares and bevel protractors
 Spirit levels

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4
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  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 Main scale 1st Alignment point
From the main scale (top row) take the
Vernier reading in whole millimetres up to the
Scale 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. Vernier 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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5
Correct use of Vernier calipers

Ensure that both of the internal jaws are placed deep


Internal into the object to be measured.
Reading

External When measuring outside diameter the work must be


Reading placed fully into the Vernier jaws.

To measure depth, ensure that the Vernier


Depth measuring scale is flush against the side of the work
Reading

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6
Reading the Vernier scale

Example One
The main scale reading = 71.00 millimetres

10mm divisions
0.02mm divisions

1mm divisions 0.1mm divisions


Inline point

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
Take Note * 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

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7
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.
Internal Locking screw
Depth measure

LCD screen Slider


External

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.
Inside
 The measuring points of the internal calipers point away
diameters
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
Outside  External calipers are used for measuring outside
diameters 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.

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8
Take Note * 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 Hole depths


Bearing surfaces Pin sizes
Engine
Cylinder bores Valve stems
Components
Camshafts Pistons

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
Centralise the of the measuring scale.
Work
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).
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9
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:

All lines = 0.5mm 0.5

47
11
11
All lines =
0.01mm

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

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10
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).

Using an inside micrometer


Reading the inside micrometer
Select an appropriate sized micrometer and anvil attachment for the hole to be
Inside measured.
Diameters
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:

3
2

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


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11
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 3


1. Sleeve
Measures 2. Thimble
hole depths 3. Ratchet
4. Adjustable anvil
2
5. Frame

4
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
Right to Left 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.

Using a Depth Micrometer


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12
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

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13
Take Note * 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
 Ensure top pivot is secure and thread not damaged

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.

General
Measuring

Using a Steel Rule to measure work.

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

Using a steel rule

Flush with 1. Position the steel rule straight across and flush with the surface to be measured.
surface 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.

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14
STRAIGHT EDGES
A standard straight edge is approximately one metre long. It is constructed from
Determine precision machined steel and has two straight edges and a measuring scale on one edge.
Warpage The straight edge is used with a feeler gauge to determine warp in cylinder heads,
engine blocks and manifolds.

Using a Straight Edge with a Feeler Gauge to measure


warp on a cylinder head.

Take Note * 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.

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.

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15
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
Datum lines 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.
Blade
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.
Stock

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.
Stock rest
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.

Take Note * 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.

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16
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
Multipurpose measurements, a groove through the centre of the blade and a spirit level attachment
Measure and that travels along the groove.
Level
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.

Take Note * 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.

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17
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.

Take Note * 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.

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18
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
Key Points 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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19
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 ____________________

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20
Q2 List 5 general rules to be considered when using measuring tools:

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Q3 Name the 2 scales on a Vernier Calipers:

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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:

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

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21
Q7 Provide an automotive use for a straight edge.

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Q8 Provide an automotive use for a measuring tape.

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Q9 What measurements can be taken using a combination square?

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

________________________________________________________________

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

________________________________________________________________

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

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

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22
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 and safety 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

3.3 Workplace documentation is processed according to workplace procedures

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23
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