Screw Drivers
Screw Drivers are one of the most common tools a small engine technician will be using. Some basic usage rules are as followed.
-Always clean the slots on screws
-Always hold screw driver at 90*
-Make sure screwdriver is the right size and fits tightly
-Exert more pressure when using non standard tips
-Never use a screwdriver to remove metal, punch, or pry
-Never use a hammer on the handle of a screw driver
-Never use a screw driver on an object you are holding. Always secure the object with a clamp or vise.
An Impact screw driver is a tool that when struck with a hammer produces a twisting motion. used to remove very tight screws.
A Flat or Standard Tip - A Standard Screw Driver - A Philips Screw Driver - A Robertson (Square) Screw Driver
-Always clean the slots on screws
-Always hold screw driver at 90*
-Make sure screwdriver is the right size and fits tightly
-Exert more pressure when using non standard tips
-Never use a screwdriver to remove metal, punch, or pry
-Never use a hammer on the handle of a screw driver
-Never use a screw driver on an object you are holding. Always secure the object with a clamp or vise.
An Impact screw driver is a tool that when struck with a hammer produces a twisting motion. used to remove very tight screws.
A Flat or Standard Tip - A Standard Screw Driver - A Philips Screw Driver - A Robertson (Square) Screw Driver
wrenches and sockets
Wrench - Used to loosen and tighten nuts and bolts. Size is referring to width of opening.
Open End = Only contacts side of nut / bolt. Often has different sizes on each end.
Box end = Prevents slipping. Fits completely around nut / bolt. Often different size on each end.
Combination = Features an open end, and a box end on the same unit. Same size on both ends. (most common today)
Adjustable = Can fit many sizes. Does not grip as well. often slips and can round off and wear out nuts / bolts.
Box end wrenches (and sockets) are available in two styles
Six Point - Provides better support and strength = better for very tight bolts. Can only be used in 6 positions.
12-Point - Thinner head Is better for tight places. Can grab bolt in 12 positions and requires less swing to use. Not for tight bolts.
Allen + Hex wrench - Six sided. usually features a 90* right angle to form a handle.
Torx Wrench - Star shaped. Can handle more torque before slipping.
Open End = Only contacts side of nut / bolt. Often has different sizes on each end.
Box end = Prevents slipping. Fits completely around nut / bolt. Often different size on each end.
Combination = Features an open end, and a box end on the same unit. Same size on both ends. (most common today)
Adjustable = Can fit many sizes. Does not grip as well. often slips and can round off and wear out nuts / bolts.
Box end wrenches (and sockets) are available in two styles
Six Point - Provides better support and strength = better for very tight bolts. Can only be used in 6 positions.
12-Point - Thinner head Is better for tight places. Can grab bolt in 12 positions and requires less swing to use. Not for tight bolts.
Allen + Hex wrench - Six sided. usually features a 90* right angle to form a handle.
Torx Wrench - Star shaped. Can handle more torque before slipping.
Allen + Hex wrench - Six sided. usually features a 90* right angle to form a handle.
Torx Wrench - Star shaped. Can handle more torque before slipping.
Torx Wrench - Star shaped. Can handle more torque before slipping.
Socket Wrenches - Usually manufactured in sets of graduated sizes. Snap into a handle. Safer and faster to use than open end, or box end wrenches. Can be used with various handle devices.
Reversible Ratchet - This is the most common handle for sockets. Has a shift lever to change direction. The ratcheting mechanism can be damaged if to much force is applied.
Breaker Bar - This bar has a drive for a socket fixed on its end. Does not ratchet. These can withstand more force and are recomended for tighter bolts.
Torque Wrench - A Special tool that features a dial or scale that indicates the amount of torque applied to a fastener. Normally measured in ft-lbs. This is used where exact specifications are required when tightening a bolt.
Extension Bars are used to reach bolts that are tucked away, But are to be avoided unless necessary for safety measures.
Reversible Ratchet - This is the most common handle for sockets. Has a shift lever to change direction. The ratcheting mechanism can be damaged if to much force is applied.
Breaker Bar - This bar has a drive for a socket fixed on its end. Does not ratchet. These can withstand more force and are recomended for tighter bolts.
Torque Wrench - A Special tool that features a dial or scale that indicates the amount of torque applied to a fastener. Normally measured in ft-lbs. This is used where exact specifications are required when tightening a bolt.
Extension Bars are used to reach bolts that are tucked away, But are to be avoided unless necessary for safety measures.
Pliers
Combination - used to hold parts, or to twist / bend materials. Feature a slip joint to allow jaws to open for wide or large items
Vise Grips - Locking Pliers. These lock into position to keep both hands free to work.
Long + Needle nose - Useful for gripping or twisting small parts. Good for reaching tighter areas. Needle nose pliers are smaller and thinner. Both can easily be damaged if used for heavy work.
Snap Ring Pliers - To grip/spread snap rings. Used to Install and remove snap rings. Two types
Internal Snap Ring Pliers - Jaws come together when handle is squeezed. This type of snap ring is used to contain components inside a hollow shaft.
External Snap Ring Pliers - Jaws spread apart when handle is squeezed. This type of snap ring fits inside a groove machined on the outside of a shaft.
Vise Grips - Locking Pliers. These lock into position to keep both hands free to work.
Long + Needle nose - Useful for gripping or twisting small parts. Good for reaching tighter areas. Needle nose pliers are smaller and thinner. Both can easily be damaged if used for heavy work.
Snap Ring Pliers - To grip/spread snap rings. Used to Install and remove snap rings. Two types
Internal Snap Ring Pliers - Jaws come together when handle is squeezed. This type of snap ring is used to contain components inside a hollow shaft.
External Snap Ring Pliers - Jaws spread apart when handle is squeezed. This type of snap ring fits inside a groove machined on the outside of a shaft.
Ball Peen Hammer - One Side is flat. The other side is rounded. Flat side can be used for normal hammering. Ball side can be used to round off rivets.
Soft faced Hammer - Made of brass, plastic, or rubber.
When Using hammers:
-Make sure head is secure
-Grip near end of the handle
-Wear safety glasses.
Soft faced Hammer - Made of brass, plastic, or rubber.
When Using hammers:
-Make sure head is secure
-Grip near end of the handle
-Wear safety glasses.
Punches - Used to make indentations in metal, or to push pins.
Center Punch - Used to mark the center of holes to be drilled. This prevents wandering of drill bit.
Starting + Pin Punch - Used to remove pins / rivets. Starting punch is used to drive a pin part way out. Pin punch is used to drive the pin the rest of the way out.
Center Punch - Used to mark the center of holes to be drilled. This prevents wandering of drill bit.
Starting + Pin Punch - Used to remove pins / rivets. Starting punch is used to drive a pin part way out. Pin punch is used to drive the pin the rest of the way out.
Clamps and vises are used to hold work pieces stationary so that both hands can be used to work on the work piece.
C Clamp - this is a portable clamp.
Bench vise - Clamped or fixed to a work bench or table. A handle is used to open and close jaws that clamp items in place. Jaws are often made of a softer metal to prevent damage to item held in place.
C Clamp - this is a portable clamp.
Bench vise - Clamped or fixed to a work bench or table. A handle is used to open and close jaws that clamp items in place. Jaws are often made of a softer metal to prevent damage to item held in place.
Hack Saw
Hack Saw - is used to cut metal to heavy to be cut with snips. Most have an adjustable frame tightened with a wing nut.
Keyhole Saw - Often has a pistol style grip. Useful in tight / awkward spots where more blade control is required.
Harder and thicker materials should be cut with a courser hacksaw blade.
-Blade should be installed with teeth slanting forward.
-Make smooth even strokes. Only apply pressure going forward.
-All work pieces should be secured. Do not holding materials being cut.
Keyhole Saw - Often has a pistol style grip. Useful in tight / awkward spots where more blade control is required.
Harder and thicker materials should be cut with a courser hacksaw blade.
-Blade should be installed with teeth slanting forward.
-Make smooth even strokes. Only apply pressure going forward.
-All work pieces should be secured. Do not holding materials being cut.
Chisels
Cold Chisel - Used to cut or form metal. Can be used to cut sheet metal, rivet heads, or split frozen nuts. (All metal cutting chisels are considered cold chisels)
Cape Chisel - Used to make gouges in metal.
Flat Chisel - Used to cut bolts, screws, or shear metal.
Diamond Point Chisel - V-Shaped grooves. used to square corners or slots.
Round Nose Chisel - Cuts semicircular grooves. used for inside corners.
When using chisels keep in mind;
- Always clamp work piece
- Hold chisel at steep angle when cutting hard metal. Use a lower angle on soft metal
- Keep your eye on cutting edge
- Smaller shallow cuts are most accurate
- Produces paring cuts
- Wear safety glasses
- Quality chisels are heat treated for safety
- Striking side of chisel is made of softer metal to eliminate shattering
- Will often 'Mushroom' on strike side. When mushroom gets excessive, grind it smooth.
Cape Chisel - Used to make gouges in metal.
Flat Chisel - Used to cut bolts, screws, or shear metal.
Diamond Point Chisel - V-Shaped grooves. used to square corners or slots.
Round Nose Chisel - Cuts semicircular grooves. used for inside corners.
When using chisels keep in mind;
- Always clamp work piece
- Hold chisel at steep angle when cutting hard metal. Use a lower angle on soft metal
- Keep your eye on cutting edge
- Smaller shallow cuts are most accurate
- Produces paring cuts
- Wear safety glasses
- Quality chisels are heat treated for safety
- Striking side of chisel is made of softer metal to eliminate shattering
- Will often 'Mushroom' on strike side. When mushroom gets excessive, grind it smooth.
tap & die
Taps and Dies are used to cut threads into metal.
Tap - Cuts female threads (into a hole) used with a tap wrench
Die - Cuts male threads (like a screw or bolt) Used with a Die Stock
Taper Tap - has a pointed end
Plug Tap - Has only a slight taper.
Bottoming Tap - Has NO taper at all
Screw Extractor - Can be used to remove a screw with a sheared head.
Tap - Cuts female threads (into a hole) used with a tap wrench
Die - Cuts male threads (like a screw or bolt) Used with a Die Stock
Taper Tap - has a pointed end
Plug Tap - Has only a slight taper.
Bottoming Tap - Has NO taper at all
Screw Extractor - Can be used to remove a screw with a sheared head.
Files
File - A cutting tool that is used to smooth surfaces and edges. Classified by the file shape, type, and number of teeth.
Tang - This is where the handle attaches to the file
Heel - This is the base of the tang. The body of the file begins at the heel.
Face - Flat side with cutting teeth.
A Course file has a small number of larger teeth. A Smooth file has a larger number of teeth, and removes less metal per stroke. Always install a handle onto the tang. apply pressure on the forward stroke. Clean files with a file card.
Tang - This is where the handle attaches to the file
Heel - This is the base of the tang. The body of the file begins at the heel.
Face - Flat side with cutting teeth.
A Course file has a small number of larger teeth. A Smooth file has a larger number of teeth, and removes less metal per stroke. Always install a handle onto the tang. apply pressure on the forward stroke. Clean files with a file card.
specialty tools
Some specialty tools will be used in the small engine repair field. Some will be explained in more detail later.
Pullers - Used to remove gears, pulleys, fittings and such
Flywheel holder and Clutch Wrench - Flywheel holder holds flywheel stationary. Clutch wrench is used to remove starter clutch.
Flywheel Puller - A puller specifically for flywheels. Many manufacturers have special pullers for use only with their engines.
Cylinder Hone - Used to smooth out high / low spots inside a cylinder. Produces the required surface finish (Cross Hatch) Attached to a power drill.
Measuring tools such as Micrometer, Feeler Gauge, and Dial Caliper will also be used.
Pullers - Used to remove gears, pulleys, fittings and such
Flywheel holder and Clutch Wrench - Flywheel holder holds flywheel stationary. Clutch wrench is used to remove starter clutch.
Flywheel Puller - A puller specifically for flywheels. Many manufacturers have special pullers for use only with their engines.
Cylinder Hone - Used to smooth out high / low spots inside a cylinder. Produces the required surface finish (Cross Hatch) Attached to a power drill.
Measuring tools such as Micrometer, Feeler Gauge, and Dial Caliper will also be used.
Hand tool safety
500,000 Hand and finger injuries occur every year and are caused by improper hand tool use. These injuries include bruises, sprains, broken bones, cuts and punctures.
- Always use the correct tool for the job. Never force a tool to do a job it was not intended for
- Regularly inspect all hand tools for defects, and wear. Replace all worn or damaged tools
- Comply with tool manufacturers instructions for use
- Never throw a tool. Always pass tools from person to person by hand
- Disconnect tool when not is use and before servicing / cleaning
- Keep tools clean and lubricate any moving parts
- Keep cutting tools sharp. Sharpen or replace any dull bits / blades
- Always use the correct tool for the job. Never force a tool to do a job it was not intended for
- Regularly inspect all hand tools for defects, and wear. Replace all worn or damaged tools
- Comply with tool manufacturers instructions for use
- Never throw a tool. Always pass tools from person to person by hand
- Disconnect tool when not is use and before servicing / cleaning
- Keep tools clean and lubricate any moving parts
- Keep cutting tools sharp. Sharpen or replace any dull bits / blades
Power tools
Power Drill - Referring to the drill motor (handheld drill). Used to drive a drill but, or screw driver bit. A power drills size is designated by the size of the chuck. 1/4" - 1/2".
Drill Bit - (also called twist drill) is the part that bores through metal. The end of the bit is called the shank. The shank is inserted into the drills chuck. Drill at high RPM for smaller holes and use a lower RPM for larger holes. A drill designed for low RPM use will have a support handle to help the user manage the extra torque. Drill bits are made from round bars that have grooves cut into them. There are different bits for cutting metal, wood, plastic, and concrete. When drilling;
- Use only grounded equipment
- Find any obstructions before drilling a hole
- Select the correct bit suitable for the material you are cutting
- Do not force the tool or bit
- Use drill bit lubricant if required
- Ensure that bit is tight in the chuck. Do not leave chuck key in chuck
- Only use sharp bits. Dull bits are more likely to bind
- When drilling a large hole, drill a small hole initially and gradually increase the bit size until desired size is reached.
Drill Bit - (also called twist drill) is the part that bores through metal. The end of the bit is called the shank. The shank is inserted into the drills chuck. Drill at high RPM for smaller holes and use a lower RPM for larger holes. A drill designed for low RPM use will have a support handle to help the user manage the extra torque. Drill bits are made from round bars that have grooves cut into them. There are different bits for cutting metal, wood, plastic, and concrete. When drilling;
- Use only grounded equipment
- Find any obstructions before drilling a hole
- Select the correct bit suitable for the material you are cutting
- Do not force the tool or bit
- Use drill bit lubricant if required
- Ensure that bit is tight in the chuck. Do not leave chuck key in chuck
- Only use sharp bits. Dull bits are more likely to bind
- When drilling a large hole, drill a small hole initially and gradually increase the bit size until desired size is reached.
Drill Press - A floor standing, or bench mounted piece of equipment that can drill precise holes. Drill bit is held stationary so that it can drill exact angles and depths.
Bench Grinder - Usually has two rotating wheels. Can have an abrasive grinding wheel, or a wire brush wheel (or both). Can be used to sharpen and smooth / polish metal. Removes rust.
Valve Face Grinder - This is used to cut engine intake and exhaust valves during engine rebuilding. Will be explained in more detail later.
Power tool safety
Electric Power Tools have three primary risks. Electrical charge, High speed movement and Momentum.
Electrical Charge - When working with electric tools, electric shock is a risk.
- Use portable Ground Fault Circuit Interrupters (GFCI) when ever possible
- Visually inspect all cords, plugs, and receptacles daily
- Always unplug tools when replacing blades, bits or grinder wheels and when servicing or cleaning.
- Never operate electric power tools in wet or damp locations
- Wear gloves. If you feel a shock or tingle discontinue use immediately.
- Use extension cords that are rated for the required current draw for the tool. Undersized cords, or to many extension cords will reduce voltage to the tool. This will affect power and performance of the tool, and risk damaging it. This can also over heat and burn the extension cord.
Electrical Charge - When working with electric tools, electric shock is a risk.
- Use portable Ground Fault Circuit Interrupters (GFCI) when ever possible
- Visually inspect all cords, plugs, and receptacles daily
- Always unplug tools when replacing blades, bits or grinder wheels and when servicing or cleaning.
- Never operate electric power tools in wet or damp locations
- Wear gloves. If you feel a shock or tingle discontinue use immediately.
- Use extension cords that are rated for the required current draw for the tool. Undersized cords, or to many extension cords will reduce voltage to the tool. This will affect power and performance of the tool, and risk damaging it. This can also over heat and burn the extension cord.
High Speed Movement - Electric power tools can operate at high speeds.
- Avoid contact with rotating parts. Contact with rotating parts may grab, tear, or trap hands, clothing, or hair
- Keep all guards on tools in place
- Use extension cords rated for the current required for the tool. undersized, or to many extension cords will reduce the voltage delivered to equipment and will affect power and performance of tool. Low voltage also risks damaging the tool. Undersized cords may also overheat and burn.
- Avoid contact with rotating parts. Contact with rotating parts may grab, tear, or trap hands, clothing, or hair
- Keep all guards on tools in place
- Use extension cords rated for the current required for the tool. undersized, or to many extension cords will reduce the voltage delivered to equipment and will affect power and performance of tool. Low voltage also risks damaging the tool. Undersized cords may also overheat and burn.
Momentum - Electric tools have a lot of torque and can cause injury if they become out of control
- Use tools with constant pressure switches. Avoid lock on power switches
- Use only sharp cutting bits. Dull bits will jam frequently
- Clamp all work pieces tightly. Do NOT hold materials that are being worked on
- Wear appropriate Personal Protective Equipment (PPE)
- Inspect tools for potential mechanical failure such as broken drill bits / blades, faulty triggers. Ensure that alll guards are installed correctly
- Use tools with constant pressure switches. Avoid lock on power switches
- Use only sharp cutting bits. Dull bits will jam frequently
- Clamp all work pieces tightly. Do NOT hold materials that are being worked on
- Wear appropriate Personal Protective Equipment (PPE)
- Inspect tools for potential mechanical failure such as broken drill bits / blades, faulty triggers. Ensure that alll guards are installed correctly
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