Sealey DBG5010 User manual

WARNING! Ensure Health and Safety, local authority and general workshop practice regulations are adhered to when using
tools and equipment.
DO NOT use the dial bore gauge if damaged.
DO NOT drop.
This is a precision instrument, always return gauge components to the internally lined storage case.
Maintain the gauge in good and clean condition for best and safest performance.
Keep the work area clean, uncluttered and ensure there is adequate lighting.
Ensure the work area floor is not slippery; wear non slip shoes.
Components to be measured and the dial bore gauge to be stored at room temperature (21°C).
DIAL BORE GAUGE 50 - 160MM
MODEL NO: DBG5010
1. SAFETY
DBG5010 Issue: 2 (H,F) - 04/04/19
Original Language Version
© Jack Sealey Limited
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE THE PRODUCT
CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL
INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these
instructions, and properly maintained, give you years of trouble free performance.
2. INTRODUCTION
Precision mechanism with Ø55mm dial and locking rotating bezel, offering an accurate method of measuring a bore or detecting a taper or
ovality. Will indicate the deviation from set size by up to 5mm with an accuracy of 0.01mm. Probe body, dial indicator, anvils and spacer rings
are also included. Supplied in wooden storage case.
3. SPECIFICATION
Model No: ............................................................................DBG5010
Range: ................................................................................50-160mm
Maximum Deviation Measurement with Stem:.............................1mm
Maximum Deviation Measurement, Gauge:.................................5mm
Weight: ......................................................................................1.12kg
4. CONTENTS
251
34
Item Description Qty
1 Dial gauge
indicator 1
2 Probe
body 1
3 Clamp
screw 1
4 Distance
piece (50mm) 1
5 Anvils and
spacer rings 1-set
Refer to
instructions

DBG5010 Issue: 2 (H,F) - 04/04/19
Original Language Version
© Jack Sealey Limited
5. OPERATION
5.1. SETTING UP (The dial ball gauge is a comparator not a measuring tool)
5.1.1. Measure the bore diameter or gap to be measured to the nearest millimetre with a rule or vernier callipers. The bore or gap
must range between 50mm and 160mm nominally with this tool. (Up to 164.5 with spacers)
5.1.2. Select the range of parts required, anvils, spacers and 50mm distance piece using the table on the last page.
5.1.3. Assemble the dial bore gauge with selected parts as shown in fig.1, fig.2 and fig.3. Ensure all components are clean and when
assembled are finger and thumb tight; no tools are to be used.
5.1.4. Insert the dial stylus into the probe body as shown in fig.4. The stylus will meet with resistance internally and the dial pointer will
begin to rotate clockwise. One complete cycle of the pointer is recommended for registration and will be indicated by the secondary dial
indicator annotated 1-5. The small pointer should now be indicating "1" [one].
5.1.5. Clamp the dial stem with the thumb screw. DO NOT overtighten.
5.2. CALIBRATION
5.2.1. Depending upon accuracy requirement, calibration can be achieved with slip gauges, micrometer or vernier callipers. In our instructions
example the micrometer is suggested, which has similar accuracy to the dial gauge.
5.2.2. Set the micrometer (50mm-75mm) to the target size "x", for example Ø63.50 and lock. In our example the tolerance required is H9 from
BS 4500:1969 (+.074/-0).
5.2.3. From instruction 5.1.2 and the tables on the back page; parts required are the anvil 60 plus spacer ring 30 or 40, from item 5 in fig.1.
Assemble as shown above.
5.2.4. Manoeuvre the gauge anvil and nib inside the measuring gap of the micrometer (fig.11). This activity could be eased by assistance or
carefully clamping the micrometer with toolmakers clamps on to an angle plate.
5.2.5. Observe the large dial pointer movement. It is essential that the axis of the gauge anvil and spring loaded nib are centralised in the
micrometer measuring faces. It is essential to observe the total sweep of the dial pointer using the small dial. Remember from the initial
setting the pointer had rotated one full cycle.
5.2.6. When satisfied with alignment, hold the position and rotate the dial bezel until the "0" [zero] aligns with the pointer. Lock the bezel with
the thumb screw. Your dial bore gauge has now been calibrated for use in a Ø63.00 to Ø64.00 bore ie +/-0.5mm of target.
5.2.7. The tolerance band can now be set using the two "markers" on the bezel. Our example states the tolerance band to be +0.074 to -0. Set
one marker opposite and in line with "0" [zero] (fig.6) and the other +7.4 (fig.7) divisions apart. Note! the larger the deflection the smaller
the bore.
Nib
Anvil
Without spacer
(1mm)
(2mm)
(3mm)
(4mm)
Use the spacer rings to achieve "x" = 51,52,53,54,56 etc..
Spacer ring for
intermediate sizes
Distance
piece
(50mm)
Insert the stylus for 1 full large pointer revolution
g.5
g.4
g.3
g.2
g.1
Small pointer on "1"
Pass Pass Fail
Fail
Fail
Fail
Tolerance markers
g.6 g.7
Example for reference only
Bezel clamping screw.
Please note the
tolerance markers will
not pass the screw when
clamped.
Be aware, nib projection is 2mm.
Aim for 0.5mm to 1.5mm as the
measurement zone.
With spacer
With spacer and distance piece

DBG5010 Issue: 2 (H,F) - 04/04/19
Original Language Version
© Jack Sealey Limited
5.3. ACCURATE MEASUREMENT
5.3.1. Follow procedure 5.1.1 through 5.1.4.
5.3.2. The bore or gap machined finish must be clean with surface texture 3.2µm to 6.4µm or better than for fiducial indication.
5.3.3. Offer the anvil end into the bore slightly tilted (fig.8) with the sprung loaded carriage entering just ahead of the anvil tip. Rock the dial
gauge tube to the upright position (fig.9) and beyond, observing the pointer sweep. The three point location offered by the two skids on
the spring loaded carriage and the anvil tip will centralise the head.
5.3.4. Rotate the bezel such that the "0" [zero] aligns with the largest sweep position of the pointer (fig.10). It is essential to observe the total
sweep of the dial pointer using the small dial. Remember from the initial setting the pointer had rotated one full cycle. Mark the position
on the component of where the measurement was taken, if required.
5.3.5. With a micrometer, measure across the anvil and the nib (fig.11), rotate the barrel of the micrometer until the dial pointer aligns with the
same "0" [zero] as the measured bore. Take the reading from the micrometer and record.
5.3.6. With the bore dial gauge now set, the bore can now be measured for taper and ovality by reference back to the initial datum "0" [zero]
reading and counting the 0.01mm divisions between datum and new. Note! the larger the deflection the smaller the bore.
g.8
g.10
g.9
g.9
g.11
"Offer the anvil end into the bore slightly tilted...."
"Rock the dial gauge tube to the upright position....."
"Rotate the bezel such that the
"0" [zero] aligns....."
"With a micrometer, measure across the anvil and the nib......"
6. MAINTENANCE
6.1. Keep all components dry and clean with a soft micro fibre cloth.
6.2. Return all items to the presentation case after use.
6.3. Store indoors in a temperature controlled dry environment, circa 21°C.
6.4. This is a precision instrument intended for use by engineers and engineering inspectors, keep out of reach of children.
Component
Component

DBG5010 Issue: 2 (H,F) - 04/04/19
Original Language Version
© Jack Sealey Limited
"x" Anvil size Spacer ring
49.5-50.5 50 No
50.5-51.5 50 1x1mm(10)
51.5-52.5 50 1x2mm(20)
52.5-53.5 50 1x3mm(30)
53.5-54.5 50 1x4mm(40)
54.5-55.5 55 No
55.5-56.5 55 1x1mm
56.5-57.5 55 1x2mm
57.5-58.5 55 1x3mm
58.5-59.5 55 1x4mm
59.5-60.5 60 No
60.5-61.5 60 1x1mm
61.5-62.5 60 1x2mm
62.5-63.5 60 1x3mm
63.5-64.5 60 1x4mm
64.5-65.5 65 No
65.5-66.5 65 1x1mm
66.5-67.5 65 1x2mm
67.5-68.5 65 1x3mm
68.5-69.5 65 1x4mm
"x" Anvil size Spacer ring
94.5-95.5 95 No
95.5-96.5 95 1x1mm
96.5-97.5 95 1x2mm
97.5-98.5 95 1x3mm
98.5-99.5 95 1x4mm
99.5 - 100.5 100 No
100.5-101.5 100 1x1mm
101.5-102.5 100 1x2mm
102.5-103.5 100 1x3mm
103.5-104.5 100 1x4mm
104.5-105.5 105 No
105.5-106.5 105 1x1mm
106.5-107.5 105 1x2mm
107.5-108.5 105 1x3mm
108.5-109.5 105 1x4mm
109.5-110.5 110 No
110.5-111.5 110 1x1mm
111.5-112.5 110 1x2mm
112.5-113.5 110 1x3mm
113.5-114.5 110 1x4mm
"x" Anvil size Spacer ring
69.5-70.5 70 No
70.5-71.5 70 1x1mm
71.5-72.5 70 1x2mm
72.5-73.5 70 1x3mm
73.5-74.5 70 1x4mm
74.5-75.5 75 No
75.5-76.5 75 1x1mm
76.5-77.5 75 1x2mm
77.5-78.5 75 1x3mm
78.5-79.5 75 1x4mm
79.5-80.5 80 No
80.5-81.5 80 1x1mm
81.5-82.5 80 1x2mm
82.5-83.5 80 1x3mm
83.5-84.5 80 1x4mm
84.5-85.5 85 No
85.5-86.5 85 1x1mm
86.5-87.5 85 1x2mm
87.5-88.5 85 1x3mm
88.5-89.5 85 1x4mm
89.5-90.5 90 No
90.5-91.5 90 1x1mm
91.5-92.5 90 1x2mm
92.5-93.5 90 1x3mm
93.5-94.5 90 1x4mm
"x" Anvil size Spacer ring Distance piece
114.5-115.5 65 No Yes
115.5-116.5 65 1x1mm Yes
116.5-117.5 65 1x2mm Yes
117.5-118.5 65 1x3mm Yes
118.5-119.5 65 1x4mm Yes
119.5-120.5 70 No Yes
120.5-121.5 70 1x1mm Yes
121.5-122.5 70 1x2mm Yes
122.5-123.5 70 1x3mm Yes
123.5-124.5 70 1x4mm Yes
124.5-125.5 75 No Yes
125.5-126.5 75 1x1mm Yes
126.5-127.5 75 1x2mm Yes
127.5-128.5 75 1x3mm Yes
128.5-129.5 75 1x4mm Yes
129.5-130.5 80 No Yes
130.5-131.5 80 1x1mm Yes
131.5-132.5 80 1x2mm Yes
132.5-133.5 80 1x3mm Yes
133.5-134.5 80 1x4mm Yes
134.5-135.5 85 No Yes
135.5-136.5 85 1x1mm Yes
136.5-137.5 85 1x2mm Yes
137.5-138.5 85 1x3mm Yes
138.5-139.5 85 1x4mm Yes
"x" Anvil size Spacer ring Distance piece
139.5-140.5 90 No Yes
140.5-141.5 90 1x1mm Yes
141.5-142.5 90 1x2mm Yes
142.5-143.5 90 1x3mm Yes
143.5-144.5 90 1x4mm Yes
144.5-145.5 95 No Yes
145.5-146.5 95 1x1mm Yes
146.5-147.5 95 1x2mm Yes
147.5-148.5 95 1x3mm Yes
148.5-149.5 95 1x4mm Yes
149.5-150.5 100 No Yes
150.5-151.5 100 1x1mm Yes
151.5-152.5 100 1x2mm Yes
152.5-153.5 100 1x3mm Yes
153.5-154.5 100 1x4mm Yes
154.5-155.5 105 No Yes
155.5-156.5 105 1x1mm Yes
156.5-157.5 105 1x2mm Yes
157.5-158.5 105 1x3mm Yes
158.5-159.5 105 1x4mm Yes
159.5-160.5 110 No Yes
160.5-161.5 110 1x1mm Yes
161.5-162.5 110 1x2mm Yes
162.5-163.5 110 1x3mm Yes
163.5-164.5 110 1x4mm Yes
Guide to Parts required versus measured size. (1mm graduations)
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534 [e-mail] www.sealey.co.uk
Note: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without
prior notice.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.
ENVIRONMENT PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to
a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely
unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids
according to local regulations.