Sealey DBG5011 User manual

 WARNING! Ensure Health and Safety, local authority and general workshop practice regualations 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).
INSTRUCTIONS FOR:
DIAL BORE GAUGE
MODEL NO: DBG5011
1. SAFETY
DBG5011 Issue: 1 - 23/06/15
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 1mm with an accuracy of 0.01mm. Included with the bore gauge are; probe body, dial
indicator, anvils, spacer rings. Supplied in wooden storage case. .
3. SPECIFICATION
Model No: ............................................................................DBG5011
Measuring Range: .............................................................160-250mm
Maximum Deviation Measurement (dial bore gauge): .................1mm
Maximum Deviation Measurement (dial gauge separate): ..........5mm
Dial Bezel Diameter:................................................................Ø55mm
Resolution:...............................................................0.01mm (0.0004")
4. CONTENTS
4.1. There are 5 main components-:
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

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 160mm and 250mm nominally with this tool. (Up to 255.5 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. Two complete cycles 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 "2" [two].
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 (150mm-175mm) to the target size "x", for example Ø163.50 and lock. In our example the tolerance required is H9
from BS 4500:1969 (+0.100/-0).
5.2.3. From instruction 5.1.2 and the tables on the back page; parts required are the anvil 160 plus spacer ring 30 or 40, from item 5 in fig.1.
Assemble as shown above in fig.2.
5.2.4. Maneouvre the gauge anvil and nib inside the measuring gap of the micrometer (fig.8). This activity could be eased by assistance or
carefully clamping the dial bore gauge in a retort stand for example.
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 two full cycles.
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 Ø163.00 to Ø164.00 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 +0.100 to -0. Set
one marker opposite and in line with "0" [zero] (fig.6) and the other +10 (fig.7) divisions apart. Note! the larger the deflection the smaller
the bore.
Nib
Anvil
Without spacer and distance piece
Use the spacer rings to achieve "x" = 161,162,163,164,166 etc..
Use the distance piece to achieve "x" = 210 and up to 255 nominally
Insert the stylus for 2 full large pointer CW revolutions
g.5
g.4
g.2
g.1 Small pointer on "2"
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.
DBG5011 Issue: 1 - 23/06/15
Original Language Version
© Jack Sealey Limited
With 50mm
distance piece

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 and example fig.10) with the sprung loaded carriage entering just ahead of the anvil
tip. Rock the dial gauge tube to the upright position (example fig.11) and beyond, observing the pointer sweep. The three point location
offered by the two guides on the spring loaded carriage and the anvil tip will centralise the head (fig.8).
5.3.4. Rotate the bezel such that the "0" [zero] aligns with the largest sweep position of the pointer (fig.9).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 two full cycles. 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.8), 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.
"Offer the anvil end into the bore slightly tilted...." "Rock the dial gauge tube to the upright position....."
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.
DBG5011 Issue: 1 - 23/06/15
Original Language Version
© Jack Sealey Limited
2.5mm approx
nib projection
1mm measurement zone g.9
g.8
g.10 generic g.11 generic
Component
example only
Component
example only
Be aware, nib projection is
2.5mm. Aim for 0.75mm to
2.25mm as the
measurement zone.
A support method when setting with a micrometer

Environmental 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.
Parts support is available for this product. To obtain a parts listing and/or diagram,
please log on to www.sealey.co.uk, email [e-mail] or telephone [phone].
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 will be required for any claim.
01284 757500
01284 703534
[e-mail]
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
www.sealey.co.uk
"x" Anvil size Spacer ring
159.5-160.5 160 No
160.5-161.5 160 1x1mm(10)
161.5-162.5 160 1x2mm(20)
162.5-163.5 160 1x3mm(30)
163.5-164.5 160 1x4mm(40)
164.5-165.5 165 No
165.5-166.5 165 1x1mm
166.5-167.5 165 1x2mm
167.5-168.5 165 1x3mm
168.5-169.5 165 1x4mm
169.5-170.5 170 No
170.5-171.5 170 1x1mm
171.5-172.5 170 1x2mm
172.5-173.5 170 1x3mm
173.5-174.5 170 1x4mm
174.5-175.5 175 No
175.5-176.5 175 1x1mm
176.5-177.5 175 1x2mm
177.5-178.5 175 1x3mm
178.5-179.5 175 1x4mm
"x" Anvil size Spacer ring
199.5 - 200.5 200 No
200.5-201.5 200 1x1mm
201.5-202.5 200 1x2mm
202.5-203.5 200 1x3mm
203.5-204.5 200 1x4mm
204.5-205.5 205 No
205.5-206.5 205 1x1mm
206.5-207.5 205 1x2mm
207.5-208.5 205 1x3mm
208.5-209.5 205 1x4mm
"x" Anvil size Spacer ring
179.5-180.5 180 No
180.5-181.5 180 1x1mm
181.5-182.5 180 1x2mm
182.5-183.5 180 1x3mm
183.5-184.5 180 1x4mm
184.5-185.5 185 No
185.5-186.5 185 1x1mm
186.5-187.5 185 1x2mm
187.5-188.5 185 1x3mm
188.5-189.5 185 1x4mm
189.5-190.5 190 No
190.5-191.5 190 1x1mm
191.5-192.5 190 1x2mm
192.5-193.5 190 1x3mm
193.5-194.5 190 1x4mm
194.5-195.5 195 No
195.5-196.5 195 1x1mm
196.5-197.5 195 1x2mm
197.5-198.5 195 1x3mm
198.5-199.5 195 1x4mm
"x" Anvil size Spacer ring Distance piece
209.5-210.5 160 No Yes
210.5-211.5 160 1x1mm Yes
211.5-212.5 160 1x2mm Yes
212.5-213.5 160 1x3mm Yes
213.5-214.5 160 1x4mm Yes
214.5-215.5 165 No Yes
215.5-216.5 165 1x1mm Yes
216.5-217.5 165 1x2mm Yes
217.5-218.5 165 1x3mm Yes
218.5-219.5 165 1x4mm Yes
219.5-220.5 170 No Yes
220.5-221.5 170 1x1mm Yes
221.5-222.5 170 1x2mm Yes
222.5-223.5 170 1x3mm Yes
223.5-224.5 170 1x4mm Yes
224.5-225.5 175 No Yes
225.5-226.5 175 1x1mm Yes
226.5-227.5 175 1x2mm Yes
227.5-228.5 175 1x3mm Yes
228.5-229.5 175 1x4mm Yes
229.5-230.5 180 No Yes
230.5-231.5 180 1x1mm Yes
231.5-232.5 180 1x2mm Yes
232.5-233.5 180 1x3mm Yes
233.5-234.5 180 1x4mm Yes
"x" Anvil size Spacer ring Distance piece
234.5-235.5 185 No Yes
235.5-236.5 185 1x1mm Yes
236.5-237.5 185 1x2mm Yes
237.5-238.5 185 1x3mm Yes
238.5-239.5 185 1x4mm Yes
239.5-240.5 190 No Yes
240.5-241.5 190 1x1mm Yes
241.5-242.5 190 1x2mm Yes
242.5-243.5 190 1x3mm Yes
243.5-244.5 190 1x4mm Yes
244.5-245.5 195 No Yes
245.5-246.5 195 1x1mm Yes
246.5-247.5 195 1x2mm Yes
247.5-248.5 195 1x3mm Yes
248.5-249.5 195 1x4mm Yes
249.5-250.5 200 No Yes
250.5-251.5 200 1x1mm Yes
251.5-252.5 200 1x2mm Yes
252.5-253.5 200 1x3mm Yes
253.5-254.5 200 1x4mm Yes
254.5-255.5 205 No Yes
255.5-256.5 205 1x1mm Yes
256.5-257.5 205 1x2mm Yes
257.5-258.5 205 1x3mm Yes
258.5-259.5 205 1x4mm Yes
Guide to Parts required versus measured size. (1mm graduations)
DBG5011 Issue: 1 - 23/06/15
Original Language Version
© Jack Sealey Limited