Chapter 3

Hand Tools

Tools

Why should you invest in the best tool for the job?

1. Cheap tools break easily2. Cheap tools sometimes damage fasteners

(rounded bolts / nuts, stripped screws)3. Quality tools last longer, perform better, and

are less likely to damage fasteners4. Quality tools come with a lifetime warranty

Quality tools are made of high strength alloy steel and should be light and easy to use in tight quarters. A quality tool is slim and properly designed to fit your hand.

Tool Design

Quality Tools are heat treated, and the working surface is at a close tolerance, a 3/4 is a 3/4 sharp edges are removed, and tools are polished.

Tool Quality

Tech Tip: Keep your tools clean! A greasy or oily tool can decrease a technician’s performance and may slip causing injury to the technician.

When buying tools, you get what you pay for !

Tips to Remember

KEEP YOUR TOOLS CLEAN! Separate cutting tools Lightly oil any tool that might rust Delicate measuring tools- keep in protective

containers micrometers etc. Engrave your tools with Drivers license. Put Name & license Number on all tools

Major brands of Quality hand tools: Snap On, Snap On, Craftsman, Craftsman, S-K Wayne, S-K Wayne, Matco, Matco, Mac, Mac, HuskeyHuskeyProto, Proto, Master MechanicMaster MechanicNew BritainNew Britain

Tool Boxes

Three Main Parts of Tool Box Top Box

(for frequently used tools)(dividers help organize small tools)

Bottom Box (Roll-away)(for larger and heavier tools)

Side Box(for lighter bulkier tools)

When working in the shop

Always wear safety glasses or a full face shield

                   

Wrenches

Wrenches are a way to remove and replace bolts etc, but they are slow. Use only as a last resort. You should use air tools or ratchets if at all possible, because they are faster.

(Remember, pull with a wrench you have better control, if you do push, push with your palm open.)

Wrench Size

size is determined by width of jaw opening.

Slug Wrench

This is the only wrench designed to be used with a hammer.

Open End Wrench

Size is determined by the width of jaw opening. The open end is angled or offset by 15 degrees

at one end to help reach fasteners in tight spots.

Box-end wrenches are available in 6 or 12 point openings. Can be double offset or box offset 15 degrees for clearance for hand.

Comes in different lengths, each end is a different size, good wrench for breaking loose tight bolts

Box End Wrench

Combination Wrench

One end open, one end boxed both the same size can be different lengths

Tubing Wrench - (flare nut)

Box type wrench with section cut away. One end sometimes might be open like a combination wrench. Make sure you buy 6pt. – (12pt. are no good, they will slip)

Adjustable Open-End WrenchAKA “Crescent” Wrench

Not a replacement for all other wrenches. Try to always use the correct size wrench. This wrench is usually used as a last resort, and tends to slip. Adjust jaws firmly. You should only put pressure on the fixed jaw.

Ignition Wrench

one end open, one end boxed or both ends open different size at each end

Socket Wrench

Sockets come in many sizes with different openings. 6 pt. & 12 pt. are the most common.

They are used to remove and install nuts and bolts. 8 pt or double square are used on square nuts. Square

(4 sided) sockets are also used in special applications

6 point 8 point 12 point

Drive size common to Automotive are 1/4, 3/8, 1/2, 3/4 - square hole

Shallow Sockets Chrome 12pt. & Impact 6pt.

Sockets

Deep Sockets chrome 12pt. & Impact 6pt.

Swivel sockets Impact or Wobbly sockets

crowfeet

Sockets

Extensionsused to extend reach of sockets

Universal Joint A “universal” is used to reach around obstructions.

Impact Standard

Sockets

Used to torque down lug nuts to the proper torque when using a impact wrench. The larger the shaft the more torque it will carry.

Torque Stix

Look up on the chart for your make and model or if you know the torque look on the chart and find the right torque stix

Torque Sticks

Socket Handles

ratchet - short and long

Swivel Head Ratchet

Socket handles

speed handle - and swivel speed handleused to rapidly spin a fastener off and on

flex handle or breaker bar long and short

sliding T bar

Torque wrenches

A torque wrench is a tool used to precisely set the torque or tightness of a fastener such as a nut or bolt.

Beam type

Dial type sometimes referred to as a Micrometer type or Click Type

Torque wrenches

Digital

Torque wrenches

Come in inch lbs and foot lbs Always look up tightening sequence Always look up the amount of Torque Recheck each fastener twice Pull with a steady pull, do not jerk Make sure threads are clean Remember that it takes more force to start a

fastener then to keep it turning.

Allen Wrenches

An Allen wrench is one type of wrench that connects to a specially made hex fastener

Screw drivers

A. Slotted

B. Pozi-Drive Phillips

C. Phillips

D. Torx

E. Allen / Hex

Screw driver Selection

Blade should fit the slot snugly and have good surface contact with no play

Screw drivers

Reed and Prince

clutch

Pozi-drive

Allen or Hex tip

Screw drivers

Scurlox or Square Drive

Torx

Screw drivers

Offset

Screw drivers

Screwdrivers are classed in size of shank such as 3/16, 1/4, 5/16, and length of shank such as 2", 4", 6". Some manufactures take length of shank and handle. Normally just the shank is measured.

Handles come in different shapes to get better torque on screw

Screw drivers

Never use a screwdriver as a pry bar or punch!Never use a screwdriver as a pry bar or punch! Some shanks are square so you may apply a

wrench If holding small object in hand do not run

screwdriver through hand, keep hand back! Screwdriver handles are not usually insulated

Screw Driver Use

Pliers

Used to grip various parts Combination slip joint pliers

Diagonal side cutters

Used for cutting soft metal

Pliers

Needle nose

Channel lock or Arc joint (Sears)

Snap-on calls them Adjustable Joint

Used to be called water pump pliers

Pliers

Linesman

Locking Pliers

Locking Pliers or Vise Grips(Brand Name)used to clamp and holdvarious parts

Needle Nose Locking Pliers or Vise Grips

Lock ring pliers

Pliers

Locking C-Clamp

Pliers

Snap Ring - Internal or External

Pliers

Spark Plug Boot Pliers

Pliers

Brake pliers

Hose clamp pliers

Pliers

Robo Grip

Pliers

Pinch off hose pliers

Pliers

Wire Strippers and Crimpers

Hammers

Claw Hammer -

this is Auto shop, not Wood shop

Hammers

Claw Hammer - this is Auto shop, not Wood shop Ball Peen Hammer - general purpose hammer most

commonly used by technicians Sledge Hammer – for heavy pounding Rubber Mallet – used for hub cap installation

More Hammers

Brass Hammers - (middle one) used to prevent damage to mild steel parts

Plastic Tipped – also used to prevent damage to softer parts Some have replaceable tips in several different types of materials

Dead Blow Hammer

A dead blow hammer is a specialized mallet helpful in minimizing damage to the struck surface and in controlling striking force with minimal rebound from the striking surface. The head of these hammers are commonly hollow and filled with sand or shot, which absorbs the impact of a strike, reducing the bounce-back. - Wikipedia

Hammers

Lead Hammers not used much any more Raw hide Hammers not used much any more(good in their day, but have been replaced by newer styles)

These have been replaced by dead blow and plastic tip hammers

Safety Tips on Hammer use

1. Strike face of hammer head squarely 2. Make sure head is secure on hammer

handle (Hammer Head is wedged on in both directions)

3. Never swing hammer in the direction that someone is standing

4. Keep handle clean and dry 5. Keep punch and chisel ends from

mushrooming by periodic grinding

Chisels & Punches

Punches

Round Nose Cape Chisel Cape Chisel Cold Chisel Center Punch Tapered Starting Punch Drift or Roll Pin Punch

Punches

Aligning punch sometimes called a Long Taper or Line-up punchused to line up holes in parts for assembly

Center punch - use before drilling or to mark metal

Chisels

Used to cut off damaged parts or fasteners

Flat Cold chisel: most common, A technician must always wear safety glasses and be sure the cutting edge is sharp. The striking surface or top of chisel should not be mushroomed, it should be smooth with a slight taper.

Punches

To sharpen, remove mushroom, or true Punches and chisels:

Hold at proper angles and dip often in water, DO NOT let them turn blue

Mushroomed Chisels

Brass Drift Punch Set

More…

Files

Are used when a small amount of material needs to be removed (usually metal)

Coarse File – Double Cut – has large cutting grooves, for removing material faster

Smooth File –Single cut – removes small amounts of metal and leaves a smoother finish

Mill Bastard - really coarse cutting grooves for maximum cutting power

The number of cuts and the size of the cuts determines the coarseness of the file

Files

Single cut - rows of teeth run in one direction Double cut - teeth run at an angle to each other

Shapes of files

flat, square, round or rat tail, half round, knife edge, 3-square or triangular, point file

Use a coarse file for soft metal, it prevents clogging

File card

Files

(3) Tech Tips:(3) Tech Tips:1. Always use a file handle1. Always use a file handle2. Use chalk to get rid of oil on a file2. Use chalk to get rid of oil on a file3. Use a file card or wire brush to clean a file 3. Use a file card or wire brush to clean a file

Rotary files

good for blind holes where a lot of material must be removed wear safety glasses

Hack saws

used to cut metal

close quarter Hack saws

Blade length 8, 10, 12, Semi-flexible blades, High speed blades.

Teeth on hack saw go forward Need at least two teeth on metal Teeth per inch (T.P.I.) 14 T.P.I. Large pieces of soft steel 18 T.P.I Large pieces of hard tool steel 24 T.P.I. Cooper brass, Light angle Iron

Tubing, sheet metal 32 T.P.I. Thin sheet metal and thin tubing Hold the hacksaw with both hands

Hack Saws - Blades

Hole saw

Used to cut round holes in thin metal or wood or plastic

Holding Tools - Vise

A vise is primarily used to hold parts during drilling, cutting, or thread repairing operations.

A vise should never be A vise should never be hammered on for any hammered on for any reason. A vise is not an reason. A vise is not an anvil!anvil!

Holding Tools – C-clamp

C-clamps hold parts on a work surface while:

Drilling Filing Cutting Welding Or other operations

Cleaning Tools

Q: Why is dirt an enemy of the automobile?

A: One grain of sand can cause a major breakdown by clogging a passage or scarring a part.

Examples of Cleaning Tools:Scraper: removes gaskets, grease, sludge, and carbon from parts.Wire Brush: Used to remove light rust and baked-on dirt from automotive parts.Solvent Tank: Used with a brush to clean oil and grease from parts.Wire Knot Brush: Used with a drill to remove gaskets, carbon, and rust deposits.

Probe & Pickup ToolsProbe & Pickup Tools

Telescoping Inspection Mirrors

Inspection mirrors allow technicians to see behind objects and in difficult to see locations.

Pick up tools

Heavy duty TelescopingMagnetic Pick-up Tool:

For picking up heavy iron or steel objects, like dropped

nuts, bolts, and tools

Mechanical FingersPick-up Tool:

For picking up light non-magnetic objects

Standard TelescopingMagnetic Pick-up Tool:

For picking up lighter iron or steel objects, like dropped

nuts and bolts

Pry-Bars

Heavy Duty Pry-Bars

Rolling Head Pry-Bars

Door Panel Trim Pry-Tool

Pry-Bars

WEAR EYE PROTECTION!WEAR EYE PROTECTION!Extreme care must be usedwhen operating a pry-bar toavoid damaging parts, do not apply excessive force

on fragile components.

Twist Drill Bits

Fractional inch size 1/16,1/4, 3/8, 7/16, ½ Letter Size A-Z Number Size 1-80

Left hand drill bits cut when going in Reverse (usually for broken bolt extraction)

Twist Drill Bits

Twist Drill Bits

Types of materials - carbon steel – Cheap drill bit

- high speed steel (HSS) better - Titanium & Cobalt best

Shanks - straight - turned down - tapered All Drill Bits must be sharp

Drill Motors

Common sizes 1/4, 3/8, ½ refers to size of chuck or how big of drill bit it will hold.

Center punch before drilling, keeps drill from wandering

Use cutting oil except on sheet metal and cast iron.

Corded and cordless Some have keyless chucks

Drill, Keyless chuck

Drill Motor

Safety Hints

1. Firm grip on the drill 2. Always unplug drill before removing or

installing drill bit 3. Don't wear loose clothing 4. Secure the work firmly (C-clamp or vise) 5. Wear safety glasses 6. Make sure drill is properly grounded 7. To avoid electric shock, do not stand on wet

surfaces when using power tools

Tap & Dies

Taps are used to cut internal threads

Taper - first 6-8 threads are Chamfered Plug - first 3-5 threads are Chamfered Bottoming have threads all the way to the

Bottom - Does not start well

Types of taps

Taps

Know these terms;Tap drilldrill bit that drills a hole the proper size for threads to be cut when using a tap (slightly smaller than thread size).

Clearance Drilldrill bit that will drill a hole the size needed to insert bolt with out threading it.

Taps

Refer to the tap drill size chart

Tap wrench

Die Stock

Dies

Dies are used to cut external threads on stock or bolts

Finding the right size Tap or Die Use a Thread pitch gaugeNational Coarse National FineNC NF½ x 13 ½ x 20 ½ size of bolt13 teeth per inch 20 teeth per inch

Tap & Dies

Thread pitch gauge

Used to find how many threads in an inch come in metric and standard

Tap and Die rules

Use cutting oil when using Taps and Dies Keep Tap square with hole Keep backing off Tap to break chips off (1 turn in

1/2 turn back Keep Taps and Dies clean and lightly oiled Keep Taps in storage box separate from others

so you will not damage the cutting edge Make sure all the tools are in the box when you

return it to the tool room

Thread chasers and thread files should be used only to repair damaged threads

Tap & Dies

Screw Extractors

For removing broken screws and studs first center punch broken bolt, lube with W.D.

40 to loosen bolt, drill out with largest size drill with out damaging threads all the way through, then insert screw extractor

square shank - hit with hammer spiral - will twist in and grab

Thread repair

Heli Coil EZ-LOK

Solder Guns

Soldering

If solder gun does not work do these three things 1. Tighten the nuts, the screw or Allen set screw

on the soldering tip. (do not over tighten as it gets hot then cold it will expand then contract these will always come lose)

2. Clean and sand the tip of the solder gun 3. tin the tip of the solder gun

Types of Solder

Rosin core - wiring Acid core - radiators

Pullers

Two jaw

Three jaw

Pullers

Steering wheel Harmonic balance puller

Pullers

Slide hammer and attachments

Hones

wheel cylinder (Drum Brake) disc brake caliper glaze breaker cylinder hones

Ring Compressor

ring compressors

Ring Expander

ring expander

Valve Spring Compressor

valve spring compressors

Brake spoon & Spanner wrench

brake spoons

spanner wrench

Tin snips / Straight Tinner Snips

Offset model aviation snips

Left cut model - for cutting straight and tight left curves Right cut model - for cutting straight and tight right curves Straight cut model - for cutting straight and mild curves both left and right

bushing drivers

bearing packer

Bushing driver & Bearing Packer

Grease Gun

Grease Gun

Seal pullers Seal installers

Seal Puller & Installer

Hand Impact

Used to remove stubborn screws

insert right size bit turn in direction you want to go and strike with a hammer.

Measuring tools

feeler gauge - flat

round or wire

Measuring tools

Feeler gauge flat & round

Measuring tools Calipers

Outside Inside

Dial

Dial indicator

Straight edge - .003 max (not shown)

Telescoping gauge

Small hole gauge

Measuring tools

Micrometer

name of parts reading mikes

Inside micrometer

See power point on micrometers

Test Light

Use to test for power or ground

Power Probe III

Use to test for power or ground and more

Questions?Questions?

Check the textbook chapter 3 for any questions you still need answered.

Check with at least three other students to try and find the answers you are missing.

Finally, Check with the instructor to learn where to go to find the answers you still need.

Still have questions?Still have questions? ContactContact

Mr. Vance Bloom at Mr. Vance Bloom at vbloom@hemetusd.k12.ca.us

Or Mr. Ed Kessel at Or Mr. Ed Kessel at ekessel@hemetusd.k12.ca.us