CHAPTER 3 © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT for SALE OR DISTRIBUTION NOT for SALE OR DISTRIBUTION

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION CHAPTER 3 © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 56 3/12/14 9:35 PM © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Care and Use of Tools © Jones & Bartlett Learning, LLC © Jones & Bartlett3 Learning, LLC ApplicableNOT FOR SALE OR to DISTRIBUTION the TradeNOT FOR SALE OR DISTRIBUTION

Primary Learning Objectives © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALEAfter reading OR DISTRIBUTIONthis chapter, you will be able to: NOT FOR SALE OR DISTRIBUTION 1. Discuss the purpose and application of gauges and meters. (pp. 61–68, 87–90) 2. Discuss the purpose and application of air-powered tools. (pp. 70–71) 3. Discuss the purpose and application of hand tools. (pp. 71–87) 4. Discuss the purpose© Jones and application & Bartlett of electric Learning, tools and equipment.LLC (pp. 68–70, 93–99)© Jones & Bartlett Learning, LLC 5. Discuss the purpose and application of lifting and supporting equipment. (pp. 99–100) NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

Knowledge Objectives © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC AfterNOT reading FOR this SALE chapter, ORyou willDISTRIBUTION be able to: NOT FOR SALE OR DISTRIBUTION 1. Discuss basic tool preparation and safety. (p. 59) 2. Discuss tools and equipment fundamentals. (pp. 59–60) 3. Discuss tool location. (pp. 60–61) © Jones & Bartlett4. List and Learning, describe precision LLC measuring tools. (pp. 61–68)© Jones & Bartlett Learning, LLC 5. List and describe power tools. (pp. 68–70) NOT FOR SALE 6. List ORand describeDISTRIBUTION air tools. (pp. 70–71) NOT FOR SALE OR DISTRIBUTION 7. List and describe common workshop tools. (pp. 71–85) 8. List and describe additional tools. (pp. 86–87) 9. List and describe diagnostic equipment. (pp. 87–90) 10. List and describe© servicing Jones equipment. & Bartlett (pp. Learning,90–91) LLC © Jones & Bartlett Learning, LLC 11. Describe oxyacetylene.NOT FOR(pp. 91–92) SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 12. List and describe cleaning equipment. (pp. 92–93) 13. List and describe electrical equipment. (pp. 93–98) 14. List and describe lifting equipment. (pp. 99–100) © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 57 3/12/14 9:35 PM © Jones & BartlettSkills Learning, Objectives LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION After reading this chapter, you will be able to: 1. Measure using an outside micrometer. (p. 64) PROCEDURE 3-1 2. Measure using a dial bore gauge. (p. 65) PROCEDURE 3-2 © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC 3. Measure using vernier calipers. (p. 66) PROCEDURE 3-3 4. Measure using a NOTdial indicator. FOR SALE(p. 67) OR DISTRIBUTION PROCEDURE 3-4NOT FOR SALE OR DISTRIBUTION 5. Select and use feeler gauge sets. (p. 68) PROCEDURE 3-5 6. Charge a battery using battery charging equipment. (p. 98) PROCEDURE 3-6

056754_CH03_p056-105.indd 58 3/12/14 9:36 PM CHAPTER 3 Care and Use of Tools Applicable to the Trade 59

have finished using them. Always return tools to their © Jones & BartlettIntroduction Learning, LLC © Jones & Bartlett Learning, LLC correct storage location. Some tools are heavy or awkward NOT FORTools SALE and OR equipment DISTRIBUTION are vital components of an effiNOT- to FOR use, SALEso seek ORassistance DISTRIBUTION if necessary, and use correct cient and effective workshop operation. They provide manual handling techniques. the means for work to be undertaken on motorcycles, from lifting to diagnosing to removing, installing, clean- Tools and Equipment ing and inspecting. Nearly© Jones all workshop & Bartlett tasks Learning, involve LLC © Jones & Bartlett Learning, LLC the use of some sort ofNOT tool orFOR piece SALE of equipment. OR DISTRIBUTION This FundamentalsNOT FOR SALE OR DISTRIBUTION makes their purchase, use and maintenance critical to the How Tools Extend Your Abilities overall performance of the workshop. Always use tools and equipment in the way they are designed to be used. Tools extend your abilities to perform many tasks. For Think about the task at hand, identify the most effective example, jacks, jack stands and hoists extend your ability to © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC tool to do the task, inspect the tool before using it, use it lift and hold heavy objects. Hand tools extend your ability correctly,NOT clean FOR and SALE inspect OR it afterDISTRIBUTION you use it and store to perform fundamentalNOT FOR tasksSALE like OR gripping, DISTRIBUTION turning, tight- it in the correct location. ening, measuring and cutting. Electrical meters enable you to measure things you cannot see, feel or hear; and power and air tools multiply your strength by performing tasks © Jones & BartlettBasic Learning,Tool Preparation LLC © Jonesquickly & andBartlett efficiently. Learning, As you work,LLC always think about NOT FOR SALEand OR Safety DISTRIBUTION NOTwhat FOR tool SALE will make OR theDISTRIBUTION job easier, safer or more efficient. As you become familiar with more tools, your productivity, Although it is important to be trained on the safe use of quality of work and effectiveness will improve. tools and equipment, it is even more critical to have a safe attitude. A safe attitude will help you avoid being involved in an accident.© Jones Students & whoBartlett think Learning, they will LLC TECHNICIAN TIP© Jones & Bartlett Learning, LLC never be involved inNOT an accident FOR SALEwill not OR be asDISTRIBUTION aware NOT FOR SALE OR DISTRIBUTION of unsafe situations as they should be, and such an The correct tools make you much more efficient and attitude could lead to accidents. Therefore, as this effective in performing your job. Without tools, it chapter discusses the various tools and equipment would be very difficult to carry out motorcycle repairs and servicing. This is the reason many technicians you will© Jones encounter & Bartlett in the workshop, Learning, pay LLC close atten- © Jones & Bartlett Learning, LLC tion to the safety and operation procedures. Tools are invest well over $16,000 in their personal tools. If NOT FOR SALE OR DISTRIBUTION purchasedNOT wisely, FOR tools SALEwill help ORyou performDISTRIBUTION more a technician’s best friend, but if used improperly, they work in a shorter amount of time, thereby making you can injure or kill. more productive. Therefore, think of your tools as an Work Safe and Stay Safe investment that pays for itself over time. © Jones &Always Bartlett think Learning,“safety first” LLCwhenever you use tools. There© Jones & Bartlett Learning, LLC NOT FORis SALE nothing OR more DISTRIBUTION important than your personal safety. IfNOT Why FOR ProperSALE OR Tool DISTRIBUTION Usage Is Critical you use tools (both hand and power) incorrectly, you could potentially injure yourself and others. Always fol- Every tool is designed to be used in a certain way to do low equipment and workshop instructions, including the job safely. It is critical to use a tool in the way it is designed to be used and to do so safely. For example, the use of recommended© Jones personal & protective Bartlett equipment Learning, LLC © Jones & Bartlett Learning, LLC a screwdriver is designed to tighten and loosen screws, (PPE). Accidents takeNOT only aFOR moment SALE to occur, OR DISTRIBUTIONbut can NOT FOR SALE OR DISTRIBUTION take a lifetime to recover from. You are ultimately respon- not to be used as a chisel. Ratchets are designed to turn sible for your own safety, so remember to work safe and sockets, not to be used as a hammer. Think about the stay safe. task you are undertaking, select the correct tools for the task and use each tool for what it was designed. Handling© Jones and & Using Bartlett Tools Learning, Safely LLC © Jones & Bartlett Learning, LLC Lockout/Tagout ToolsNOT must FORbe safely SALE handled OR and DISTRIBUTION used to prevent injury NOT FOR SALE OR DISTRIBUTION and damage. Always inspect tools prior to use and never Lockout/tagout is an umbrella term that describes a set use damaged tools or any replacement tool. Check the of safety practices and procedures. These practices and manufacturer documentation and the workshop proce- procedures are intended to reduce the risk of technicians’ © Jones &dures, Bartlett or ask Learning,your supervisor LLC if you are uncertain about© Jonesinadvertently & Bartlett using Learning, tools, equipment LLC or materials that NOT FORhow SALE to use OR any DISTRIBUTION tool. Inspect and clean tools when youNOT have FOR been SALE determined OR DISTRIBUTION to be unsafe or potentially unsafe,

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or that are in the process of being serviced. An example © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC of lockout is physically securing a broken, unsafe or out- NOT FOR SALE OR DISTRIBUTION NOTof-service FOR SALE tool so OR that DISTRIBUTION it cannot be used by a technician. In many cases, the item is also tagged out so it is not inadvertently placed back into service or operated. An example of tagout is affixing a clear and unavoidable label © Jones & Bartlett Learning, LLCto a piece of equipment that© describesJones & the Bartlett fault found, Learning, LLC NOT FOR SALE OR DISTRIBUTIONthe name of the person whoNOT found FOR the fault SALE and the OR date DISTRIBUTION that the fault was found, and that warns not to use the equipment FIGURE 3-1 .

A © Jones & Bartlett Learning, LLC TECHNICIAN© Jones & BartlettTIP Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Standardized lockout/tagout procedures are a mandatory part of workplace safety regulations in most countries. Familiarize yourself with your local legislation and with the specific lockout/tagout © Jones & Bartlett Learning, LLC © Jonespractices & Bartlett that apply Learning, in your workplace. LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

Tool Location © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC A workshop usually has a selection of tools available for NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION B use, and these tools will be located in a number of areas FIGURE 3-2 . Types of tools include specialized manufac- FIGURE 3-1 A. An example of lockout is physically securing turer tools; high-cost tools; and tools that are not portable, broken or unsafe tools in some way or in some place so that such as hoists and compressors. Technicians also have a they cannot be accessed and used by someone who may be unaware© Jones of the potential & Bartlett danger of Learning, doing so. B. An LLC example selection of© their Jones own &tools Bartlett as prescribed Learning, by the LLC Motor of NOTtagout is FORaffixing SALEa clear and OR unavoidable DISTRIBUTION label to a piece of Industry BargainingNOT FOR Council SALE (MIBCO), OR DISTRIBUTION including various equipment that describes the fault found and that warns not hand tools and electrical meters. Technicians often add to use it. to their toolboxes over time. Identifying Metric and © Jones & Bartlett Learning, LLC © JonesImperial & Bartlett Designations Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Many tools, measuring instruments and fasteners come in metric and imperial sizes. Tools are identified as metric or imperial by markings identifying their sizes, or by the increments on measuring instruments. Fasteners © Jones & Bartlett Learning, LLCbought new will have their designation© Jones &identified Bartlett on Learning, the LLC NOT FOR SALE OR DISTRIBUTIONpackaging. Other fasteners mayNOT have FOR to beSALE measured OR byDISTRIBUTION a ruler or vernier caliper to identify their designation. Manufacturers’ charts showing thread and fastener sizing will assist in identifying standard or metric sizing. © Jones & Bartlett Learning, LLC To identify© Jones metric & or Bartlett imperial Learning, designation, LLC follow NOT FOR SALE OR DISTRIBUTION these steps:NOT FOR SALE OR DISTRIBUTION 1. Examine the component, tool or fastener to see whether any marking identifies it as metric or FIGURE 3-2 Often workshop tools will be together in a wall imperial. Manufacturer specifications and workshop © Jones & Bartlettcabinet for easy Learning, selection and LLCreplacement. © Jonesmanuals & Bartlett may beLearning, referred to LLCand may identify com- NOT FOR SALE OR DISTRIBUTION NOT FORponents SALE as ORmetric DISTRIBUTION or imperial.

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2. If no markings are available, use measuring devices © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC to gauge the size of the item and compare thread NOT FOR SALEand fastener OR DISTRIBUTION charts to identify the sizing. Inch-to-NOT FOR SALE OR DISTRIBUTION metric conversion charts will assist in identifying component designation.

Precision Measuring© Jones & Bartlett Tools Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Technicians are required to perform a variety of measure- A ments while carrying out their job. This requires knowledge of what tools are available and how to use them. Measuring tools can generally be classified according to B © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC what type of measurements they can make. A measuring NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION tape is useful for measuring longer distances and is accu- FIGURE 3-3 A. Measuring tape. B. Steel rule. rate to a fraction of an inch or a millimeter FIGURE 3-3A . A steel rule is capable of accurate measurements on shorter lengths, down to a fraction of an inch or a millimeter locking mechanism to hold the extended measuring tape FIGURE 3-3B . Precision measuring tools are accurate to © Jones & Bartlett Learning, LLC © Jonesagainst & the Bartlett spring returnLearning, mechanism. LLC NOT FORmuch SALE smaller OR dimensions: DISTRIBUTION a micrometer, for example, canNOT FOR SALE OR DISTRIBUTION accurately measure down to 1/10,000 of an inch (0.0001) Stainless Steel Rulers or 1/1,000 of a millimeter (0.001 mm) in some cases. As the name suggests, a stainless steel ruler is a ruler that is made from stainless steel. Stainless steel rulers com- © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC TECHNICIAN TIP monly come in 12, 24 and 36 or 30-cm, 60-cm and NOT FOR SALE OR DISTRIBUTION1-meter lengths. They are usedNOT like FOR any ruler SALE to measure OR DISTRIBUTION The imperial and metric systems are two sets of and mark out items. They are very strong, have precise standards for quantifying weights and measurements. markings and resist damage. When using a stainless steel Each system has defined units. For example, the ruler, you can rest it on its edge so the markings are closer imperial© Jones system & uses Bartlett inches, feetLearning, and yards; LLCwhereas to the material© Jones being measured, & Bartlett which Learning, helps to mark LLC the theNOT metric FOR system SALE uses millimeters, OR DISTRIBUTION centimeters and work precisely.NOT Always FOR protect SALE the OR steel DISTRIBUTION ruler from damage meters. Conversions can be undertaken from one by storing it carefully; a damaged ruler will not give an system to the other. For example, 1 inch is equal to accurate measurement. Never take measurements from 25.4 mm, and 1 foot is equal to 304.8 mm. the very end of a damaged steel ruler, as damaged ends Tools that make use of a measuring system, such as may affect the accuracy of your measurements. © Jones & wrenches,Bartlett sockets,Learning, drill bits, LLC micrometers, rulers © Jones & Bartlett Learning, LLC NOT FOR SALEand many OR others, DISTRIBUTION come in both imperial and metric NOT FOR SALE OR DISTRIBUTION measurements. In the United States, imperial TECHNICIAN TIP measurements are the standard. However, conversion tables can be used to convert from one system to the If the end of a ruler is damaged, you may be able to other if needed. measure from the 1 mark and subtract an inch from © Jones & Bartlett Learning, LLCthe measurement. © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Measuring Tape Outside, Inside and Depth Micrometers Measuring tapes are a flexible type of ruler and are a common measuring tool. The most common type found Micrometers are precise measuring tools designed to meas- in workshops© Jones is &a thin Bartlett metal stripLearning, about 0.5 LLC to 1 (13 to ure small distances,© Jones and & are Bartlett available Learning, in both inch LLC( ) and 25 mm)NOT wide FOR that SALE is rolled OR up DISTRIBUTION inside a housing with a millimeter NOT(mm) calibrations.FOR SALE Typically, OR DISTRIBUTION they can measure spring return mechanism. Measuring tapes can be of down to a resolution of 1/1,000 of an inch (0.001 ) for a various lengths, with 16 to 25 (5 or 8 m) being very standard micrometer or 1/100 of a millimeter (0.01 mm) for common. The measuring tape is pulled from the housing a metric micrometer. Vernier micrometers equipped with the © Jones &to measureBartlett items, Learning, and a spring LLC return winds it back into© Jonesaddition & ofBartlett a vernier Learning,scale can measure LLC down to 1/10,000 of NOT FORthe SALE housing. OR TheDISTRIBUTION housing will usually have a built-inNOT an FOR inch SALE(0.0001 OR ) or 1/1,000DISTRIBUTION of a millimeter (0.001 mm).

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The most common types of micrometers are the outside, © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC inside and depth micrometers. As the name suggests, an TECHNICIAN TIP NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION outside micrometer FIGURE 3-4A measures the outside dimensions of an item. For example, it could measure the Micrometers are precision measuring instruments and must be handled and stored with care. They should diameter of a valve stem. The inside micrometer measures always be stored with a gap between the spindle and inside dimensions. For example, the inside micrometer anvil so metal expansion does not interfere with their could measure an engine© cylinderJones bore & Bartlett FIGURE 3-4B Learning,. Depth LLCcalibration. © Jones & Bartlett Learning, LLC micrometers measureNOT the depth FOR of SALEan item, OR such DISTRIBUTION as how NOT FOR SALE OR DISTRIBUTION far a piston is below the surface of the block FIGURE 3-4C .

The most common micrometer is an outside micrometer. The horseshoe-shaped part is the frame. It is built to © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC make sure the micrometer holds its shape. Some frames NOT FOR SALE OR DISTRIBUTION have plasticNOT finger FOR pads soSALE that body OR heat DISTRIBUTION is not transferred to the metal frame as easily, because heat can cause the metal to expand slightly and affect the reading. On one end of the frame is the anvil, which contacts one side of the part © Jones & Bartlett Learning, LLC © Jonesbeing &measured. Bartlett The Learning, other contact LLC point is the spindle. NOT FOR SALE OR DISTRIBUTION NOTThe FOR micrometer SALE OR measures DISTRIBUTION the distance between the anvil and spindle, so that is where the part being measured fits. The measurement is read on the sleeve/barrel and thimble. The sleeve/barrel is stationary and has the linear A markings on it. The thimble fits over the sleeve and has © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC the graduated markings on it. The thimble is connected NOT FOR SALE OR DISTRIBUTIONdirectly to the spindle, and NOTboth turn FOR as SALEa unit. Because OR DISTRIBUTION the spindle and sleeve/barrel have matching threads, the thimble rotates the spindle inside of the sleeve/barrel, and the thread moves the spindle inward and outward. © Jones & Bartlett Learning, LLC The thimble© usuallyJones incorporates& Bartlett eitherLearning, a ratchet LLC or a NOT FOR SALE OR DISTRIBUTION clutch mechanism,NOT FOR which SALE prevents OR overtightening DISTRIBUTION of the micrometer thimble when taking a reading. A lock nut, lock ring or lock screw is used on most micrometers and locks the thimble in place while you read the micrometer.

All micrometers need to be checked for calibration (also called zeroing) before each use. A 0–1 or © Jones & Bartlett Learning, LLC0–25 mm outside micrometer© Jonescan be lightly & Bartlett closed Learning, LLC NOT FOR SALE OR DISTRIBUTIONall of the way. If the anvil andNOT spindle FOR are clean,SALE OR DISTRIBUTION the micrometer should read 0.000, indicating the micrometer is calibrated correctly. If the micrometer is bigger than 1 or 25 mm, then a “standard” is used to verify the calibration. A standard is a hardened © Jones & Bartlett Learning, LLC machined© rod Jones of a precise & Bartlett length, such Learning, as 2 or LLC NOT FOR SALE OR DISTRIBUTION 50 mm. WhenNOT inserted FOR SALE in the same-sized OR DISTRIBUTION micrometer, C the reading should be exactly the same as listed on the standard. If a micrometer is not properly calibrated, FIGURE 3-4 A. Outside micrometer. B. Inside micrometer. it should not be used until it is recalibrated. See the C. Depth micrometer. tool’s instruction manual for the calibration procedure. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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Standard micrometers use a specific thread of 40 tpi 2. Check to see if it passed the 0.5-mm mark (example: © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC on the spindle and sleeve. This means that the thimble 0.50 mm). NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION will rotate exactly 40 turns in 1 inch. Every complete 3. Check to see which mark on the thimble lines up rotation moves the spindle a 40th of an inch, or 0.025 with or is just passed (example: 37 3 0.01 mm 5 (1  40 5 0.025). In four rotations, the spindle moves 0.37 mm). 0.100 (0.025 3 4 5 0.100). The linear markings on 4. Total all of the numbers (example: 23 mm 1 the sleeve show each of© theJones 0.100 & marks Bartlett between Learning, 0 and LLC © Jones & Bartlett Learning, LLC 0.50 mm 1 0.37 mm 5 23.87 mm). 1 inch as well as eachNOT of the FOR 0.025 SALE marks. OR Since DISTRIBUTION the NOT FOR SALE OR DISTRIBUTION thimble has graduated marks from 0 to 24 (each mark If the micrometer is equipped with a vernier gauge, representing 0.001), every complete turn of the thimble meaning it can read down to 1/10,000 of an inch will uncover another one of the 0.025 marks on the (0.0001) or 1/1,000 of a millimeter (0.001 mm), you sleeve. If the thimble stops short of any complete turn, need to complete one more step. Identify which of © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC it will indicate the exact number of 0.001 marks past the vernier lines is closest to one of the lines on the the zeroNOT line FOR on the SALE sleeve. OR DISTRIBUTION thimble. SometimesNOT FOR it SALEis hard ORto determine DISTRIBUTION which is To read a standard micrometer, perform the follow- the closest, so decide which three are the closest and ing steps: then use the center line. At the frame side of the sleeve will be a number that corresponds to the vernier line. © Jones & 1. Bartlett Verify that Learning, the micrometer LLC is properly calibrated. © JonesIt will & be Bartlett numbered Learning, 1 to 0. Take LLC the vernier number NOT FOR 2.SALE Verify OR what DISTRIBUTION size of micrometer you are using. If it isNOT and FOR add SALE it to the OR end DISTRIBUTION of your reading. For example: a 0–1 micrometer, start with 0.000. If it is a 1–2 2.363 1 0.0007 5 2.3637, and 23.77 1 0.007 5 micrometer, start with 1.000. A 2–3 micrometer 23.777 mm. would start with 2.000, and so on. (This example For inside measurements, the inside microm- uses 2.000.) eter works on the same principles as the outside © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC 3. Read how many 0.100 marks the thimble has uncov- micrometer, and so does the depth micrometer. The NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION ered (example: 0.300). only difference is that the scale on the sleeve of the depth micrometer is backward, so be careful when 4. Read how many 0.025 marks the thimble has uncov- ered past the 0.100 mark in step 3 (example: 2 3 reading it. 0.025 5 0.050). © Jones & Bartlett Learning, LLC Using a Micrometer© Jones & Bartlett Learning, LLC 5. Read the number on the thimble that lines up with theNOT zero FOR line onSALE the sleeve OR (example:DISTRIBUTION 13 3 0.001 5 To maintainNOT accuracy FOR ofSALE measurements, OR DISTRIBUTION it is impor- 0.013). tant that both the micrometer and the items to be measured are clean and free of any dirt or debris. 6. Total all of the individual readings (example: 2.000 1 0.300 1 0.050 1 0.013 5 2.363). Also make sure the micrometer is zeroed before tak- © Jones & Bartlett Learning, LLC © Jonesing any & measurements.Bartlett Learning, Never overtightenLLC a microm- NOT FOR SALEA metric OR micrometer DISTRIBUTION uses the same components asNOT eter FOR or SALEstore it ORwith DISTRIBUTION its measuring surfaces touching, the standard micrometer. However, it uses a differ- as this may damage the tool and affect its accuracy. ent thread pitch on the spindle and sleeve. A metric When measuring, make sure the item can pass through micrometer uses a 0.5-mm thread pitch (2.0 threads per the micrometer surfaces snugly and squarely. This is millimeter) and opens up approximately 25 mm. Each best accomplished by using the ratchet to tighten the rotation of the thimble© movesJones the & spindle Bartlett 0.5 Learning,mm, and LLCmicrometer. Always take the© Jonesmeasurement & Bartlett a number Learning, LLC it therefore takes 50 NOTrotations FOR of theSALE thimble OR toDISTRIBUTION move of times and compare resultsNOT to ensure FOR you SALE have OR meas DISTRIBUTION- the full 25-mm distance. The sleeve/barrel is labeled ured accurately. with individual millimeter marks and half-millimeter To measure using an outside micrometer, follow the marks, from the starting millimeter to the ending mil- guidelines in PROCEDURE 3-1 . limeter,© Jones 25 mm away.& Bartlett The thimble Learning, has graduated LLC marks © Jones & Bartlett Learning, LLC fromNOT 0 to 49.FOR SALE OR DISTRIBUTION TelescopingNOT GaugeFOR SALE OR DISTRIBUTION Reading a metric micrometer involves the following steps: For measuring distances in awkward spots, like the bottom of a cylinder, the telescoping gauge has spring- 1. Read the number of full millimeters the thimble has loaded plungers that can be unlocked with a screw on © Jones & Bartlettpassed (to Learning, give an example: LLC 23 mm). © Jonesthe handle & Bartlett so they Learning,slide out and LLC touch the walls of the NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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© Jones & Bartlett Learning, LLC 4 With your left hand, hold the© Jonespart you are& Bartlettmeasuring Learning, LLC NOT FOR SALE OR DISTRIBUTIONand place the micrometerNOT over it. FOR SALE OR DISTRIBUTION 5 Using your thumb and forefinger, lightly tighten the ratchet. It is important that the correct amount of force is applied to the spindle when taking a measurement. The spindle and anvil should just touch © Jones & Bartlett Learning, LLC the component,© Jones with & a Bartlettslight amount Learning, of drag when LLC the NOT FOR SALE OR DISTRIBUTION micrometerNOT is FORremoved SALE from the OR measured DISTRIBUTION piece. Be careful that the part is square in the micrometer so the reading is correct. Try rocking the micrometer in all directions to make sure it is square.

© Jones & Bartlett Learning, LLC © Jones 6 Once & Bartlett the micrometer Learning, is properly LLC snug, tighten the NOT FOR SALE OR DISTRIBUTION NOT FORlock SALE mechanism OR so DISTRIBUTION the spindle will not turn. 1 Select the correct size of micrometer. Verify that the anvil and spindle are clean and that it is calibrated properly. 7 Read the micrometer and record your reading. 8 When all readings are finished, clean the micrometer, 2 Clean the surface of the part you are measuring. position the spindle so it is backed off from the anvil 3 In your right hand,© hold Jones the frame & Bartlettof the micrometer Learning, LLCand return it to its protective© Jonescase. & Bartlett Learning, LLC between your littleNOT finger, FOR ring finger SALE and ORpalm ofDISTRIBUTION your NOT FOR SALE OR DISTRIBUTION hand, with the thimble between your thumb and forefinger.

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC cylinder FIGURE 3-5 . The screw then locks them in that Split Ball Gauge position,NOT the FOR gauge SALE can be OR withdrawn DISTRIBUTION and the distance NOT FOR SALE OR DISTRIBUTION A split ball gauge (small hole gauge) is good for measur- across the plungers can be measured with an outside ing small holes where telescoping gauges cannot fit. They micrometer or calipers to convey the diameter of the cyl- use a similar principle to the telescoping gauge, but the inder at that point. Telescoping gauges come in a variety measuring head uses a split ball mechanism that allows of sizes to fit various sizes of holes and bores. © Jones & Bartlett Learning, LLC © Jonesit to fit & intoBartlett very small Learning, holes. Split LLC ball gauges are ideal NOT FOR SALE OR DISTRIBUTION NOTfor FOR measuring SALE valve OR guidesDISTRIBUTION on a cylinder head for wear. A split ball gauge can be fitted in the bore and expanded until there is a slight drag. Then it can be retracted and measured with an outside micrometer. Like some of the © Jones & Bartlett Learning, LLCother measuring instruments© Jones discussed, & Bartlett the split ballLearning, LLC gauge may have a dial or digital measurement scale fit- NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION ted for direct reading purposes. Dial Bore Gauge A dial bore gauge is used to measure the inside diam- © Jones & Bartlett Learning, LLC eter of bores© Joneswith a high & Bartlett degree of Learning,accuracy and LLC speed NOT FOR SALE OR DISTRIBUTION FIGURE 3-6NOT. The FOR dial bore SALE gauge OR can DISTRIBUTION measure a bore directly by using telescoping pistons on a T-handle with a dial mounted on the handle. The dial bore gauge combines a telescoping gauge and dial indicator in one © Jones & BartlettFIGURE 3-5 Learning, Telescoping gauge. LLC © Jonesinstrument. & Bartlett A dial Learning,bore gauge determines LLC whether the NOT FOR SALE OR DISTRIBUTION NOTdiameter FOR SALE is worn, OR tapered DISTRIBUTION or out-of-round according to

056754_CH03_p056-105.indd 64 3/12/14 9:36 PM CHAPTER 3 Care and Use of Tools Applicable to the Trade 65

Hold the gauge in line with the bore and slightly rock © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC it to ensure it is centered. Read the dial when it is fully NOT FOR SALE OR DISTRIBUTION NOTcentered FOR SALE and square OR toDISTRIBUTION the bore to determine the correct measurement. Store a bore gauge carefully in its storage box and ensure the locking mechanism is released while in stor- © Jones & Bartlett Learning, LLCage. Bore gauges are available© inJones different & Bartlettranges of size.Learning, LLC NOT FOR SALE OR DISTRIBUTIONIt is important to select a gaugeNOT with FOR the SALE correct OR range DISTRIBUTION for the bore you are measuring. When measuring, make sure the gauge is at a 90-degree angle to the bore and read the dial. Always take the measurement a number of times and compare results to ensure you have measured © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC accurately. NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION FIGURE 3-6 A dial bore gauge set. To measure using a dial bore gauge, follow the guidelines in PROCEDURE 3-2 .

Vernier Calipers © Jones &the Bartlett manufacturer’s Learning, specifications. LLC The resolution of a dial© Jones & Bartlett Learning, LLC NOT FORbore SALE gauge OR is typicallyDISTRIBUTION accurate to 5/10,000 of an inchNOT Vernier FOR SALEcalipers areOR a precisionDISTRIBUTION instrument used for meas- (0.0005) or 1/100 of a millimeter (0.01 mm). uring outside dimensions, inside dimensions and depth measurements, all in one tool. They have a graduated bar Using a Dial Bore Gauge with markings like a ruler. On the bar, a sliding sleeve To use a dial bore gauge, select an appropriately sized with jaws is mounted for taking inside or outside meas- adapter to fit the internal© Jones diameter & ofBartlett the bore, Learning,and install LLCurements. Measurements on© olderJones versions & Bartlett of vernier Learning, LLC it to the measuring head.NOT Many FOR dial SALEbore gauges OR alsoDISTRIBUTION have calipers are taken by readingNOT the FORgraduated SALE bar ORscales, DISTRIBUTION a fixture to calibrate the tool to the size you desire. The while fractional measurements are read by comparing the fixture is set to the size desired, and the dial bore gauge scales between the sliding sleeve and the graduated bar. is placed in it. The dial bore gauge is then adjusted to Technicians will often use vernier calipers to measure the proper© Jones reading. & Bartlett Once it isLearning, calibrated, LLCthe dial bore length and© diameters Jones of& boltsBartlett and pinsLearning, or the depth LLC of gauge can be inserted inside the bore to be measured. blind holes in housings. NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

PROCEDURE 3-2 Measuring Using a Dial Bore Gauge © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 1 Select the correct size of the dial bore gauge you will use and fit any adapters to it. 2 Check the calibration and adjust it as necessary. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION 3 Insert the dial bore gauge intoNOT the FOR bore. TheSALE accurate OR DISTRIBUTION measurement will be at exactly 90 degrees to the bore. To find the accurate measurement, rock the dial bore gauge handle slightly back and forth until you find the centered position. © Jones & Bartlett Learning, LLC 4 Read the© dialJones to determine & Bartlett the bore Learning, measurement. LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 5 Always clean the dial bore gauge and return it to its protective case when you have finished using it.

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Newer versions of vernier calipers have dial and digital accurately measures movement of the plunger in and out © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC scales. The dial vernier has the main scale on the gradu- as it rests against an object. For example, they can be used NOT FORated SALE bar, whileOR DISTRIBUTION fractional measurements are taken fromNOT to FOR measure SALE the truenessOR DISTRIBUTION of a rotating disc brake rotor. a dial with a rotating needle. These tend to be easier A dial indicator can also measure how round some- to read than the older versions. More recently, digital thing is. A crankshaft can be rotated in a set of V blocks. scales on vernier calipers have become commonplace. If the crankshaft is bent, it will show as movement on The principle of their© useJones is the & sameBartlett as any Learning, vernier LLCthe dial indicator as the crankshaft© Jones is rotated.& Bartlett The dialLearning, LLC caliper; however, theyNOT have FORa digital SALE scale thatOR reads DISTRIBUTION the indicator senses slight movementNOT atFOR its tip SALE and magnifies OR DISTRIBUTION measurement directly. it into a measurable swing on the dial. Dial indicators normally have either one or two indica- Using Vernier Calipers tor needles. The large needle indicates the fine reading Always store vernier calipers in a storage box to protect of thousandths of an inch. If it has a second needle, it © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC them and ensure the measuring surfaces are kept clean for will be smaller and indicates the coarse reading of tenths accurateNOT measurement. FOR SALE If makingOR DISTRIBUTION an internal or external of an inch. NOTThe large FOR needle SALE is ableOR toDISTRIBUTION move numerous measurement, make sure the caliper is at right angles to times around the outer scale. One full turn may represent the surfaces to be measured. You should always repeat 0.100 or 1 mm. The small inner scale indicates how the measurement a number of times and compare results many times the outer needle has moved around its scale. © Jones &to ensureBartlett you Learning, have measured LLC accurately. © JonesIn this & way, Bartlett the dial Learning, indicator is LLCable to read movement NOT FOR SALETo measure OR usingDISTRIBUTION vernier calipers, follow the guidelinesNOT of FOR up to SALE 1 or 2 ORcm. DISTRIBUTION in PROCEDURE 3-3 . Dial indicators can measure with an accuracy of 0.001 Dial Indicators or 0.01 mm. The type of dial indicator you use will be determined by the amount of movement you expect from Dial indicators can also be known as dial gauges, and, the component you are measuring. The indicator must be © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC as the name suggests, they have a dial and needle where set up so that there is no gap between the dial indicator measurements are read.NOT They FOR have SALE a measuring OR DISTRIBUTIONplunger and the component to be measured.NOT FOR Most SALE dial indicator OR DISTRIBUTION with a pointed contact end that is spring-loaded and sets contain various attachments and support arms so connected via the housing to the dial needle. The dial they can be configured specifically for the measuring task.

© Jones & Bartlett Learning, LLC © Jones 1 Verify & Bartlett that the vernier Learning, caliper is calibratedLLC (zeroed) NOT FOR SALE OR DISTRIBUTION NOT FORbefore SALE using ORit. If itDISTRIBUTION is not zeroed, notify your mentor, who will get you a replacement vernier caliper.

2 Position the caliper correctly for the measurement you are making. Internal and external readings are normally made with the vernier caliper positioned © Jones & Bartlett Learning, LLCat 90 degrees to the face of© the Jones component & Bartlett to be Learning, LLC NOT FOR SALE OR DISTRIBUTIONmeasured. Length and depthNOT measurements FOR SALE are OR DISTRIBUTION usually made parallel to or in line with the object being measured. Use your thumb to press or withdraw the sliding jaw to measure the outside or inside of the part.

© Jones & Bartlett Learning, LLC 3 Read the© scaleJones of the & vernier Bartlett caliper, Learning, being careful LLCnot NOT FOR SALE OR DISTRIBUTION to changeNOT the FORposition SALE of the movable OR DISTRIBUTION jaw. Always read the dial or face straight on. A view from the side can give a considerable parallax error. Parallax error is a visual error caused by viewing measurement markers at an incorrect angle. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 66 3/12/14 9:36 PM CHAPTER 3 Care and Use of Tools Applicable to the Trade 67

being checked. Straight edges are often used to measure © Jones Using& Bartlett a Dial Learning, Indicator LLC © Jones & Bartlett Learning, LLC the amount of warpage the surface of a cylinder head has. NOT FORDial SALE indicators OR DISTRIBUTION are used in many types of service jobs.NOT FOR SALE OR DISTRIBUTION They are particularly useful in determining run-out on rotating shafts and surfaces. Run-out is the side-to-side Feeler Gauges variation of movement when a component is turned. Feeler gauges (also called feeler blades) are used to meas- When attaching a dial indicator, keep support arms as © Jones & Bartlett Learning, LLCure the width of gaps, such© asJones the clearance & Bartlett between Learning, LLC short as possible. Make sure all attachments are tightened valves and rocker arms. Feeler gauges are flat metal strips NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION to prevent unnecessary movement between the indica- of varying thicknesses. The thickness of each feeler gauge tor and the component. Make sure the dial indicator is clearly marked on each one. They are sized from frac- pointer is positioned at 90 degrees to the face of the tions of an inch or fractions of a millimeter. They usu- component to be measured. Always read the dial face ally come in sets with different sizes and are available straight© Joneson, as a &view Bartlett from the Learning, side can give LLC a consider- in imperial© and Jones metric & measurements. Bartlett Learning, Some sets LLC con- able parallaxNOT FOR error. SALE The outer OR faceDISTRIBUTION of the dial indicator tain feeler gaugesNOT FORmade SALEof brass. OR These DISTRIBUTION are used to take is designed so it can be rotated so that the zero mark measurements between components that are magnetic. If can be positioned directly over the pointer. This is how steel gauges were used, the drag caused by the magnet- a dial indicator is zeroed. ism would mimic the drag of a proper clearance. Brass To measure using a dial indicator, follow the guidelines © Jones & Bartlett Learning, LLC © Jonesgauges & are Bartlett not subject Learning, to magnetism, LLC so they work well in PROCEDURE 3-4 . in that situation. NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Straight Edge Some feeler gauges come in a bent arrangement to be more easily inserted in cramped spaces. Others come in a Straight edges are usually made from hardened steel stepped version. Two or more feeler gauges can be stacked and are machined so that the edge is perfectly straight. together to make up a desired thickness. Alternatively, A straight edge is used© to Jones check the & Bartlettflatness of Learning, a surface. LLCif you want to measure an unknown© Jones gap, & Bartlettyou can inter Learning,- LLC It is placed on its edgeNOT against FOR the surface SALE to OR be checked. DISTRIBUTION change feeler gauges until youNOT find FORthe one SALE or more OR that DISTRIBUTION fit The gap between the straight edge and the surface can be snugly into the gap, and total their thickness to measure measured by using feeler gauges. Sometimes the gap can the gap. In conjunction with a straight edge, they can be be seen easily if light is shone from behind the surface used to measure surface irregularities in a cylinder head. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION PROCEDURE 3-4 Measuring Using a Dial Indicator

© Jones & Bartlett Learning, LLC © Jones 1 Select & Bartlett the gauge Learning,type, size, attachment LLC and bracket NOT FOR SALE OR DISTRIBUTION NOT FORthat SALE fit the partOR you DISTRIBUTION are measuring. Mount the dial indicator firmly to keep it stationary.

2 Adjust the indicator so that the plunger is at 90 degrees to the part you are measuring and lock it in place. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC 3 Rotate the part one complete turn and locate the low NOT FOR SALE OR DISTRIBUTIONspot. Zero the indicator. NOT FOR SALE OR DISTRIBUTION

4 Find the point of maximum height and note the reading. This will indicate the run-out value.

5 © Jones & Bartlett Learning, LLC Continue© Jonesthe rotation & andBartlett make sure Learning, the needle doesLLC not go below zero. If it does, reverse the indicator and NOT FOR SALE OR DISTRIBUTION remeasureNOT the FOR point ofSALE maximum OR variation. DISTRIBUTION

6 Check your readings against the manufacturer’s specifications. If the deviation is greater than the specifications allow, consult your supervisor. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 67 3/12/14 9:36 PM 68 CHAPTER 3 Care and Use of Tools Applicable to the Trade

1 Select the appropriate type and size of feeler gauge set © Jones & Bartlett Learning, LLCfor the job you are working© on.Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION 2 Inspect the feeler gauges toNOT make FOR sure they SALE are clean, OR DISTRIBUTION rust-free and undamaged, but slightly oiled for ease of movement.

3 Choose one of the smaller wires or blades, and try to © Jones & Bartlett Learning, LLC insert it ©in theJones gap on &the Bartlett part. If it slips Learning, in and out easily, LLC NOT FOR SALE OR DISTRIBUTION choose NOTthe next FOR size up. SALE When you OR find DISTRIBUTION one that touches both sides of the gap and slides with only gentle pressure, then you have found the exact width of that gap.

4 Read the markings on the wire or blade, and check these against the manufacturer’s specifications for this © Jones & Bartlett Learning, LLC © Jonescomponent. & Bartlett If gap Learning, width is outside LLC the tolerances NOT FOR SALE OR DISTRIBUTION NOT FORspecified, SALE inform OR DISTRIBUTIONyour supervisor.

5 Clean the feeler gauge set with an oily cloth to prevent rust when you store the set.

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Using Feeler Gauges Power Tools If the feeler gauge feels too loose when measuring a gap, select© the Jones next size & larger Bartlett and measure Learning, the gap LLC again. Repeat Power tools© are Jones typically & poweredBartlett by Learning, an electric motor LLC or this procedureNOT FOR until SALE the feelerOR DISTRIBUTION gauge has a slight drag compressedNOT air. They FOR may SALE also be OR powered DISTRIBUTION by burning of between both parts. If the feeler gauge is too tight, select propellant, as in the case of a nail gun, or by a petroleum a smaller size until the feeler gauge fits properly. When engine, as in the case of a portable compressor. A power measuring a spark plug gap, feeler gauges should not be tool may be stationary, such as a bench grinder, or port- used because the surfaces are not perfectly parallel, so it is able, such as a portable electric drill. There are many © Jones &preferable Bartlett to useLearning, wire feeler LLCgauges. Wire feeler gauges use© Jonesdifferent & Bartlettpower tools Learning, designed to LLC perform specific tasks. NOT FORaccurately SALE OR machined DISTRIBUTION pieces of wire instead of metal strips.NOTSome FOR are SALE corded OR and DISTRIBUTION have to be plugged in, and others To select and use feeler gauge sets, follow the guidelines are cordless and have batteries. Power tools make many in PROCEDURE 3-5 . tasks quicker and easier to perform, and they can save many hours of work when used and maintained correctly. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC TECHNICIAN TIP Drills and Drill Bits NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION A portable drill may be corded or cordless FIGURE 3-7A . Never use feeler gauges on operating machinery. A corded drill has a lead that has to be plugged into an electrical supply. The operating voltage of a drill depends on the country’s supply. Corded drills are a good choice © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC Safety when moderate power is needed or when extended drill- NOT FOR SALE OR DISTRIBUTION ing is required.NOT Cordless FOR SALE drills use OR their DISTRIBUTION own internal bat- Feeler gauges are strips of hardened metal that have teries FIGURE 3-7B . Use a cordless drill when you cannot been ground or rolled to a precise thickness. They can bring the work to the drill; instead take the drill to the be very thin and will cut through skin if not handled work. However, do not expect a cordless drill to be able © Jones & correctly.Bartlett Learning, LLC © Jonesto drill & large Bartlett holes through Learning, hard metal.LLC Although they are NOT FOR SALE OR DISTRIBUTION NOTvery FOR versatile, SALE the OR amount DISTRIBUTION of work they can do is limited

056754_CH03_p056-105.indd 68 3/12/14 9:36 PM CHAPTER 3 Care and Use of Tools Applicable to the Trade 69

FIGURE 3-7 A. Portable drill. B. Cordless drill. C. Drill bits. D. Drill press.

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION by their power rating. The biggest drill bit that will fit into tang of a file. It fits snugly into the drill spindle, which the chuck of these drills is usually marked on the body of has a similar taper on its inside. The tang on the drill the drill or chuck, along with the speeds at which it will bit is located in the spindle, and it drives the drill. It is a turn. Some portable drills have two operating speeds, but quick way to change drills without constantly adjusting most© have Jones a variable & Bartlett speed rating Learning, that is determined LLC by the chuck.© Jones & Bartlett Learning, LLC how NOTmuch FORpressure SALE is placed OR onDISTRIBUTION the trigger and which NOT FOR SALE OR DISTRIBUTION may be set to any speed within the drill’s range. Drill bits come in many closely spaced sizes and types TECHNICIAN TIP FIGURE 3-7C . The most common is the twist drill. It has a point with cutting flutes that form a common angle © Jones & Bartlett Learning, LLC © JonesDrills & areBartlett also used Learning, to drive other LLC accessories such as of 118 degrees. Its body, which usually has two spiral rotary files, screwdriver bits and sockets. NOT FORgrooves, SALE and OR its DISTRIBUTION shank, are gripped in the jaws of the drillNOT FOR SALE OR DISTRIBUTION chuck. A drill chuck is a device for gripping drill bits securely in a drill. The twist drill is a good all-purpose bit for drilling metals. When there is a hole already drilled in sheet metal A drill press allows© Jonesfor accurate & Bartlett drilling Learning, and has LLCthat needs enlarging, a multi-fluted© Jones tapered-hole& Bartlett Learning,drill LLC more control than is offeredNOT FORby a portable SALE drill—which, OR DISTRIBUTION will do the job in practicallyNOT the FORsame timeSALE it takes OR toDISTRIBUTION although convenient, can be difficult to guide accurately say the name of this tool. A drilling speed chart is usu- FIGURE 3-7D . A mounted drill can feed the drill bit at ally supplied with the drill press and should be kept a controlled rate, and the worktable on the drill typi- nearby for handy reference. It compares drill sizes and cally has a vise to secure the job at a constant angle to metals to show the proper speed. For example, to drill a the drill© Jones bit. This & Bartletttype of drill Learning, can also beLLC set to run 0.375 (10-mm)© Jones hole through& Bartlett a piece Learning, of aluminum, LLC the at differentNOT FOR drilling SALE speeds. OR Most DISTRIBUTION drill presses have a drill speed NOTshould FOR be 1,800 SALE rpm. OR Note DISTRIBUTION also that drilling drill chuck that takes bits up to 0.5 (13 mm) or more metals is best performed with the aid of a lubricant. The in diameter. lubricant helps cool the cutting edges of the drill bit as Morse taper is a system for securing drill bits to drills. well as lubricate it. Each metal requires its own type of © Jones &The Bartlett Morse taper Learning, size changes LLC according to drill size.© Joneslubricant, & Bartlett so check Learning,a drilling guide LLC to identify the correct NOT FORThe SALE shank OR of theDISTRIBUTION drill bit is tapered and looks like theNOT lubricant FOR SALE for the OR metal DISTRIBUTION you are working on.

056754_CH03_p056-105.indd 69 3/12/14 9:36 PM 70 CHAPTER 3 Care and Use of Tools Applicable to the Trade

© Jones Bench& Bartlett and Learning, Angle Grinders LLC © Jones & Bartlett Learning, LLC NOT FORPower SALE grinders OR DISTRIBUTION are available in a range of sizes andNOT FOR SALE OR DISTRIBUTION speeds. The size of a power grinder is usually determined by the diameter of the largest grinding wheel or disc that can be fitted to it. Some grinders are fixed to a bench or pedestal© andJones the work& Bartlett is brought Learning, to the LLC © Jones & Bartlett Learning, LLC grinder; others are portableNOT FOR devices SALE that mayOR beDISTRIBUTION taken NOT FOR SALE OR DISTRIBUTION to the work. Bench or pedestal grinders are generally powered by electricity, whereas portable grinders may be electric or air powered. Grinding wheels and discs usually have a maximum A safe operating© Jones speed & Bartlett printed Learning,on them. This LLC maximum © Jones & Bartlett Learning, LLC speedNOT must FORnever beSALE exceeded, OR orDISTRIBUTION the wheel or disc could NOT FOR SALE OR DISTRIBUTION disintegrate. Every well-equipped workshop has a sol- idly mounted grinder, either on a pedestal bolted to the workshop floor or securely attached to the workbench. © Jones &Appropriate Bartlett eyeLearning, protection LLC must be worn when grind©- Jones & Bartlett Learning, LLC ers are being used, and the wheel guards, tool rests and NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION shields must be correctly and firmly in place. A bench grinder (pedestal grinder) usually has a rating specifying the size of the grinding wheel it can take FIGURE 3-8A . Do not attempt to install a grinding wheel larger or smaller© Jones than & theBartlett grinder’s Learning, rating. LLC © Jones & Bartlett Learning, LLC Grinding wheels comeNOT in gradesFOR SALEfrom coarse OR DISTRIBUTIONto very B NOT FOR SALE OR DISTRIBUTION fine, depending on the size of the abrasive grains that are bonded together to make the wheel. They also range FIGURE 3-8 A. Bench grinder. B. Angle grinder. in hardness, depending on the abrasive used and the material© Jones used to bond& Bartlett the particles Learning, together. LLC When a par- © Jones & Bartlett Learning, LLC ticular grinding application is required, a check should NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION be done to verify the most suitable grinding wheel for Air Tools the application. An angle grinder is usually needed when the bench Air tools operate by using compressed air at high pressure. grinder is not appropriate FIGURE 3-8B . The angle grinder Air compressors in motorcycle workshops typically run at © Jones &uses Bartlett discs rather Learning, than wheels. LLC During grinding, the face© Jonesgreater & than Bartlett 90 psi (621Learning, kPa), so exerciseLLC caution around NOT FORof SALE the disc OR is used DISTRIBUTION instead of the edge. An angle grinderNOT them. FOR Compressed SALE OR air DISTRIBUTION is transported through pipes and can emit sparks to a distance of many feet, so direct the hoses. Air tools have quick-connect fittings so that various sparks in a safe direction or set up a guard to catch them. air tools can easily be used on the same air hose. There Use hearing protection whenever grinding, as it is very are several styles of quick-connect fittings; a workshop noisy and can damage your ears. usually uses one style throughout the entire workshop. Although not as common© Jones in & a Bartlett motorcycle Learning, work- LLCThe most common air tool© inJones a motorcycle & Bartlett workshop Learning, LLC shop, the straight grinderNOT acceptsFOR SALE conventional OR DISTRIBUTION grind- is the air impact wrench FIGURENOT 3-9A FOR. It isSALE also called OR anDISTRIBUTION ing wheels, just like the stationary grinders. However, impact gun or rattle gun, and it is easy to understand why the grinding wheel diameter is limited to about 4.75 when you hear one. Taking the wheels off a motorcycle to (126 mm). In many cases, the grinder has a long shaft replace the tires is a typical application for this air tool. that moves© Jones the grinding & Bartlett wheel Learning, away from the LLC motor. This Removing ©lug Jones nuts often & Bartlettrequires a Learning,lot of torque toLLC twist makesNOT it useful FOR for SALE getting OR into DISTRIBUTION recessed areas. the nuts free,NOT and FORair impact SALE wrenches OR DISTRIBUTION work well for that. Hand-held cut-off wheels are powered either by elec- The air impact wrench may be set to spin in either tricity or air. They use a special thin grinding disk to direction, and a valve controls roughly how much torque enable them to cut. They use the edge of the wheel for it applies. It should never be used for final tightening of cutting and are useful for jobs that cannot be reached wheel nuts. There is a danger in overtightening the wheel © Jones &with Bartlett a hacksaw. Learning, LLC © Jonesnuts, as& thisBartlett could cause Learning, the bolts LLC to fail and the wheel to NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 70 3/12/14 9:36 PM CHAPTER 3 Care and Use of Tools Applicable to the Trade 71

A BB A © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

E © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FORD SALE OR DISTRIBUTION

FIGURE 3-9 A. Air impact wrench. B. Air ratchet. C. Air hammer. D. Air drill. E. Air nozzle.

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION separate from the motorcycle while it is moving. Another An air nozzle is probably the simplest air tool rule to remember about the air impact wrench is that you FIGURE 3-9E . It simply controls the flow of compressed air. have to use special hardened impact sockets, extensions It is controlled by a lever or valve and is used to blast debris and joints.© Jones The sockets& Bartlett are special Learning, heavy-duty, LLC six-point and dirt out© of Jonesconfined & spaces. Bartlett Blasting Learning, debris and LLCdirt can types, and the flats can withstand the hammering force be dangerous, so eye protection must be worn whenever this NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION that the impact wrench subjects them to. tool is used. Noise levels are usually high, so ear protection An air ratchet uses the force of compressed air to turn should also be worn. It is dangerous to use an air nozzle to a ratchet drive FIGURE 3-9B . It is used on smaller nuts clean yourself off. Its blast should always be directed away and bolts. Once the nut is loosened, the air ratchet spins from the user and anyone else working nearby. © Jones &it offBartlett in a fraction Learning, of the time LLC it would take by hand. The© Jones & Bartlett Learning, LLC NOT FORair SALE ratchet OR also DISTRIBUTIONworks well when there is not much roomNOT Grease FOR SALE Gun OR DISTRIBUTION to swing a ratchet handle. Air can also be used to power a grease gun, which is An air hammer, sometimes called an air chisel, is use- used to lubricate components with grease fittings. The ful for driving and cutting FIGURE 3-9C . The extra force air power forces the grease through the aperture. that is generated by the compressed air makes it more © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC efficient than a hand chisel and hammer. Just as there Creeper are many chisels, thereNOT are many FOR bits SALE that fit OR into DISTRIBUTION the air NOT FOR SALE OR DISTRIBUTION hammer, their selection depending on the job at hand. To work underneath some types of ATVs, technicians An air drill has some important advantages over the use creepers, which are platforms on rollers that allow more common electric power drill FIGURE 3-9D . With technicians to roll under these ATVs while on their backs. the right© Jones attachment, & Bartlett an air drillLearning, can drill LLCholes, grind, © Jones & Bartlett Learning, LLC polishNOT and cleanFOR parts. SALE Unlike OR the DISTRIBUTION electric drill, it does not CommonNOT FOR Workshop SALE OR DISTRIBUTION Tools carry the risk of producing sparks, which is an important consideration around flammable liquids or petroleum A large percentage of your personal tools will be hand tanks. An air drill does not trail a live electric lead behind tools. These are available in a variety of shapes, sizes and it that could be cut and possibly cause shock and burns. functions and, like all tools, they extend your ability to © Jones &Neither Bartlett does Learning,it become hot LLC with heavy use. © Jonesdo work. & Bartlett Over the years,Learning, manufacturers LLC have introduced NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 71 3/12/14 9:36 PM 72 CHAPTER 3 Care and Use of Tools Applicable to the Trade

new fasteners, wire harness terminals, quick-connect fit- The ends of box-end wrenches are bent or offset so they © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC tings for fuel and other lines, and additional technolo- are easier to grip, and have different-sized heads at each NOT FORgies SALE that requireOR DISTRIBUTION their own specific types of hand tools.NOT end. FOR One SALE disadvantage OR DISTRIBUTION of the box-end wrench is that it This means that technicians need to add tools to their can be awkward to use once the nut or bolt has been toolboxes all of the time. loosened a little because you have to lift it off the head of the fastener and move it to each new position. © Jones & Bartlett Learning, LLCThe open-end wrench is open© Jones on the end,& Bartlett and the twoLearning, LLC TECHNICIANNOT TIP FOR SALE OR DISTRIBUTIONparallel flats grip only two NOTpoints FORof the SALEfastener. OR Open- DISTRIBUTION end wrenches usually have either different-sized heads Invest in quality tools. Because tools extend your on each end of the wrench, or heads the same size but abilities, poor-quality tools will affect the quality and with different angles. The head is at an angle to the quantity of your work. Price is not always the best handle, and is not bent or offset, so it can be flipped indicator© Jones of quality, & Bartlett but it plays Learning, a role. As you LLC learn © Jones & Bartlett Learning, LLC over and used on both sides. This is a good wrench to theNOT purpose FOR and SALEfunction ORof the DISTRIBUTION tools in this section, NOT FOR SALE OR DISTRIBUTION you should be able to identify high-quality tools versus use in very tight spaces as you can flip it over at the poor-quality tools by looking at them, handling them end of its travel and get a new angle, so the head can and putting them to work. catch new points on the fastener. Although an open- end wrench often gives the best access to a fastener, it © Jones & Bartlett Learning, LLC © Jonesshould & not Bartlett be used Learning, if the fastener LLC is extremely tight, as NOT FOR SALE OR DISTRIBUTION NOTthis FOR type SALE of wrench OR DISTRIBUTIONgrips only two points. If the jaws Wrenches flex slightly or the flats do not fit tightly around them, Wrenches are used to tighten and loosen nuts and bolts, the wrench could suddenly slip when force is applied. which are two types of fasteners. There are three com- This slippage can round off the points of the fastener. The best way to tackle a tight fastener is to use a box- monly used wrenches:© the Jones box-end & Bartlett wrench, theLearning, open- LLC © Jones & Bartlett Learning, LLC end wrench and the combination wrench. The box-end end wrench to break the bolt or nut free; then use wrench fits fully aroundNOT the FOR head SALEof the bolt OR or DISTRIBUTION nut and the open-end wrench to finishNOT the FOR job. SALE The open-end OR DISTRIBUTION grips each of the six points at the corners, just like a wrench should be used only on fasteners that are no socket. This is precisely the kind of grip needed if a nut or more than firmly tightened. bolt is very tight, and it gives you a better chance at loos- The combination wrench has an open-end head on one ening© very Jones tight fasteners.& Bartlett Its grip Learning, also makes LLC the box-end end and a closed-end© Jones &head Bartlett on the other.Learning, Both ends LLC are wrenchNOT less FOR likely SALE than the OR open-end DISTRIBUTION wrench to round usually theNOT same size,FOR so SALE the closed OR end DISTRIBUTION may be used to off the points on the head of the bolt FIGURE 3-10A–C . break the bolt loose and the open end for turning the bolt. Because of its versatility, this is probably the most popular wrench for technicians. A variation on the open-end wrench is the flare-nut © Jones & Bartlett Learning, LLC © Joneswrench &, Bartlettalso called Learning, a flare-tubing LLC wrench FIGURE 3-10D . NOT FOR SALE OR DISTRIBUTION NOTThis FOR type SALE of wrench OR DISTRIBUTIONgives a better grip than the open- A end wrench because it grabs all six points of the fastener, instead of two. However, because it is open on the end, it is not as strong as a box-end wrench. The partially open B © Jones & Bartlett Learning, LLCsixth side allows the wrench© to Jones be placed & overBartlett tubing Learning, or LLC NOT FOR SALE OR DISTRIBUTIONpipes so it can be used to turnNOT the FOR tube fittings.SALE ORDo notDISTRIBUTION C use the flare-nut wrench on extremely tight fasteners as the jaws may spread, damaging the nut. Another open-end wrench is the open-end adjustable D wrench, or crescent wrench. This wrench has a movable © Jones & Bartlett Learning, LLC jaw that, by© turning Jones an & adjusting Bartlett screw, Learning, can be adjusted LLC NOT FOR SALE ORE DISTRIBUTION to fit any NOTfastener FOR within SALE its range. OR DISTRIBUTION It should be used only if other wrenches are not available because it is FIGURE 3-10 A. Box-end wrench. B. Open-end wrench. not as strong as a fixed wrench, and could slip off of C. Combination wrench. D. Flare-nut wrench. E. Ratcheting and damage the heads of tight bolts or nuts. Still, it is © Jones & Bartlettbox-end wrench. Learning, LLC © Jonesa handy & Bartletttool to have Learning, because it LLC can be adjusted to fit NOT FOR SALE OR DISTRIBUTION NOTmost FOR fastener SALE sizes. OR DISTRIBUTION

056754_CH03_p056-105.indd 72 3/12/14 9:36 PM CHAPTER 3 Care and Use of Tools Applicable to the Trade 73

A ratcheting box-end wrench is a useful tool for some © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC applications because it can be repositioned without NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION having to be removed FIGURE 3-10E . It has an inner piece that fits over and grabs the fastener points and is able to rotate within the outer housing. A ratcheting mechanism allows it to rotate in one direction and lock in the other direction.© In Jones some cases, & Bartlett the wrench Learning, needs LLC © Jones & Bartlett Learning, LLC simply to be flippedNOT over FORto be SALEused in OR the DISTRIBUTIONopposite NOT FOR SALE OR DISTRIBUTION direction. In other cases, it has a lever that changes the direction from clockwise to counterclockwise. Be A B careful to not overstress this tool by using it to tighten or loosen very tight fasteners, as the outer housing is © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC not very strong. ThereNOT is alsoFOR a ratchetingSALE OR open-end DISTRIBUTION wrench, but it uses NOT FOR SALE OR DISTRIBUTION no moving parts. One of the sides is partially removed so that only the bottom one-third remains to catch a point on the bolt. The normal side works just like a FIGURE 3-11 A. Pipe wrench. B. Oil-filter wrench. © Jones &standard Bartlett open-end Learning, wrench. LLC The shorter side of the© Jones & Bartlett Learning, LLC NOT FORopen-end SALE OR wrench DISTRIBUTION catches the point on the fastener soNOT FOR SALE OR DISTRIBUTION it can be turned. When moving the wrench to get a new bite, the wrench is pulled slightly outward, dis- engaging the short side while leaving the long side to The jaw is adjustable so it can be threaded in or out to slide along the faces of the bolt. The wrench is then fit different pipes sizes. Pipe wrenches are also available © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC rotated to the new position and pushed back in so the in different lengths, allowing increased leverage to be short side engages theNOT next FOR point. SALE This wrench,OR DISTRIBUTION like applied to the pipe. NOT FOR SALE OR DISTRIBUTION other open-end wrenches, is not designed to tighten A specialized tool called an oil-filter wrench grabs the or loosen tight fasteners, but it does work well in blind filter and gives you extra leverage to remove an oil fil- places where a socket or ratcheting box-end wrench ter when it is tight FIGURE 3-11B . These are available cannot© Jonesbe used. & Bartlett Learning, LLC in various ©designs Jones and & sizes.Bartlett Some Learning, oil-filter wrenchesLLC NOT FOR SALE OR DISTRIBUTION are adjustableNOT to FORfit many SALE filter OR sizes. DISTRIBUTION Note also that an oil-filter wrench should be used only to remove an oil filter, never to install it. Almost all oil filters should be TECHNICIAN TIP installed by hand.

© Jones & WrenchesBartlett doLearning, a job properly LLC only if they are the right © JonesSockets & Bartlett Learning, LLC NOT FOR SALEsize for ORthe given DISTRIBUTION nut or bolt head. The size used to NOT FOR SALE OR DISTRIBUTION describe a wrench is the distance across the flats of Sockets are very popular because of their adaptabil- the nut or bolt. There are two systems in common ity and ease of use FIGURE 3-12 . Sockets are a good use—imperial (in inches) and metric (in millimeters). choice when the top of the fastener is reasonably eas- Each system provides a range of sizes, which are ily accessible. The socket fits onto the fastener snugly identified either by a© fraction, Jones which & Bartlett indicates Learning, LLCand grips it on all six corners,© Jones providing & Bartlett the type Learning, of LLC fractions of an inch forNOT the imperialFOR SALE system, ORor by DISTRIBUTION a grip needed on any nut or boltNOT that FOR is extremely SALE OR tight. DISTRIBUTION number, which indicates millimeters for the metric They are available in a variety of configurations, and system. technicians usually have a lot of sockets so they can access a multitude of tight places. Individual sockets fit a particular size of nut or bolt, so they are usually © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC purchased in sets. TheNOT pipe FORwrench SALE grips pipes OR and DISTRIBUTION can exert a lot of force Sockets NOTare classified FOR SALE by the followingOR DISTRIBUTION characteristics: to turn them FIGURE 3-11A . Because the handle pivots slightly, the more pressure put on the handle to turn the ■■ Metric or imperial depending on the motorcycle wrench, the more the grip tightens. The jaws are hardened manufacturer and serrated, so increasing the pressure increases the ■■ Size of drive used to turn them: 1/ , 3/ , and 1/  © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC 2 8 4 risk of marking or even gouging the metal of the pipe. are most common; 1 and 3/  are less common. NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION4

056754_CH03_p056-105.indd 73 3/12/14 9:36 PM 74 CHAPTER 3 Care and Use of Tools Applicable to the Trade

FIGURE 3-12 The construction of a socket.

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION ■■ Number of points: 6 and 12 areDescription: most common; TECHNICIAN TIP 4 and 8 are less common. The anatomy of a socket. Because sockets are usually purchased in sets, with ■■ Depth of socket: Standard and deep are most com- each set providing a slightly different capability, you mon; shallow is ©less Jones common. & Bartlett Learning, LLCcan see why technicians could© Joneseasily have & severalBartlett Learning, LLC ■■ Thickness of wall:NOT Standard FOR SALEand impact OR areDISTRIBUTION most hundred sockets in their toolbox.NOT FOR SALE OR DISTRIBUTION common; thin wall is less common. Sockets are built with a recessed square drive that Turning a socket requires a handle. The most com- fits over the square drive of the ratchet or other driver. mon socket handle, the ratchet, makes easy work of The ©size Jones of the &drive Bartlett determines Learning, how much LLC twisting © Jones & Bartlett Learning, LLC tightening or loosening a nut when not a lot of pressure forceNOT can be FOR applied SALE to the OR socket. DISTRIBUTION The larger the drive, NOT FOR SALE OR DISTRIBUTION is involved FIGURE 3-13B . A ratchet may be set to turn the larger the twisting force. Small fasteners usually in either direction and does not need much room to need only a small torque, so do not use a drive larger than you need because too large a drive may impede the socket’s access to the bolt. For fasteners that are © Jones &really Bartlett tight, anLearning, impact wrench LLC exerts a lot more torque© Jones & Bartlett Learning, LLC NOT FORon SALE a socket OR than DISTRIBUTION turning it by hand. Impact socketsNOT FOR SALE OR DISTRIBUTIONA are usually thicker walled than standard wall sockets and have six points so they can withstand the forces B generated by the impact wrench as well as grip the fastener securely. © Jones & Bartlett Learning, LLC C© Jones & Bartlett Learning, LLC As a general rule, 6-NOT and 12-point FOR SALE sockets OR fit theDISTRIBUTION heads NOT FOR SALE OR DISTRIBUTION of hexagonal-shaped fasteners, and 4- and 8-point sockets fit the heads of square-shaped fasteners. Because 6-point D and 4-point sockets fit the exact shape of the fastener, they have the strongest grip on the fastener, but they E fit on© theJones fastener & Bartlett in only halfLearning, as many LLCpositions as a © Jones & Bartlett Learning, LLC 12-pointNOT or FOR 8-point SALE socket. OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION F Another factor in accessing a fastener is the depth of the socket. If a nut is threaded quite a distance down a FIGURE 3-13 A. Deep socket. B. Ratchet. C. Power bar. stud, then a standard-length socket will not fit far enough D. Sliding T-handle. E. Square drive. F. An extension with © Jones &over Bartlett the stud Learning,to reach the nut.LLC In this case, a deep socket© Jonesa handle & Bartlett attached. Learning, LLC NOT FORwill SALE usually OR reach DISTRIBUTION the nut FIGURE 3-13A . NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 74 3/12/14 9:36 PM CHAPTER 3 Care and Use of Tools Applicable to the Trade 75

swing. It is built to be convenient, not super strong, © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC so too much pressure could damage it. For heavier NOT FORtightening SALE OR or loosening,DISTRIBUTION a breaker bar gives the mostNOT FOR SALE OR DISTRIBUTION leverage FIGURE 3-13C . When that is not available, a sliding T-handle may be more useful. With this tool, both hands may be used, and the position of the tee piece is adjustable to ©clear Jones any obstructions & Bartlett when Learning, turn- LLC © Jones & Bartlett Learning, LLC ing it FIGURE 3-13D . NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION The connection between the socket and the acces- sory is made by a square drive FIGURE 3-13E . The larger the drive, the heavier and bulkier the socket. The 1/ -inch drive is for small work in difficult areas. ©4 Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC The 3/ -inch drive accessories handle a lot of general NOT8 FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION work where torque requirements are not too high. FIGURE 3-15 Pliers are used for grasping and cutting. 1 The /2-inch drive is required for all-around service. 3 The /4-inch and 1-inch are required for large work with high-torque settings. Many fasteners are located © Jones &in Bartlettpositions Learning,where access LLC can be difficult. There are© Jones & Bartlett Learning, LLC NOT FORmany SALE different OR DISTRIBUTION lengths of extensions available to allowNOT it. FOR One commonSALE OR model DISTRIBUTION has four different-sized sockets, the socket to be on the fastener while extending the one on each arm. drive point out to where a handle can be attached Pliers FIGURE 3-13F . A universal joint takes the turning force that needs to Pliers are a hand tool designed to hold, cut or compress © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC be applied to the socket through an angle FIGURE 3-14B . materials FIGURE 3-15 . They are usually made out of two A speed brace or speederNOT handle FOR is theSALE fastest OR way DISTRIBUTION to spin pieces of strong steel joined NOTat a fulcrum FOR point,SALE with OR jaws DISTRIBUTION a fastener on or off a thread by hand, but it cannot apply and cutting surfaces at one end and handles designed to much torque to the fastener; therefore, it is used mainly provide leverage at the other. There are many types of to remove a fastener that has already been loosened, or pliers, including slip-joint, combination, arc joint, needle- to run© Jones the fastener & Bartlett onto the Learning, thread until LLC it begins to nosed and ©flat-nosed. Jones & Bartlett Learning, LLC tightenNOT FIGURE FOR 3-14A SALE. A lugOR wrench DISTRIBUTION FIGURE 3-14C has Quality NOTcombination FOR SALE pliers OR FIGURE DISTRIBUTION 3-16A are the special-sized lug nut sockets permanently attached to most commonly used pliers in a workshop. They are

C B D © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION E C F

FIGURE 3-16 A. Combination pliers. B. Needle-nosed FIGURE 3-14 A. Speed brace. B. Universal joint. pliers. C. Flat-nosed pliers. D. Diagonal-cutting pliers. © Jones & BartlettC. Lug wrench. Learning, LLC © JonesE. Nippers. & Bartlett F. Internal Learning, snap-ring pliers. LLC G. Circlip pliers. NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 75 3/12/14 9:36 PM 76 CHAPTER 3 Care and Use of Tools Applicable to the Trade

made from two pieces of high-carbon or alloy steel. They © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC pivot together so that any force applied to the handles NOT FORis SALEmultiplied OR in DISTRIBUTION the strong jaws. Some pliers provide NOTa FOR SALE OR DISTRIBUTION powerful grip on objects, whereas others are designed to cut. Combination pliers can do both, which is why they are the most commonly used (please note that pliers are job specific). © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC Combination pliersNOT offer two FOR surfaces, SALE one OR for grippingDISTRIBUTION NOT FOR SALE OR DISTRIBUTION flat surfaces and one for gripping rounded objects, and two pairs of cutters. The cutters in the jaws should be used for softer materials that will not damage the blades. The cutters next to the pivot can shear through hard, thin © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC materials, like steel wire or pins. NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Most pliers are limited by their size in what they can FIGURE 3-17 Locking pliers or vise grips. grip. Beyond a certain point, the handles are spread too wide, or the jaws cannot open wide enough, but water- pump pliers overcome that limitation with a movable © Jones &pivot. Bartlett These areLearning, often called LLC Channellocks, after the com©- Jones &TECHNICIAN Bartlett Learning, TIP LLC NOT FORpany SALE that ORfirst DISTRIBUTIONmade them. These pliers have parallel jawsNOT FOR SALE OR DISTRIBUTION that allow you to increase or decrease the size of the jaws When applying pressure to pliers, make sure your by selecting a different set of channels. They are useful hands are not greasy, or they might slip. Select the for a wider grip and a tighter squeeze on parts too big right type and size of pliers for the job. As with most for conventional pliers. tools, if you have to exert almost all your strength to © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC There are a few specialized pliers in most work- get something done, then you are using either the shops. Needle-nosedNOT pliers FOR, which SALE have long,OR DISTRIBUTIONpointed wrong tool or the wrong technique.NOT FOR If the SALE pliers slip, OR DISTRIBUTION jaws, can reach tight spots or hold small items that you will get hurt. At the very least, you will damage other pliers cannot. For example, they can pick up a the tool and what you are working on. Pliers get a lot of hard use in the workshop, so they do get worn and small bolt that has fallen into a tight spot FIGURE 3-16B . damaged. If they are worn or damaged, they will be Flat-nosed pliers have an end or nose that is flat and © Jones & Bartlett Learning, LLC inefficient© andJones can be & dangerous. Bartlett Always Learning, check the LLC square;NOT in contrast, FOR SALE combination OR DISTRIBUTION pliers have a rounded conditionNOT of all workshopFOR SALE tools onOR a regularDISTRIBUTION basis. end. A flat nose makes it possible to bend wire or even a thin piece of sheet steel accurately along a straight edge FIGURE 3-16C . Diagonal-cutting pliers FIGURE 3-16D are used for cutting wire or cotter pins. Locking pliers, also called vise grips, are general- © Jones &Diagonal Bartlett cutters Learning, are the mostLLC common cutters in the© Jonespurpose & Bartlett pliers used Learning, to clamp andLLC hold one or more NOT FORtoolbox, SALE butOR they DISTRIBUTION should not be used on hard or heavy-NOTobjects FOR SALEFIGURE 3-17OR .DISTRIBUTION Locking pliers are helpful because gauge materials because the cutting surfaces will be they free up one or more of your hands when working; damaged. End cutting pliers, also called nippers, have a they clamp something and lock themselves in place to cutting edge at right angle to their length FIGURE 3-16E . hold it. They are also adjustable, so they can be used They are designed to cut through soft metal objects for a variety of tasks. To clamp an object with locking © Jones & Bartlett Learning, LLCpliers, put the object between© Jones the jaws, & turn Bartlett the screw Learning, LLC sticking out from a surface.NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Circlip pliers have metal pins that fit in the holes until the handles are almost closed, then squeeze them of a circlip. Circlips can be of the internal or external together to lock them shut. You can increase or decrease type. If internal, then internal circlip pliers compress the gripping force with the adjustment screw. To release the circlip so it can be removed from and installed them, squeeze the release lever and they should open up. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC in its internal groove FIGURE 3-16F . If external, then Cutting Tools externalNOT circlip FOR pliers SALE are OR used DISTRIBUTION to remove and install NOT FOR SALE OR DISTRIBUTION the circlip in its external groove FIGURE 3-16G . Always Bolt cutters cut heavy wire, non-hardened rods and bolts wear safety glasses when working with circlips, as the FIGURE 3-18A . Their compound joints and long handles rings can easily slip off the snap-ring pliers and fly give the leverage and cutting pressure needed for heavy- © Jones &off Bartlett at tremendous Learning, speeds, LLC possibly causing severe eye© Jonesgauge &materials. Bartlett Tin Learning, snips are theLLC nearest thing in the NOT FORinjuries. SALE OR DISTRIBUTION NOTtoolbox FOR SALE to a pair OR of scissors DISTRIBUTION FIGURE 3-18B . They cut thin

056754_CH03_p056-105.indd 76 3/12/14 9:36 PM CHAPTER 3 Care and Use of Tools Applicable to the Trade 77

traditional Allen key is a hexagonal bar with a right-angle © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC bend at one end. They are made in various sizes in both NOT FOR SALE OR DISTRIBUTION NOTmetric FOR andSALE imperial. OR AsDISTRIBUTION their popularity has increased, so A too has the number of tool variations. Now Allen sockets are available, as are T-handle Allen keys.

© Jones & BartlettB Learning, LLCScrewdrivers © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTIONThe correct screwdriver to NOTuse depends FOR SALEon the ORtype DISTRIBUTIONof slot or recess in the head of the screw or bolt, and how accessible it is. Most screwdrivers cannot grip as securely C as wrenches, so it is very important to match the tip of © Jones & Bartlett Learning, LLC the screwdriver© Jones exactly & with Bartlett the slot Learning,or recess in the LLC head NOT FOR SALE OR DISTRIBUTION of a fastener;NOT otherwise FOR SALEthe tool OR might DISTRIBUTION slip, damaging FIGURE 3-18 A. Bolt cutters. B. Tin snips. C. Aviation snips. the fastener or the tool and possibly injuring you. When using a screwdriver, always check where the screwdriver tip could end up if it slipped off the head of the screw. Many technicians who have not taken this precaution © Jones &sheet Bartlett metal, and Learning, lighter versions LLC make it easy to follow the© Joneshave stabbed& Bartlett a screwdriver Learning, into LLCor through their hand. NOT FORoutline SALE of ORgaskets. DISTRIBUTION Most snips come with straight blades,NOT FORThe SALE most common OR DISTRIBUTION screwdriver has a flat tip, or but if there is an unusual shape to cut, there is a pair blade, which gives it the name flat-tip screwdriver with left- or right-hand curved blades. Aviation snips FIGURE 3-20A . The tip should be almost as wide and thick are designed to cut soft metals FIGURE 3-18C . They are as the slot in the fastener, so that twisting force applied to easy to use because the handles are spring-loaded open © Jones & Bartlett Learning, LLCthe screwdriver is transferred© right Jones out to & the Bartlett edges of Learning, the LLC and double-pivoted for extra leverage. NOT FOR SALE OR DISTRIBUTIONhead where it has most effect.NOT The FOR tip should SALE be ORa snug DISTRIBUTION Allen Wrenches fit in the slot of the screw head. Then the twisting force is applied evenly along the sides of the slot. This will guard Allen wrenches, sometimes called hex keys, are tools against the screwdriver suddenly chewing a piece out of designed to tighten and loosen fasteners with Allen heads the slot and slipping just when the most force is being FIGURE© Jones3-19 . The & AllenBartlett head Learning,has an internal LLC hexagonal exerted. Flat-tip© Jones screwdrivers & Bartlett are available Learning, in a LLCvariety recessNOT that theFOR Allen SALE key fits OR into. DISTRIBUTION Allen keys come in sets, of sizes andNOT lengths, FOR so findSALE the OR right DISTRIBUTION one for the job. and there is a correct key size for every Allen head. They If viewed from the side, the tip should taper slightly give the best grip on a screw or bolt of all the drivers, and until the very end where the tip fits into the slot. If the tip their shape makes them good at getting into tight spots. Care is not clean and square, it should be reshaped or replaced. © Jones &must Bartlett be utilized Learning, to make sure LLC the correct size of Allen key is© JonesWhen & Bartlettyou use a flat-tipLearning, screwdriver, LLC support the shaft used, or the key and/or socket head will be rounded off. The with your free hand as you turn it (but keep it behind NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

FIGURE 3-20 A. Flat-tip screwdriver. B. Phillips screwdriver. © Jones & BartlettFIGURE 3-19 Learning, Allen wrench. LLC © JonesC. Pozidriv& Bartlett screwdriver. Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 77 3/12/14 9:36 PM 78 CHAPTER 3 Care and Use of Tools Applicable to the Trade

the tip). This helps keep the tip square on the slot and stripped with the use of a standard screwdriver. The force © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC centered. Screwdrivers that slip are a common source of of the hammer pushing the bit into the screw, and at the NOT FORdamage SALE and OR injury DISTRIBUTION in workshops. NOTsame FOR time SALE turning OR it, DISTRIBUTION makes it more likely the screw will A screw or bolt with a cross-shaped recess re- break loose. The impact driver accepts a variety of special, quires a Phillips screwdriver or a Pozidriv screwdriver impact tips. Choose the right one for the screw head, fit FIGURE 3-20B . The cross-shaped slot holds the tip of the the tip in place and then tension it in the direction it has screwdriver securely on© Jonesthe head. & The Bartlett Phillips Learning, tip fits a LLCto turn. A sharp blow with the© Joneshammer &breaks Bartlett the screw Learning, LLC tapered recess, whereasNOT the FORPozidriv SALE fits intoOR slotsDISTRIBUTION with free, and then it can be unscrewed.NOT FOR SALE OR DISTRIBUTION parallel sides in the head of the screw FIGURE 3-20C . Both a Phillips and a Pozidriv screwdriver are less likely to slip Magnetic Pickup Tools and sideways because the point is centered in the screw, but Mechanical Fingers again, the screwdriver must be the right size. The fitting © Jones & Bartlett Learning, LLC Magnetic pickup© Jones tools & and Bartlett mechanical Learning, fingers are LLC very process is simplified for these two types of screwdrivers useful for grabbing items in tight spaces FIGURE 3-22 . becauseNOT four FOR sizes SALE are enough OR toDISTRIBUTION fit almost all fasteners NOT FOR SALE OR DISTRIBUTION A magnetic pickup tool is typically a telescoping stick with this type of screw head. that has a magnet attached to the end on a swivel joint. The offset screwdriver fits into spaces where a straight The magnet is strong enough to pick up screws, bolts screwdriver cannot and is useful where there is not much and sockets. For example, if a screw is dropped into a © Jones &room Bartlett to turn itLearning,FIGURE 3-21A LLC. The two tips look identical,© Jones & Bartlett Learning, LLC tight crevice where your fingers cannot reach, a magnetic but one is set at 90 degrees to the other. This is because NOT FOR SALE OR DISTRIBUTION NOTpickup FOR SALEtool can OR be used DISTRIBUTION to extract it. sometimes there is room to make only a quarter turn of the driver. Thus the driver has two tips on opposite ends, so that offset ends of the screwdriver can be used alternately. The ratcheting screwdriver is a popular screwdriver TECHNICIAN TIP © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC handle that usually comes with a selection of flat and NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Phillips tips FIGURE 3-21B . It has a ratchet inside the The challenge is to get the magnet down inside some handle that turns the tip in only one direction depend- areas because the magnet wants to keep sticking to ing on how the slider is set. When set for loosening, a the sides. One trick in this situation is to roll up a piece of paper so that a tube is created. Stick that down into screw can be undone without removing the tip from the the area of the dropped part, then slide the magnet head© of Jonesthe screw. & WhenBartlett set forLearning, tightening, LLC a screw can down the© tube, Jones which & will Bartlett help it get Learning, past magnetic LLC be insertedNOT FORjust as SALE easily. OR DISTRIBUTION objects. OnceNOT the FOR magnet SALE is down, OR you DISTRIBUTION may want to An impact driver is used when a screw or a bolt is remove the roll of paper. Just remember two things: rusted/corroded in place, or overtightened, and needs a First, patience is important when using this tool; and tool that can apply more force than the other members second, don’t drop anything in the first place! of this family FIGURE 3-21C . Screw slots could easily be © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

A © Jones & Bartlett Learning, LLC A© Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION B B

FIGURE 3-21 A. Offset screwdriver. B. Ratcheting FIGURE 3-22 A. Mechanical fingers. B. Magnetic © Jones & Bartlettscrewdriver. C.Learning, Impact driver. LLC © Jonespickup & tools.Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 78 3/12/14 9:36 PM CHAPTER 3 Care and Use of Tools Applicable to the Trade 79

Mechanical fingers are also designed to extract or © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC insert objects in tight spaces. Because they actually grab NOT FORthe SALE object, OR they DISTRIBUTION can pick up non-magnetic items, whichNOT FOR SALE OR DISTRIBUTION A makes them handy for picking up rubber or plastic parts. They use a flexible body and come in different lengths, B but are typically about 12–18 (300–450 mm) long. They have expanding© grappling Jones &fingers Bartlett on oneLearning, end to LLC © Jones & Bartlett Learning, LLC grab items, and the otherNOT end FOR has aSALE push mechanism OR DISTRIBUTION to NOT FOR SALE ORC DISTRIBUTION expand the fingers and a retracting spring to contract the fingers. D Hammers E © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC HammersNOT are FOR a vital SALE part of OR the workshopDISTRIBUTION tool collection, NOT FOR SALE OR DISTRIBUTION and a variety are commonly used. The most common hammer in an motorcycle workshop is the ball-peen FIGURE 3-23 A. Ball-peen hammer. B. Steel hammer. (engineer’s) hammer FIGURE 3-23A . Like most hammers, C. Club hammer. D. Nylon/Brass tip mallet. E. Dead-blow its head is hardened steel. A punch or a chisel can be hammer. © Jones &driven Bartlett with theLearning, flat face. LLCIts name comes from the ball© Jones & Bartlett Learning, LLC NOT FORpeen, SALE or roundedOR DISTRIBUTION face. It is usually used for flatteningNOT FOR SALE OR DISTRIBUTION and peening a rivet. The hammer should always match being moved. For example, it can be used to tap a the size of the job, and it is better to use one that is too crankshaft, to measure end play or to break a gasket big than too small. seal on an aluminum casing. © Jones & Bartlett Learning, LLCA dead-blow hammer ©is designedJones & not Bartlett to bounce Learning, LLC NOT FOR SALE OR DISTRIBUTIONback when it hits somethingNOT FIGURE FOR 3-23E SALE . A rebound OR DISTRIBUTION- TECHNICIAN TIP ing hammer can be dangerous or destructive. A dead- blow hammer may be made with a lead head or, more The hammer you use depends on the part you are striking. Hammers with a metal face should almost commonly, a hollow polyurethane head filled with always© Jones be harder & thanBartlett the part Learning, you are hammering. LLC lead shot or© Jonessand. The & headBartlett absorbs Learning, the blow LLC when NeverNOT strike FOR two SALE hardened OR tools DISTRIBUTION together, as this can the hammerNOT makes FOR contact, SALE reducingOR DISTRIBUTION any bounce- cause the hardened parts to shatter. back or rebounding. This hammer can be used when working on the motorcycle chassis or when dislodg- ing stuck parts. Hitting chisels with a steel hammer is fine, but some- © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC times you need only to tap a component to position it Safety NOT FORFIGURE SALE 3-23B OR. DISTRIBUTIONA steel hammer might mark or damageNOT FOR SALE OR DISTRIBUTION the part, especially if it is made of a softer metal such as When using hammers and chisels, safety goggles must aluminum. In such cases, a soft-faced hammer should always be worn. be used for the job. Soft-faced hammers range from very soft, with rubber or plastic© Jones heads, &to Bartlettslightly harder, Learning, with LLC © Jones & Bartlett Learning, LLC brass or copper heads.NOT FOR SALE OR DISTRIBUTIONChisels NOT FOR SALE OR DISTRIBUTION When a large chisel needs a really strong blow, it is time to use a club hammer FIGURE 3-23C . The club ham- The most common kind of chisel is a cold chisel mer is like a small mallet, with two square faces made of FIGURE 3-24A . It gets its name from the fact that it is high-carbon steel. It is the heaviest type of hammer that used to cut cold metals, rather than heated metals. It can be© Jonesused one-handed. & Bartlett The Learning, club hammer LLC is used in has a flat ©blade Jones made &of Bartletthigh-quality Learning, steel and aLLC cutting conjunctionNOT FOR with aSALE chisel to OR cut DISTRIBUTIONoff a bolt where corrosion angle of approximatelyNOT FOR SALE70 degrees. OR DISTRIBUTIONThe cutting end is has made it impossible to remove the nut. tempered and hardened because it has to be harder than The most common mallet in the workshop has a the metals to be cut. The head of the chisel needs to be head made of hard rubber FIGURE 3-23D . It is a special- softer so it will not chip when it is hit with a hammer. © Jones &purpose Bartlett tool Learning, and is often LLCused for moving things into© JonesTechnicians & Bartlett sometimes Learning, use a cold LLC chisel to remove bolts NOT FORplace SALE where OR it DISTRIBUTION is important not to damage the itemNOT whose FOR headsSALE have OR rounded DISTRIBUTION off.

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A © JonesA & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

B B © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION FIGURE 3-24 A. Cold chisel. B. Cross-cut chisel. FIGURE 3-25 A. Pry bar. B. Roll bar.

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALETECHNICIAN OR DISTRIBUTION TIP NOT FOR SALE OR DISTRIBUTION Chisels and punches are designed with a softer striking end than hammers. Over time, this softer metal “mushrooms,” and small fragments are prone to breaking off when© hammered. Jones & These Bartlett fragments Learning, LLC © Jones & Bartlett Learning, LLC could cause eye or otherNOT penetrative FOR SALE injuries OR to DISTRIBUTION NOT FOR SALE OR DISTRIBUTION people in the area. Always inspect chisels and punches FIGURE 3-26 A gasket scraper. for mushrooming and dress them on a grinder when necessary.

© Jones & Bartlett Learning, LLC Gasket Scrapers© Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION A cross-cut chisel is so named because the sharp- A gasket scraper has a hardened, sharpened blade. It is ened edge is across the blade width. This chisel narrows designed to remove a gasket without damaging the sealing down along the stock, so it is good for getting in grooves face of the component, when used properly FIGURE 3-26 . FIGURE 3-24B . It is used for cleaning out or even making On one end, it has a comfortable handle to grip like a © Jones &key Bartlett ways. The Learning, flying chips LLC of metal should always ©be Jonesscrewdriver & Bartlett handle; Learning, on the other end,LLC a blade is fitted with NOT FORdirected SALE away OR DISTRIBUTIONfrom the user. NOTa FOR sharp edgeSALE to assist OR inDISTRIBUTION the removal of gaskets. The gasket scraper should be kept sharp to make it easy to remove Pry Bars all traces of the old gasket and sealing compound. The blades come in different sizes, with a typical size being 1 Pry bars (also known as crowbars) are composed of (25 mm) wide. Whenever you use a gasket scraper, be very a strong metal and are used as levers to move, adjust © Jones & Bartlett Learning, LLCcareful not to nick or damage© theJones surface & beingBartlett cleaned. Learning, LLC or pry. Pry bars are availableNOT FOR in a varietySALE of OR shapes DISTRIBUTION and NOT FOR SALE OR DISTRIBUTION sizes. Many have a tapered end that is slightly bent, with a plastic handle on the other end FIGURE 3-25A . This design works well for applying force to tension belts or for TECHNICIAN TIP moving parts into alignment. Another type of pry bar is Many engine components are made of aluminum. the roll© Jonesbar FIGURE & Bartlett3-25B . One Learning, end is sharply LLC curved and © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION Because NOTaluminum FOR is quite SALE soft, ORit is critical DISTRIBUTION that tapered and is used for prying. The other end is tapered you use the gasket scraper very carefully so as to a dull point and is used to align larger holes, such not to damage an aluminum surface. This can be as transmission bell housings or engine motor mounts. accomplished by keeping the gasket scraper at a fairly Because pry bars are made of hardened steel, care should flat angle to the surface. The gasket scraper should © Jones &be Bartletttaken when Learning, using them LLC on softer materials to avoid© Jonesalso & be Bartlett used only byLearning, hand, not with LLC a hammer. NOT FORany SALE damage. OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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© Jones Files& Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FORFiles SALE are OR cutting DISTRIBUTION devices designed to remove smallNOT FOR SALE OR DISTRIBUTION amounts of material from the surface of a workpiece. Files are available in a variety of shapes, sizes and coarse- ness, depending on the material being worked and the size of the job. Files have© Jones a pointed & tangBartlett on one Learning, end that LLC © Jones & Bartlett Learning, LLC is fitted to a handle. FilesNOT are FOR often SALEsold without OR DISTRIBUTIONhandles, NOT FOR SALE OR DISTRIBUTION but they should not be used until a handle of the right size has been fitted. A correctly sized handle fits snugly without working loose when the file is in use. Always check the handle before using the file. If the handle is loose,© give Jones it a sharp & Bartlett rap to tighten Learning, it up, LLCor if it is the © Jones & Bartlett Learning, LLC threadedNOT type, FOR screw SALE it on ORtighter. DISTRIBUTION If it fails to fit snugly, NOT FOR SALE OR DISTRIBUTION you must use a different-sized handle.

© Jones & BartlettSafety Learning, LLC © JonesFIGURE & Bartlett 3-28 Common Learning, flat files. LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Hands should always be kept away from the surface of the file and the metal that is being worked on. Filing can produce small slivers of metal that can be difficult much less material on each stroke, and the finish is much to remove from a finger or hand. Clean hands will help smoother. On a job, the coarse file is used first to remove avoid slipping and lessen© Jones the corrosion & Bartlett caused byLearning, acids LLCmaterial quickly, then a smoother© Jones file gently& Bartlett removes Learning, the LLC last of it and leaves a clean finish to the work. and moisture from theNOT skin. FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION The full list of grades in flat files, from rough to smooth, follows FIGURE 3-28 . What makes one file different from another is not just ■■ Rough files have the coarsest teeth, with approxi- the shape© Jones but also & Bartletthow much Learning, material it is LLC designed to mately© 20 Jones teeth per & 1Bartlett inch or 25 Learning, mm. They are LLC used when a lot of material must be removed quickly. removeNOT with FOR each SALEstroke. TheOR teeth DISTRIBUTION on the file determine NOT FOR SALE OR DISTRIBUTION how much material will be removed FIGURE 3-27 . Since They leave a very rough finish and have to be fol- the teeth face one direction only, the file cuts in only one lowed by finer files to produce a smooth final finish. direction. Dragging the file backward over the surface of ■■ Coarse bastard files are still coarse files, with the metal only dulls the teeth and wears them out quickly. approximately 30 teeth per 1 inch or 25 mm, but © Jones & TeethBartlett on a Learning,coarse-grade LLC file are longer, with a greater© Jones they& Bartlett are not asLearning, coarse as the LLC rough file. They are NOT FORspace SALE between OR DISTRIBUTION them. A coarse-grade file working onNOT a FORalso SALE used toOR rough DISTRIBUTION out or remove material quickly piece of mild steel will remove a lot of material with each from the job. stroke, but it leaves a rough finish. A smooth-grade file ■■ Second-cut files have approximately 40 teeth per has shorter teeth cut more closely together. It removes 1 inch or 25 mm, and provide a smoother finish © Jones & Bartlett Learning, LLC than the rough or coarse© bastardJones file. & BartlettThey are goodLearning, LLC NOT FOR SALE OR DISTRIBUTIONall-round intermediaryNOT files FORand leave SALE a reasonably OR DISTRIBUTION smooth finish. ■■ Smooth files have approximately 60 teeth per 1 inch or 25 mm, and are a finishing file used to provide © Jones & Bartlett Learning, LLC a smooth© Jones final finish.& Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION ■■ Dead-smoothNOT FOR files SALE have 100OR teethDISTRIBUTION per 1 inch or 25 mm, or more, and are used where a very fine finish is required. Some flat files are available with one smooth edge and © Jones & BartlettFIGURE 3-27 Learning, The teeth on LLC a file. © Jonesare called & Bartlett safe-edge Learning,files. They allow LLC filing up to an edge Description: without damaging it. NOT FOR SALE OR DISTRIBUTIONThe teeth on a file. NOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 81 3/12/14 9:36 PM 82 CHAPTER 3 Care and Use of Tools Applicable to the Trade

The thread file cleans clogged or distorted threads © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC on bolts and studs FIGURE 3-30B . Thread files are avail- NOT FOR SALE OR DISTRIBUTION NOTable FOR in eitherSALE metric OR orDISTRIBUTION imperial configurations, so make sure you use the correct file. Each file has eight different A surfaces that match different thread dimensions, so the right face must be used. © Jones & Bartlett Learning, LLCFiles should be cleaned © after Jones each & use. Bartlett If they Learning, are LLC NOT FOR SALE OR DISTRIBUTIONclogged, they can be cleanedNOT by using FOR a SALEfile card OR or DISTRIBUTIONfile B brush FIGURE 3-30C . This tool has short steel bristles that clean out the small particles that clog the teeth of the file. Rubbing a piece of chalk over the surface of the file prior to filing will make it easier to clean. © Jones & BartlettC Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Hacksaw FIGURE 3-29 A. Warding file.B. Square file. C. Triangular file. The hacksaw is used for the general cutting of metals for a crude cut FIGURE 3-31 . The frames and blades are © Jones & Bartlett Learning, LLC © Jonesadjustable. & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Flat files are fine on straightforward jobs, but you need Clamps files that work in some awkward spots as well. Awarding file is thinner than other files and comes to a point; it is The bench vise is a useful tool for holding anything that used for working in narrow slots FIGURE 3-29A . A square can fit into its jaws FIGURE 3-32A . Some common uses file has teeth on all four© Jones sides, &so Bartlettyou can use Learning, it in a LLCinclude sawing, filing or chiseling.© Jones The & jaws Bartlett are serrated Learning, LLC square or rectangularNOT hole FORFIGURE SALE 3-29B . ORA square DISTRIBUTION file to give extra grip. They are alsoNOT very FOR hard, SALE which OR means DISTRIBUTION can make the right shape for a squared metal key to fit that when the vise is tightened, the jaws can mar what- in a slot. A triangular file has three sides FIGURE 3-29C . ever they grip. To prevent this, a pair of soft jaws may be Because it is triangular, it can get into internal corners; fitted whenever the danger of damage arises. These are it is able to cut right into a corner without removing usually made of aluminum or some other soft metal, or material© Jones from the & sides. Bartlett Learning, LLC can have a ©rubber-type Jones & surface Bartlett applied Learning, to them. LLC CurvedNOT filesFOR are SALE either OR half-round DISTRIBUTION or round. A half- When materialsNOT FOR are tooSALE awkward OR DISTRIBUTION to grip vertically round file has a shallow convex surface that can file in a plain vise, it may be easier to use an offset vise. in a concave hollow or in an acute internal corner The offset vise has its jaws set to one side to allow long FIGURE 3-30A . The fully round file, sometimes called a components to be held vertically. For example, a long © Jones &rat-tail Bartlett file, can Learning, make holes LLC bigger. It can also file inside© Jonesthreaded & Bartlett bar can be Learning, held vertically LLC in an offset vise to NOT FORa SALEconcave OR surface DISTRIBUTION with a tight radius. NOTcut FOR a thread SALE with OR a die. DISTRIBUTION

B © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION C

056754_CH03_p056-105.indd 82 3/12/14 9:36 PM CHAPTER 3 Care and Use of Tools Applicable to the Trade 83

being assembled, drilled or welded. It can reach around © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC awkwardly shaped pieces that will not fit in a vise. It is NOT FOR SALE OR DISTRIBUTION NOTalso FOR commonly SALE usedOR DISTRIBUTIONto retract disc brake caliper pistons. This clamp is portable, so it can be taken to the work. Taps and Dies © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC Taps cut threads inside holes or nuts FIGURE 3-33A . They NOT FOR SALE OR DISTRIBUTIONusually are available in threeNOT different FOR types. SALE The OR first DISTRIBUTION is known as a taper tap. It narrows at the tip to give it a good start in the hole where the thread is to be cut. The diameter of the hole is determined by a tap drill chart, A © Jones & Bartlett Learning, LLC which can be© obtainedJones & from Bartlett engineering Learning, suppliers. LLC This NOT FOR SALE OR DISTRIBUTION chart showsNOT what FORhole size SALE has to OR be drilled DISTRIBUTION and what tap size is needed to cut the right thread for any given bolt size. Remember that if you are drilling a 0.250 (6-mm) or larger hole, you should use a smaller pilot drill first. Once the properly sized hole has been drilled, the taper © Jones & Bartlett Learning, LLC © Jonestap can & tapBartlett a thread Learning, right through LLC a piece of steel to NOT FOR SALE OR DISTRIBUTION NOTenable FOR aSALE bolt to ORbe screwed DISTRIBUTION into it. The second type of tap is an intermediate tap, also known as a plug tap, and the third is a bottoming tap. They are used to tap a thread into a hole that does not © Jones & Bartlett Learning, LLCcome out the other side of the© material, Jones called& Bartlett a blind hole Learning,. LLC NOT FOR SALE OR DISTRIBUTIONA taper tap is used to start theNOT thread FOR in the SALE hole and OR then DISTRIBUTION B the intermediate tap is used, followed by a bottoming tap to take the thread right to the bottom of the blind hole. A tap handle FIGURE 3-33B has a right-angled jaw that matches the squared end that all taps have. The jaws are © Jones & Bartlett Learning, LLC designed to© hold Jones the tap & securely, Bartlett and Learning, the handles provideLLC NOT FOR SALE OR DISTRIBUTION the leverageNOT for the FOR operator SALE to rotate OR theDISTRIBUTION tap comfortably to cut the thread. To cut a thread in an awkward space,

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION C A FIGURE 3-32 A. Bench vise. B. Drill vise. C. C-clamp. B © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION A drill vise is designed to hold material on a drill worktable. The drill worktable has slots cut into to it D to allow the vise to be bolted down on the table to hold material© Jones securely & FIGURE Bartlett 3-32B Learning,. To hold something LLC firmly © JonesC & Bartlett Learning, LLC and drillNOT it FORaccurately, SALE the ORobject DISTRIBUTION must be secured in the NOT FOR SALE OR DISTRIBUTION jaws of the vise. The vise can be moved on the bed until the precise drilling point is located, and then tightened down by bolts to hold the drill vise in place during drilling. © Jones & TheBartlett name Learning, for the G-clamp LLC comes from its shape© JonesFIGURE & Bartlett 3-33 A. Taps.Learning, B. Tap handle. LLC C. Stock. D. Die nut. NOT FORFIGURE SALE 3-32C OR. DISTRIBUTIONIt holds parts together while they areNOT FOR SALE OR DISTRIBUTION

056754_CH03_p056-105.indd 83 3/12/14 9:36 PM 84 CHAPTER 3 Care and Use of Tools Applicable to the Trade

a T-shaped tap handle is very convenient. Its handles are tool looks like an ordinary tap and die set, but instead © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC not as long, so it fits into tighter spaces; however, it is of cutting the threads, it reshapes the damaged portion NOT FORharder SALE to ORturn DISTRIBUTIONand to guide accurately. NOTof FOR the thread. SALE OR DISTRIBUTION To cut a brand-new thread on a blank rod or shaft, a Threads that have substantial damage require other die held in a diestock is used FIGURE 3-33C . The die may methods of repair. A common method for repairing dam- be split so that it can be adjusted more tightly onto the aged internal threads is a thread insert. A number of work with each pass of© the Jones die, as &the Bartlett thread is cutLearning, deeper LLCmanufacturers make thread© inserts, Jones and & they Bartlett all work Learning, in LLC and deeper, until the nutNOT fits FOR properly. SALE The ORdie nutDISTRIBUTION is also a similar fashion. The threadNOT insert FOR is a SALEsleeve that OR has DISTRIBUTION common in the workshop FIGURE 3-33D . It is hexagonal- both an internal and external thread. The internal thread shaped to fit a wrench, and it is commonly used to clean on the insert matches the original damaged thread size. up threads that are rusty or have been damaged. The hole with the damaged thread is made larger and a Screw extractors are devices designed to remove fresh, larger-diameter thread is cut. This thread matches © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC screws, studs or bolts that have broken off in threaded the external thread on the insert. The thread insert can holes.NOT A common FOR SALE type of ORextractor DISTRIBUTION uses a coarse, left- then be screwedNOT and FOR secured SALE into OR the preparedDISTRIBUTION hole. The hand tapered thread formed on its hardened body. insert provides a brand-new threaded inside thread that Usually, a hole is drilled in the center of the broken matches the original size. screw and then the extractor is screwed into the hole. © Jones &The Bartlett left-hand Learning, thread grips LLC the broken part of the bolt© JonesPullers & Bartlett Learning, LLC NOT FORand SALE unscrews OR it.DISTRIBUTION The extractor is marked with the sizesNOT Pullers FOR SALE are a veryOR DISTRIBUTION common, universal tool that are of the screw it is designed to remove and the hole that used for removing bearings, bushes, pulleys and gears needs to be drilled. It is important to drill the hole care- FIGURE 3-34A . Specialized pullers are also available for fully in the center of the bolt or stud in case you end specific tasks where a standard puller is not as effective. up having to drill the bolt out. If you drill the hole off- © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC center, you will not be able to drill it out all the way to the inside diameter ofNOT the threads, FOR SALE and removal OR DISTRIBUTION will be NOT FOR SALE OR DISTRIBUTION nearly impossible.

Thread Repair © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC ThreadNOT repair FOR is used SALE in situations OR DISTRIBUTION where it is not possible NOT FOR SALE OR DISTRIBUTION to replace a damaged component. This may be because the thread is located in a large, expensive component, such as the engine block or cylinder head, or because parts are not available. The aim of thread repair is to © Jones &restore Bartlett the thread Learning, to a condition LLC that restores the fasten©- Jones & Bartlett Learning, LLC NOT FORing SALE integrity. OR It DISTRIBUTION can be performed on internal threads,NOT FOR SALE OR DISTRIBUTION such as in a housing, engine block or cylinder head, or A on external threads, such as on a bolt.

Types of Thread Repair © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC Many different tools andNOT methods FOR SALEcan be used OR toDISTRIBUTION repair NOT FOR SALE OR DISTRIBUTION a thread. The least invasive method is to reshape the threads. If the threads are not too badly damaged—for example, if the outer thread is slightly damaged from being started crooked (cross-threaded)—then a thread file ©may Jones be used & toBartlett clean them Learning, up, or a LLCrestoring tool © Jones & Bartlett Learning, LLC may NOTbe used FOR to reshape SALE them. OR EachDISTRIBUTION thread file has eight NOT FOR SALE OR DISTRIBUTION different sets of file teeth that match various thread pitches. Select the set that matches the bolt you are B working on and file the bolt in line with the threads. The © Jones &file Bartlett removes Learning,any distorted LLC metal from the threads. File© JonesFIGURE & Bartlett 3-34 A. Puller.Learning, B. Gear puller. LLC NOT FORonly SALE until OR the badDISTRIBUTION spot is reshaped. The thread-restoringNOT FOR SALE OR DISTRIBUTION

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The most common pullers have two or three legs that © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC grip the part to be removed. A center bolt, called a forc- NOT FORing SALE screw orOR jacking DISTRIBUTION bolt, is then screwed in, producing NOTa FOR SALE OR DISTRIBUTION jacking or pulling action, which extracts the part. Gear pullers come in a range of sizes and shapes, all designed for particular applications FIGURE 3-34B . They consist of three main parts:© Jones jaws, a &cross-arm Bartlett and Learning, a forcing LLC © Jones & Bartlett Learning, LLC screw. There are generallyNOT two FOR or three SALE jaws OR on DISTRIBUTIONa puller. NOT FOR SALE OR DISTRIBUTION They are designed to work either externally around a pulley or internally. The forcing screw is a long, fine- A threaded bolt that is applied to the center of the cross- arm. When the forcing screw is turned, it applies many © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC tons of force through the component you are removing. Screw T-handle The cross-armNOT FOR attaches SALE the OR jaws DISTRIBUTION to the forcing screw. NOT FOR SALE OR DISTRIBUTION There may be two, three or four arms. If the cross-arm has four arms, three of the arms are spaced 120 degrees Adapters apart. The fourth arm is positioned 180 degrees apart Yoke © Jones &from Bartlett one arm. Learning, This allows LLC the cross-arm to be used as© Jones & Bartlett Learning, LLC NOT FOReither SALE a two- OR or DISTRIBUTION a three-arm puller. NOT FOR SALE OR DISTRIBUTION

Flaring Tools Clamp

A tube-flaring tool is used to flare the end of a tube so Cone it can be connected to© another Jones tube & Bartlettor component. Learning, One LLC © Jones & Bartlett Learning, LLC example of this is where the brake line screws into a Die block wheel cylinder. The flaredNOT end FOR is compressed SALE OR between DISTRIBUTION two NOT FOR SALE OR DISTRIBUTION threaded parts so that it will seal the joint and withstand high pressures. The three most common shapes of flares B are the single flare, for tubing carrying low pressures, like a© fuel Jones line; the& Bartlett double flare Learning,, for higher LLC pressures, © Jones & Bartlett Learning, LLC such NOTas in aFOR brake SALE system; OR and DISTRIBUTIONthe ISO flare (sometimes NOT FOR SALE OR DISTRIBUTION called a bubble flare), which is the metric version used in Description: brake systems FIGURE 3-35A . Components of a flare tool. Flaring tools have two parts: a set of bars with holes Label parts. that match the diameter of the tube end that is being © Jones &shaped; Bartlett and aLearning, yoke that drives LLC a cone into the mouth of© Jones & Bartlett Learning, LLC NOT FORthe SALE tube ORFIGURE DISTRIBUTION 3-35B . To make a single flare, the endNOT FOR SALE OR DISTRIBUTION of the tube is placed level with the surface of the top of the flaring bars. With the clamp screw firmly tightened, the feed screw flares the end of the tube. C Making a double flare© Jones is similar, & Bartlett but an extra Learning, step is LLC © Jones & Bartlett Learning, LLC added and more of theNOT tube FOR is exposed SALE to ORallow DISTRIBUTION for the NOT FOR SALE OR DISTRIBUTION folding over into a double flare. A double-flaring button FIGURE 3-35 A. Single flare, double flare, and ISO flare. B. Components of a flare tool. C. Tubing cutter. is placed into the end of the tube, and when it is removed after tightening, the pipe looks like a bubble. Placing the cone and yoke over the bubble allows you to turn the feed© Jones screw and & Bartlett force the bubbleLearning, to fold LLC in on itself, A tubing© cutter Jones is more & Bartlett convenient Learning, and neater LLC than a formingNOT the FOR double SALE flare. OR DISTRIBUTION saw when cuttingNOT FOR pipes SALEand metal OR tubing DISTRIBUTION FIGURE 3-35C . An ISO flare uses a flaring tool made specifically for The sharpened wheel does the cutting. As the tool turns that type of flare. It is similar to the double-flare proc- around the pipe, the screw increases the pressure, driv- ess but stops with the use of the button. It does not get ing the wheel deeper and deeper through the pipe until © Jones &doubled Bartlett back Learning, on itself. It should LLC resemble a bubble shape© Jonesit finally & Bartlett cuts through. Learning, There is LLC a larger version that is NOT FORwhen SALE you OR are finished.DISTRIBUTION NOTused FOR for SALE cutting OR exhaust DISTRIBUTION pipes.

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© Jones & BartlettTECHNICIAN Learning, TIPLLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION A flaring tool is used to produce a pressure seal for A sealing brake lines and fuel system tubing. Make sure you test the flared joint for leaks before completing the repair; otherwise the brakes could fail or the fuel could catch on fire. © Jones & Bartlett Learning, LLC B© Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

Additional Tools © Jones & Bartlett Learning, LLC © Jones & BartlettC Learning, LLC PunchesNOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION FIGURE 3-37 A. Pin punch. B. Wad punch. C. Number Punches are used when the head of the hammer is too punch set. large to strike the object being hit without causing damage to adjacent parts. A punch transmits the hammer’s © Jones &striking Bartlett power Learning, from the soft LLC upper end down to the tip© Jones & Bartlett Learning, LLC NOT FORthat SALE is made OR ofDISTRIBUTION hardened high-carbon steel. A punchNOT does FOR not SALE spread OR the endDISTRIBUTION of the pin and make it an even transmits an accurate blow from the hammer at exactly tighter fit. Once the starter drift has got the pin moving, one point, something that cannot be guaranteed using a a suitable pin punch will drive the pin out or in. A drift hammer on its own. punch also works well for aligning holes on two mating When marks need to be drawn on an object like a steel objects, such as a valve cover and cylinder head. Forcing plate to help locate a ©hole Jones to be drilled,& Bartlett a prick Learning, punch LLCthe drift punch in the hole ©will Jones align both & Bartlett components Learning, LLC is used to mark the pointsNOT so FOR they willSALE not ORrub off.DISTRIBUTION They for easier installation of theNOT remaining FOR bolts. SALE OR DISTRIBUTION can also be used to scribe intersecting lines between given Pin punches are available in various diameters. A pin points. The prick punch’s point is very sharp, so a gentle punch has a long, slender shaft with straight sides. It is tap leaves a clear indentation FIGURE 3-36A . The center used to drive out rivets or pins FIGURE 3-37A . A lot of punch© isJones not as &sharp Bartlett as a prick Learning, punch and LLC is usually components© are Jones either held& Bartlett together Learning,or accurately locatedLLC biggerNOT FIGURE FOR 3-36B SALE. It makes OR DISTRIBUTIONa bigger indentation that by pins. PinsNOT can FOR be pretty SALE tight, OR and DISTRIBUTION a group of pin centers a drill bit at the point where a hole needs to punches is specially designed to deal with them. be drilled. Special punches with hollow ends are called wad A drift punch is also named a starter punch because you punches or hollow punches FIGURE 3-37B . They are the should always use it first to get a pin moving FIGURE 3-36C . most efficient tool to make a hole in soft sheet material © Jones &It hasBartlett a tapered Learning, shank, and LLC the tip is slightly hollow so ©it Joneslike shim & Bartlett steel, plastic Learning, and leather LLC or, most commonly, in a NOT FOR SALE OR DISTRIBUTION NOTgasket. FOR WhenSALE they OR are DISTRIBUTION used, there should always be a soft surface under the work, ideally the end grain of a wooden block. If a hollow punch loses its sharpness or has nicks around its edge, it will make a mess instead of a hole. Numbers and letters, like the engine numbers on some © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC A cylinder blocks, are usually made with number and letter NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION punches that come in boxed sets FIGURE 3-37C . The rules for using these punches are the same as for all punches. The B punch must be square with the surface being worked on, not on an angle, and the hammer must hit the top squarely. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION RivetingNOT Tools FOR SALE OR DISTRIBUTION C There are many applications for blind rivets, and various rivet types and tools may be used to do the riveting. Pop- FIGURE 3-36 A. Prick punch. B. Center punch. rivet guns are convenient for occasional riveting of light © Jones & BartlettC. Drift punch. Learning, LLC © Jonesmaterials & Bartlett FIGURE 3-38 Learning,. A typical LLC pop or blind rivet has NOT FOR SALE OR DISTRIBUTION NOTa FOR body, SALEwhich forms OR DISTRIBUTIONthe finished rivet, and a mandrel,

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The rivet is inserted into the riveting tool, which, when © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC squeezed, pulls the end of the mandrel back through the NOT FOR SALE OR DISTRIBUTION NOTbody FOR of SALE the rivet. OR Because DISTRIBUTION the mandrel head is bigger than the hole through the body, it swells out as it comes through the body. Finally, the mandrel head will snap off under the pressure and fall out, leaving the rivet body © Jones & Bartlett Learning, LLCgripping the two sheets of material© Jones together. & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Diagnostic Equipment The motorcycle people ride today has certainly evolved significantly, even over just the last few years. Yet despite © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC all the innovations, motorcycle emissions still harm the NOT FOR SALE OR DISTRIBUTION environment,NOT as FOR well as SALE human OR health, DISTRIBUTION and therefore FIGURE 3-38 Pop-rivet guns. need to be monitored and kept in check. Motorcycle repair technicians know that emissions testing and repair remedies are a big part of day-to-day © Jones &which Bartlett is discarded Learning, when LLC the riveting is completed© Jonesbusiness. & Bartlett In the interest Learning, of public LLC health, keeping motor- NOT FORFIGURE SALE 3-39 OR. It DISTRIBUTION is called a blind rivet because there is noNOT cycles FOR running SALE clean OR isDISTRIBUTION a mandate. Low tailpipe emissions need to see or reach the other side of the hole in which also mean a motorcycle is running efficiently, which helps the rivet goes to do the work. In some types, the rivet is to conserve energy. plugged shut so that it is waterproof or pressure-proof. Pollutants © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTIONMotorcycles emit evaporativeNOT emissions, FOR known SALE as volatileOR DISTRIBUTION TECHNICIAN TIP organic compounds (VOCs) to the atmosphere. VOCs may be fuel or oil vapors emitted from the fuel tank, fuel A rivet is a one-time-use fastener. Unlike a nut and lines, the engine crankcase or elsewhere. In earlier models, bolt, which can generally be disassembled and reused, engine draft tubes spewed VOCs from the crankcase onto a rivet© Jones cannot. &The Bartlett metal shell Learning, that makes up LLC a pop the road, as© evidenced Jones by& Bartlettdark center-of-lane Learning, deposits LLC on rivetNOT is crushed FOR into SALE place OR so that DISTRIBUTION it holds the parts uphill stretchesNOT of FOR road. SALESimilarly, OR hot DISTRIBUTION summer days pro- firmly together. If it ever needs to be removed, it must duced the smell of gasoline fumes around filling stations be drilled out. and around parked vehicles…but not today! Dynamometer © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOTA FOR dynamometer SALE OR is a DISTRIBUTIONmachine that measures the torque Mandrel head and power produced by an engine FIGURE 3-40 . It applies various loads to an engine and is usually connected to a Rivet body computer that can analyze and calculate all the aspects Shank of engine operation measured. Rivet head© Jones & Bartlett Learning, LLCDynamometers are particularly© Jones useful & in Bartlettdesigning andLearning, LLC NOT FOR SALE OR DISTRIBUTIONrefining engine technology.NOT They FORcan help SALE identify OR how DISTRIBUTION an engine or its drivetrain need to be modified or tuned to achieve more efficient power transfer. There are two types of dynamometer: © Jones & Bartlett Learning, LLC ■■ Engine© Jonesdynamometer. & Bartlett The engine Learning, dynamometer LLC NOT FOR SALE OR DISTRIBUTION measuresNOT engine FOR performance SALE OR only,DISTRIBUTION usually when the engine is removed from the motorcycle and mounted onto a special frame. It is coupled directly to the engine flywheel and measures performance Description: FIGURE 3-39 Anatomy of a blind or pop rivet. © Jones & Bartlett Learning, Anatomy ofLLC a rivet. Label parts. © Jones independent& Bartlett ofLearning, the motorcycle’s LLC drivetrain, such as NOT FOR SALE OR DISTRIBUTION NOT FORits SALE gearbox, OR transmission DISTRIBUTION or differential.

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© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION FIGURE 3-40 A chassis dynamometer. Notice the rollers on FIGURE 3-41 Tire pressure gauge with attached inflation the floor to drive the vehicle’s wheels. device.

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE■■ Chassis OR dynamometer.DISTRIBUTION The chassis dynamometerNOT FORMost SALEgauges areOR designed DISTRIBUTION to read “nought” at atmos- measures the power from the engine through a pheric pressure (1 bar at sea level or 14.7 psi) as a base motorcycle’s driven wheel(s). The whole motorcy- measurement. cle is mounted on rollers and fixed to the ground to Here are some common types and applications: prevent it jumping when it is operated during test- © Jones & Bartlett Learning, LLC■■ Tire pressure gauge© withJones attached & Bartlett inflation Learning, LLC ing. The motorcycle is operated in gear, and turns NOT FOR SALE OR DISTRIBUTIONdevice. This type of gaugeNOT isFOR the oneSALE familiar OR DISTRIBUTIONto the rollers without moving, while its power output most people. Tire pressure gauges are normally part is measured. of a tire inflation device and are used to ensure that the air pressure inside a motorcycle’s tires is main- ©Safety Jones & Bartlett Learning, LLC tained© at Jones the recommended & Bartlett setting Learning, FIGURE LLC3-41 . NOT FOR SALE OR DISTRIBUTION ■■ Tire pressureNOT FOR gauge SALE with OR no DISTRIBUTION inflation device. In many cases, the motorcycle is being operated at full Gauges that only measure—that is, they just check throttle and making maximum power. Always make the pressure without being able to inflate as well— sure the motorcycle is secured effectively and the area are also quite common. FIGURE 3-42 is an example is clear of tools, equipment and people before using a of this type, known as a “pencil-type” pressure gauge. © Jones & chassisBartlett dynamometer. Learning, If the LLC motorcycle were ever to © Jones & Bartlett Learning, LLC NOT FOR SALEbreak free, OR the DISTRIBUTION resulting accident would be catastrophic. NOT FOR SALE OR DISTRIBUTION

Pressure Testers/Tire Inflators © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC There is a range of pressureNOT FOR testers, SALE or gauges, OR DISTRIBUTIONused in NOT FOR SALE OR DISTRIBUTION the motorcycle industry. All are used to provide information about the potential condition of various systems and components. All gauges consist of a measurement scale, from which a reading© Jones is taken. & BartlettDepending Learning, on its type LLCof fitting, the © Jones & Bartlett Learning, LLC gaugeNOT is normally FOR SALE fitted ORto the DISTRIBUTION motorcycle component NOT FOR SALE OR DISTRIBUTION via a pipe or tube. Instructions provided with the gauge describe how to take a correct reading. These should include the specific operational circumstances under © Jones &which Bartlett the reading Learning, should LLC be taken, to enable correct© JonesFIGURE & Bartlett 3-42 Tire Learning, pressure gauge withLLC no inflation device. NOT FORinterpretation SALE OR ofDISTRIBUTION the condition of the item being tested.NOT FOR SALE OR DISTRIBUTION

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© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION FIGURE 3-43 Pressure vacuum gauge. FIGURE 3-45 Cooling system pressure gauge.

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC ■■ Pressure vacuum gauge. Pressure vacuum gauges Scan Tools NOT FOR SALEare aOR particular DISTRIBUTION type of pressure gauge that measNOT- FOR SALE OR DISTRIBUTION Essentially, a scan tool (“scanner”) is a device able to com- ures “negative” pressure below atmospheric pressure municate electronically with and extract data from the FIGURE 3-43 . They are normally used to determine an engine’s general operational condition. Depending on motorcycle’s one or more on-board computers. On-board the reading, a number© Jones of engine & faults Bartlett can be Learning,identified. LLCcomputer modules include the© Jones powertrain & Bartlett control mod Learning,- LLC ule (PCM), electronic brake control module (EBCM), ■■ Pressure compressionNOT FOR gauge. SALE Pressure OR compres DISTRIBUTION- body control module (BCM),NOT the FORtransmission SALE controlOR DISTRIBUTION sion gauges are used to measure the compression module (TCM) and perhaps numerous others. Simple pressures inside an engine cylinder and can identify scan tools from the 1980s could read and erase fault overall condition and pressure leakage situations codes and little more. Today, such scanners are sold to ©that Jones could &be Bartlett caused by Learning, a range of LLCengine faults consumers.© But Jones as on-board & Bartlett systems Learning, have become LLC more NOTFIGURE FOR 3-44 .SALE OR DISTRIBUTION complex, soNOT too have FOR professional-grade SALE OR DISTRIBUTION scan tools used ■■ Cooling system pressure gauge. Cooling system in the service bay. pressure gauges are used to identify faults in cool- Cost and complexity increase commensurate with ing systems and components like pressure caps the bells and whistles desired in a scanner. Motorcycle FIGURE 3-45 . technicians today are finding that they must use faster © Jones & Bartlett Learning, LLC © Jonesand more & Bartlett accurate Learning,diagnostic instruments—like LLC graph- NOT FOR SALE OR DISTRIBUTION NOTing FOR scan SALE tools—to OR see DISTRIBUTION hidden faults in component or system waveforms. Scanners are now used to monitor engine compression, vacuum, internal engine anomalies and so forth. They are used to “drive” various components © Jones & Bartlett Learning, LLCand systems to test for their proper© Jones function. & Bartlett Scanners Learning, are LLC NOT FOR SALE OR DISTRIBUTIONused—along with digital storageNOT oscilloscopes, FOR SALE portable OR DISTRIBUTION 5- and 6-gas emissions analyzers and much more—for effective time-saving diagnostic routines. Training and experience play a major role in using these modern information-gathering tools effectively. © Jones & Bartlett Learning, LLC Understanding© Jones the principles & Bartlett of Learning, combustion LLC theory, NOT FOR SALE OR DISTRIBUTION internal combustionNOT FOR engine SALE operation OR DISTRIBUTION and emissions are essential ingredients for success. Indeed, the field demands extensive training—and also a sizeable investment! As one tool manufacturer has said, “It takes a lot to © Jones & BartlettFIGURE 3-44 Learning, Pressure compression LLC gauge. © Jonesbe an motorcycle& Bartlett technician!” Learning, Opportunities LLC abound for NOT FOR SALE OR DISTRIBUTION NOTthe FOR technician SALE who OR understands DISTRIBUTION the theory and masters

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the use of the scanner to quickly and efficiently analyze, © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC diagnose and solve problems on today’s advanced engine NOT FORsystems. SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

Servicing Equipment Workshops are equipped© Jones with machines & Bartlett that helpLearning, tech- LLC © Jones & Bartlett Learning, LLC nicians carry out servicingNOT procedures. FOR SALE Those OR machines DISTRIBUTION NOT FOR SALE OR DISTRIBUTION include computerized wheel alignment machines, pneumatic tire changing machines and engine analyzers, which pinpoint faults in engine systems. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC EngineNOT Analyzer FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION An engine analyzer is a diagnostic or service tool that is FIGURE 3-46 An engine analyzer has a screen to display used to view electrical and electronic signals and data waveforms. FIGURE 3-46 . They will usually have a screen for display- © Jones &ing Bartlett test results Learning, and waveforms. LLC The anlayzer will have ©a Jones & Bartlett Learning, LLC number of leads that are connected to the motorcycle to NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION perform a number of tests. They are often used to check the performance of a motorcycle’s ignition and other electrical systems. Some systems will also incorporate, on the same stand, other diagnostic equipment like exhaust emission analyzers. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Wheel Alignment Machine Wheel alignment systems are often incorporated into a special-purpose hoist and use light beams with calibration equipment© Jones to check & Bartlett quad wheel Learning, alignment LLCFIGURE 3-47 . © Jones & Bartlett Learning, LLC The hoistNOT allows FOR easy SALE access OR for DISTRIBUTION the technician to adjust NOT FOR SALE OR DISTRIBUTION under-body components where necessary. The wheel FIGURE 3-47 A wheel alignment machine is often aligner enables technicians to check and adjust for caster, incorporated into a hoist to allow the technician easy access to camber, toe in and toe out. Most modern wheel alignment make quad steering adjustments. machines also produce printouts for the technician and © Jones &customer Bartlett on Learning,before and after LLC settings. © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Off-Vehicle Wheel Balancer Off-vehicle wheel balancers require the wheel to be removed from the motorcycle and mounted on the wheel balancer. The balancer© uses Jones an electric & Bartlett motor toLearning, run the LLC © Jones & Bartlett Learning, LLC wheel at speed, and analyzesNOT FORthe wheel’s SALE balance, OR DISTRIBUTION provid- NOT FOR SALE OR DISTRIBUTION ing a report to the technician on the amount of weights required and their position on the wheel FIGURE 3-48 . The safety cover should always be lowered over the wheel before© runningJones the & machine.Bartlett Most Learning, machines LLC have a safety © Jones & Bartlett Learning, LLC featureNOT whereby FOR theSALE machine OR DISTRIBUTION will not run unless the NOT FOR SALE OR DISTRIBUTION cover is in place. Pneumatic Tire Changer FIGURE 3-48 An off-vehicle wheel balancer spins the wheel © Jones &Tire Bartlett changers Learning, are designed LLC to break the bead of the tire© Jonesat speed. & Bartlett The safety shieldLearning, should always LLC be lowered while the wheel is spinning. NOT FORand SALE remove OR and DISTRIBUTION reinstall it on the rim. Pneumatic footNOT FOR SALE OR DISTRIBUTION controls are usually used on the tire changer to allow both

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FIGURE 3-49 Pneumatic tire changers run on FIGURE 3-50 Brake lathes are used to machine discs and compressed air. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC drums. Always refer to manufacturer’s minimum machining NOT FOR SALE OR DISTRIBUTIONspecifications. NOT FOR SALE OR DISTRIBUTION

hands of the technician to be free to work on the tire. Tire changers usually incorporate a tire inflating device © Jones & Bartlett Learning, LLC has two pressure© Jones gauges. & Bartlett One gauge Learning, shows how LLC much and pressure gauge FIGURE 3-49 . pressure is in the cylinder, and the other gauge shows NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Drum/Disc Lathe how much pressure is in the line. The line (hose) pressure is adjusted on the pressure regulator by the opera- Drum and disc lathes are special purpose lathes tor. The hoses run from each regulator to the flashback designed specifically to machine brake drums and discs arrestors on the torch handle. The acetylene hose is red, © Jones &FIGURE Bartlett 3-50 .TheyLearning, remove LLC small amounts of metal to© Jonesand the & oxygenBartlett hose Learning, is green. The LLC flashback arrestors NOT FORrefinish SALE theOR drumDISTRIBUTION or disc surface. Its important not NOTto are FOR spring-loaded SALE OR check DISTRIBUTION valves that allow flow through remove too much material from the drum or disc. Always the hoses in one direction only—from the cylinders to check manufacturers’ specifications for minimum allow- the torch handle. They prevent flame from traveling back able thicknesses of drum and disc. up the hose in the case of a flashback, which is when the oxygen and acetylene ignite inside the torch handle. © Jones & Bartlett Learning, LLCFlashback happens if the torch© Jones valves are & setBartlett lower than Learning, LLC OxyacetyleneNOT FOR SALE OR DISTRIBUTIONthey should be for a particularNOT tip, FOR which SALE produces OR low DISTRIBUTION Oxyacetylene torches are occasionally used by techni- gas flow out of the tip; if a welding spark jumps up into cians to heat, braze, weld and cut metal. Acetylene is a the tip; or if the torch is set with too much oxygen flow- highly combustible gas, and when combined with oxygen, ing. The torch handle usually has the flashback arrestors it produces© Jones a very & hotBartlett temperature Learning, of 6300°F LLC to 6800°F screwed into© it.Jones The gas & flow Bartlett valves Learning,are also near LLCthe base (3480°CNOT to FOR 3760°C). SALE Heating OR DISTRIBUTIONis used to loosen rusted of the handle.NOT The FOR top ofSALE the handle OR DISTRIBUTIONis threaded so that fasteners to help remove them. Brazing uses brass filler different tips can be installed. rod, which is melted by the torch to join or patch metals. Oxyacetylene Torch Safety The torch consists of an acetylene cylinder, an oxygen © Jones &cylinder, Bartlett a pressure Learning, regulator LLC for each cylinder, hoses, ©a JonesSafety & needs Bartlett to be Learning, first and foremost LLC when working NOT FORflashback SALE OR arrestor DISTRIBUTION for each hose, the torch handle and theNOT with FOR an SALE oxyacetylene OR DISTRIBUTION torch. Oxyacetylene cylinders tip. The cylinders hold the gases. Each pressure regulator carry very high pressures. The acetylene pressure in

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a full cylinder is approximately 250 psi (1724 kPa), Because pressure washers spray water at very high © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC and the oxygen cylinder is approximately 2,200 psi pressures, it is important that the water jet is directed NOT FOR(15,168 SALE kPa). OR IfDISTRIBUTION an oxygen cylinder falls over and breaksNOT properly. FOR SALE It can ORpeel DISTRIBUTIONthe paint off painted surfaces if the the main valve off, the cylinder will become a missile nozzle is brought too close to the surface. It can also and can even go through concrete block walls, so always damage soft parts such as labels and rubber hoses. Some secure the cylinders properly to the wall or an approved components can be harmed by water, such as paper filters welding cart. © Jones & Bartlett Learning, LLCand some electronic components,© Jones including & Bartlett electronic Learning, LLC Wear a leather apronNOT or similar FOR protective SALE OR clothing DISTRIBUTION and control units, ignition coilsNOT and distributors.FOR SALE You OR may DISTRIBUTION welding gloves when using an oxyacetylene torch. T-shirts need to cover those devices with plastic bags. or nylon- and polyester-blend clothing will not provide enough protection because ultraviolet light and sparks Spray-Wash Cabinets of hot metal will pass through them. Always use proper © Jones & Bartlett Learning, LLC Spray-wash© cabinetsJones & spray Bartlett high-temperature, Learning, LLC high- welding goggles. Do not use sunglasses because they do NOT FOR SALE OR DISTRIBUTION pressure cleaningNOT FOR solutions SALE onto OR parts DISTRIBUTION inside a sealed not filter the extreme ultraviolet light as effectively, and cabinet. They are automated and act like a dishwasher the plastic used in the lenses of sunglasses will not protect for parts. This significantly reduces the labor required your eyes from sparks. to clean parts because once the door is closed and they Never point the lighted flame toward another person are turned on, the technician is free to move onto other © Jones &or anyBartlett flammable Learning, material. LLC Always light the oxyacetylene© Jonestasks. &They Bartlett are available Learning, in a variety LLC of sizes to cater to NOT FORtorch SALE with OR the DISTRIBUTIONstriker. A cigarette lighter could explode,NOT different-sized FOR SALE parts, OR DISTRIBUTIONand provide a high level of cleaning and a match would put your hand too close to the ignit- performance. The cleaning solution is designed to clean ing tip. Wherever possible, use a heat shield behind the effectively without leaving residue on the parts, and most component you are heating. This will prevent nearby spray cabinets are fitted with a filtering system to reduce objects from becoming hot. After heating a piece of metal, © Jones & Bartlett Learning, LLCthe frequency of cleaning solution© Jones changes. & Bartlett Learning, LLC label it as “HOT” with a piece of chalk so that others will NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION not attempt to pick it up. Solvent Tanks A solvent tank is a cleaning tank that is filled with a suit- Cleaning Equipment able solvent to clean parts by removing oil, grease, dirt and grime. Solvent tanks are available in different sizes. Pressure© Jones Washers & Bartlett and Learning, Cleaners LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION Many solventNOT tanks FOR have SALE a pump OR that DISTRIBUTIONpushes solvent out Pressure washers/cleaners are a valuable tool in the of a nozzle into a sink, where it can be directed to the parts workshop for cleaning motorcycles, engine compart- being cleaned. A brush either on the nozzle or separate ments and components. They can be powered by an from it can be used to loosen the grease and grime. The electric motor or a petroleum engine fitted to a high-pres- solvent falls back into the bottom of the solvent tank, © Jones &sure Bartlett pump. TheLearning, pressure washerLLC takes water at normal© Joneswhere & the Bartlett heavier residueLearning, settles LLC to the bottom. Other NOT FORpressure SALE and OR boosts DISTRIBUTION it through the high-pressure pump toNOT solvent FOR SALEtanks are OR designed DISTRIBUTION so that parts can be immersed exit through a cleaning gun, which has a control trigger. into the tank on racks or suspended on pieces of wire, The cleaning gun has a high-pressure nozzle that focuses and slowly lowered and soaked in the tank for a period high-pressure water (possibly more than 2,000 psi, or of time. Some solvent tanks may have an agitation system or use a heated cleaning fluid to speed up the process. 13,790 kPa) to clean ©accumulated Jones & dirtBartlett and grease Learning, from LLC © Jones & Bartlett Learning, LLC They may also have a circulation system and filters to components quickly. SomeNOT pressure FOR SALE washers OR have DISTRIBUTION a pro- NOT FOR SALE OR DISTRIBUTION vision for detergent to be injected into the high-pressure remove debris and residue in the solvent to extend its output to clean more effectively. Others have the ability life between changes. to heat the water, in some cases hot enough to turn it to Brake Washers steam. Hot water and steam help loosen oil and grease buildup.© Jones & Bartlett Learning, LLC Brake washers© Jones are used & toBartlett wash brake Learning, dust from LLC wheel PressureNOT FOR washers SALE are OR dangerous DISTRIBUTION because of their brake unitsNOT and their FOR components. SALE OR Because DISTRIBUTION it is possible high pressure and possibly high temperature. Always that the brake dust may contain asbestos, which is a wear appropriate PPE when working with pressure cancer-causing agent, and because dust in general is a cleaners—for example, goggles or face shield, protec- lung irritant, brake washers are designed to capture the © Jones &tive Bartlett gloves, close-fittingLearning, LLCclothes with long sleeves and© Jonesbrake &dust Bartlett before itLearning, enters the workshop LLC environment. NOT FORfull-length SALE OR trousers DISTRIBUTION and leather-type boots or shoes. NOTIt FOR does soSALE by wetting OR DISTRIBUTION down the dust on the brake parts

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and then washing it into the cleaning tray. Brake washers © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC incorporate a built-in waste recovery system where the NOT FORcontaminated SALE OR washerDISTRIBUTION fluids can be captured to enableNOT FOR SALE OR DISTRIBUTION disposal in an environmentally friendly manner. Brake washers are normally designed to operate at low pressure and use a range of cleaning agents. The most popular agent is an aqueous© Jones solution & Bartlett made up Learning, of water LLC © Jones & Bartlett Learning, LLC and a water-soluble detergent.NOT FOR A low-pressure SALE OR air DISTRIBUTION blower NOT FOR SALE OR DISTRIBUTION may be provided to remove the fluid from the component into the tray area and then back to the tank by gravity. Avoid using solvent when cleaning brake components, as it contaminates friction materials and may cause seals © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC to swell. Never use paraffin oil as a general cleaning agent to cleanNOT brake FOR components, SALE OR as DISTRIBUTION it does not clean away NOT FOR SALE OR DISTRIBUTION brake fluid, can be absorbed into lining materials and can cause seals to swell. Water is a good cleaning agent FIGURE 3-51 A digital multimeter can be used to measure for brake components. voltage, resistance and current © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FORSand SALE or OR Bead DISTRIBUTION Blasters NOT FOR SALE OR DISTRIBUTION Sand or bead blasters use high pressure to blast small abrasive particles to clean the surface of parts. The most common method of propelling the sand or glass beads is © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC with compressed air. In workshops, sand or bead blasting can occur in a speciallyNOT FOR designed SALE cabinet, OR DISTRIBUTIONor there NOT FOR SALE OR DISTRIBUTION are portable models that are available for use in open-air situations. The cabinets contain the blasting operation in a controlled, safe environment and are best for smaller parts© that Jones can fit & into Bartlett the cabinet. Learning, Portable LLC systems that © Jones & Bartlett Learning, LLC do notNOT operate FOR within SALE a cabinetOR DISTRIBUTION can blast larger parts NOT FOR SALE OR DISTRIBUTION but do require more protection for the operator and sur- rounding environment. The sand or bead blaster cabinet is fitted with a hand- operated blasting nozzle, a viewing port and an on/off © Jones &switch Bartlett (often Learning,this may be aLLC foot-operated switch), and ©it Jones & Bartlett Learning, LLC FIGURE 3-52 An oscilloscope displays a graph of voltage NOT FORhas SALE openings OR with DISTRIBUTION tough rubber gloves sealed into themNOT FORover time.SALE OR DISTRIBUTION to allow a technician’s hands to be inside the cabinet while being protected from the abrasive sand or beads. Wet sand or bead blasters are also available, and have the are obtained. Once a reading is obtained, it needs to be additional advantage of© reducing Jones the& Bartlett amount of Learning, dust and LLC © Jones & Bartlett Learning, LLC providing additional cleaning to the part being cleaned. interpreted and applied to diagnose the circuit under NOT FOR SALE OR DISTRIBUTIONtest. This section provides anNOT explanation FOR SALE of how OR to use DISTRIBUTION and set up a multimeter for measuring voltage, current Electrical Equipment and resistance. Digital multimeters (DMMs) FIGURE 3-51 , which are also Using Ohm’s Law to Diagnose Circuits known© Jonesas digital & volt-ohmmeters Bartlett Learning, (DVOMs) ,LLC and oscillo- © Jones & Bartlett Learning, LLC scopesNOT FIGURE FOR 3-52 SALE are electrical OR DISTRIBUTION measuring tools fre- Ohms law NOTis used FOR to calculate SALE electrical OR DISTRIBUTION quantities in an quently used to diagnose and repair electrical faults. Like electrical circuit and is valuable as a way of cross-checking many diagnostic tools, practice is required to under- actual measured results within a circuit. For example, if stand how the multimeter and oscilloscope are used the resistance and voltage of a circuit is known, then the © Jones &to Bartletttake electrical Learning, measurements, LLC and how to connect© Jonestheoretical & Bartlett current canLearning, be calculated LLC using Ohm’s law. The NOT FORthem SALE into OR electrical DISTRIBUTION circuits to ensure correct readingsNOT calculated FOR SALE result OR can thenDISTRIBUTION be compared with the measured

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results from an ammeter to determine whether the circuit © Jones & Bartlett Learning, LLC © JonesChecking & Bartlett a Circuit Learning, with Fused LLC Jumper Leads is functioning correctly. Technicians will often do a quick NOT FOR SALE OR DISTRIBUTION NOTJumper FOR SALEleads may OR be DISTRIBUTIONused in a number of ways to assist in calculation, in their heads, to obtain an approximate value checking circuits. They can be created by the technician of an electrical quantity before they take actual measure- or purchased in a range of sizes, lengths and fittings, or ments. This gives them a good indication of what they connectors. They are used to extend connections to allow will be measuring and allows them to set the measur- circuit readings or tests to be undertaken with a multim- © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC ing tool to the correct range. Always remember that a eter, scope, current clamps on fuses, relays and connector calculation may be onlyNOT an approximateFOR SALE value OR because,DISTRIBUTION plugs on components. In someNOT circumstances, FOR SALE jumperOR DISTRIBUTION in actual circuits, variation or tolerances exist in compo- leads may provide an alternative current or ground source nents, causing some variation between calculated values for components under test. Regardless of their applica- and actual measurements. tion, it is important that the circuit remain protected by © Jones & Bartlett Learning, LLC a fuse of the© correctJones size. & Bartlett To determine Learning, the correct LLC size NOTTECHNICIAN FOR SALE TIPOR DISTRIBUTION of fuse requiredNOT forFOR any SALE particular OR application, DISTRIBUTION refer to the manufacturer’s information. When checking continuity with a multimeter, the power supplied to the circuit during operation must Locating Opens, Shorts, Grounds and High Resistance © Jones & beBartlett switched Learning, OFF. LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOTMultimeters, FOR SALE test OR lamps DISTRIBUTION and simulated loads tend to be the tools used most often for locating opens, shorts, grounds Electrical Testing Equipment and high-resistance faults. An open circuit is a break in the electrical circuit where either the power supply or Using a Multimeter to Measure Voltage ground circuit has been interrupted. Most open circuits The electrical system ©is becomingJones & increasingly Bartlett Learning, complex LLCcan be located by probing ©along Jones the circuit& Bartlett at various Learning, LLC on modern motorcycles,NOT and FOR measuring SALE voltages OR DISTRIBUTION with a points to test for power, andNOT at the groundFOR SALE point to OR check DISTRIBUTION multimeter is a very common task when diagnosing elec- for an effective ground. Perform a systematic check of the trical faults. For most measurements, set the multimeter circuit by first checking the voltages at the component, to auto range for ease of use. Select multimeter leads and if possible. Analysis of the readings will usually dictate probe© ends Jones to match & Bartlett the task atLearning, hand; for example, LLC if you the next point© Jones to be checked. & Bartlett Learning, LLC needNOT to take FOR a measurement SALE OR but DISTRIBUTION require both hands to Shorts orNOT short FOR circuits SALE may ORoccur DISTRIBUTION anywhere in the be free, use probe ends with alligator clips. Ensure that circuit and can be difficult to locate, especially if they you do not exceed the maximum allowable voltage or are intermittent. A short is a circuit fault where current current for the multimeter. If you are measuring high travels along an accidental or unintended route. The short voltages, ensure you wear appropriate personal protec- may occur to ground or to supply voltage. A short to © Jones &tive Bartlett equipment, Learning, such as high-voltage LLC safety gloves, long-© Jonesground & causes Bartlett low circuitLearning, resistance. LLC The low-resistance NOT FORsleeved SALE shirts, OR longDISTRIBUTION trousers and protective eyewear, andNOT fault FOR would SALE cause OR an DISTRIBUTIONabnormally high current flow in the remove any personal jewelry or items that may cause an circuit and could cause the circuit-protection devices, accidental short circuit. such as fuses or circuit breakers, to open circuit. A short to supply voltage may cause the circuit to remain live Checking a Circuit with a Test Light © Jones & Bartlett Learning, LLCeven after the switch is turned© Jones off. For example,& Bartlett a short Learning, LLC Non-powered test lamps are useful in determining the between a fuse with power on all the time and a fuse live part of a circuit; however,NOT FOR make SALE sure that OR the DISTRIBUTION circuit switched by the ignition switchNOT would FOR cause SALE the ORcircuit DISTRIBUTION voltage you are testing is not higher than the test light controlled by the ignition switch to remain on after the is rated for, otherwise the test light could be damaged. switch is turned off. Shorts may be caused by faulty com- Most test lights are rated for 6- or 12-volt systems, and ponents or damaged wiring. using© them Jones in a& 24-volt Bartlett system Learning, will usually LLC blow out Grounds© isJones a term & often Bartlett used inLearning, conjunction LLC with the bulb.NOT You FOR should SALE use OR a test DISTRIBUTION light to test SRS (sup- shorts and NOTis usually FOR a reference SALE ORto a shortDISTRIBUTION to ground. An plemental restraint systems), as unintended employment initial test may be conducted by carrying out resistance of the air bags could result—a very dangerous and costly checks or by disconnecting the load. To test the blower mistake. In addition, using a test light on a computer motor, for example, disconnect the blower motor and, circuit designed for very small amounts of current flow if the short is still in place, then the wiring between © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC can damage the circuit. the fuse or circuit breaker and the load must be at NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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fault. To further narrow down the site of the short to The apparent position of the marks, frozen by the strobo- © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC ground, inspect the wiring harness, looking for obvi- scopic effect, indicates the current timing of the spark in NOT FORous SALE signs ORof damage. DISTRIBUTION Another test may be conductedNOT relation FOR SALEto piston OR position. DISTRIBUTION A reference pointer is attached by connecting a test lamp or buzzer in place of a fuse: to the flywheel housing or other fixed point, andan current will flow through the test lamp or buzzer and engraved scale gives the offset between the spark time find a ground through the short; parts of the circuit and the top dead center (TDC) position of the piston may then be disconnected© Jones along & Bartlettthe wiring Learning, harness LLCin the cylinder. The distributor© Jones can be & rotated Bartlett slightly Learning, LLC to narrow down the NOTlocation FOR of the SALE short. OR Specialized DISTRIBUTION until the reference pointer alignsNOT with FOR the SALE specified OR point DISTRIBUTION short-circuit detection tools are also available. They on the timing scale. work by injecting a signal into the wiring where a short Fuel-injected engines or engines with microprocessor is suspected. A receiving device is then moved along controls may require special procedures to allow basic the wiring loom and indicates where a short is located. spark timing to be observed without control effects from © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC This type of device is very useful in situations where the engine computer. On most motorcycle engines, the it is difficultNOT FOR to accessSALE the OR wiring; DISTRIBUTION for example, under timing is setNOT based FOR on the SALE number OR 1 cylinder.DISTRIBUTION guards or motorcycle trim. Simple timing lights may just contain a neon lamp High resistance refers to a circuit where there is unin- operated by the energy provided by the ignition circuit. tended resistance, which then causes a fault. It can be Timing lights using xenon strobe lamps electronically © Jones &caused Bartlett by a Learning, number of faults;LLC for example, corroded© Jonestriggered & Bartlett by the spark Learning, provide brighterLLC light, allowing NOT FORor SALE loose harness OR DISTRIBUTION connectors, incorrectly sized cable forNOT use FOR of theSALE timing OR lamp DISTRIBUTION under normal shop lighting or the circuit current flow, incorrectly fitted terminals and daylight conditions. poorly soldered joints. The high resistance causes an The timing light may be a self-contained instrument, unintended voltage drop in a circuit when the current but is sometimes combined with a voltmeter, rpm meter flows. The high-resistance fault reduces the current flow and a dwell angle meter, or may be incorporated into © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC in the circuit, affecting its performance. It can be located a more comprehensive instrument such as an engine by conducting a resistanceNOT checkFOR withSALE a multimeter, OR DISTRIBUTION or analyzer. Self-contained unitsNOT used FOR to time SALE motorcycle OR DISTRIBUTION by checking for voltage drop in the power and ground engines have an inductive pickup that clamps around circuits. Resistance checks are initial tests undertaken the proper spark plug wire and serves as the trigger for on components—for example, testing the resistance of the strobe. Power for the strobe comes directly from the a fuel© injector Jones or & ignitionBartlett coil—but Learning, should LLC always be motorcycle’s© battery.Jones Some& Bartlett older timing Learning, lights requireLLC followedNOT up FOR with SALEworking OR tests, DISTRIBUTION using a multimeter or the removalNOT of the FOR spark SALE plug boot OR inDISTRIBUTION order to attach a oscilloscope. Due the relatively low resistance of wires, direct pickup between the wire’s terminal and the center it is usually more effective to conduct voltage-drop tests conductor of the spark plug FIGURE 3-53 . while the load current is flowing through the circuits. To locate opens, shorts, grounds and high resistance, © Jones &follow Bartlett these steps:Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 1. Identify the circuit to be checked and conduct a visual inspection. 2. Select and set up appropriate test equipment, and determine the type and location of the fault: opens, shorts, grounds or© high Jones resistance. & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION 3. Determine and perform the necessary actions. Using a Timing Light The timing light is a stroboscope used to dynamically set the© ignitionJones timing& Bartlett of an internal Learning, combustion LLC engine © Jones & Bartlett Learning, LLC equippedNOT with FOR a distributor.SALE OR Today’s DISTRIBUTION modern electroni- NOT FOR SALE OR DISTRIBUTION cally controlled motorcycle engines require use of a scan tool to display ignition timing. The timing light is connected to the ignition circuit and used to illuminate the timing marks on the engine’s FIGURE 3-53 Timing light. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC crankshaft pulley or flywheel, with the engine running. NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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© Jones Using& Bartlett an Ignition Learning, Distributor LLC Test Bench © Jones & Bartlett Learning, LLC NOT FORThe SALE ignition OR distributor DISTRIBUTION tester test bench is designed toNOT FOR SALE OR DISTRIBUTION perform all the dynamic and static tests on both electronic and standard types of ignition systems, including electronic modules, magnetic pickups, magnetos, ignition coils and other electronic/mechanical combinations. In © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC order to facilitate the testing of the various components that make up an ignitionNOT systems FOR in SALE motorcycle OR DISTRIBUTIONinternal NOT FOR SALE OR DISTRIBUTION combustion engines, a standard test bench normally has the following:

■■ ©AC Jones electric &motor Bartlett to drive Learning, the bench LLC © Jones & Bartlett Learning, LLC ■■ NOTMotor FORwith electronic SALE OR speed DISTRIBUTION control to control the NOT FOR SALE OR DISTRIBUTION clockwise/counterclockwise rotation of the distributor or magneto from 0 to 5,000 rpm, engine speed FIGURE 3-54 Distributor tester. to 10,000 rpm © Jones & ■Bartlett■ An analog Learning, tachometer LLC to display the rotation speed© Jones & Bartlett Learning, LLC NOT FOR SALEof component OR DISTRIBUTION under test NOT FOR SALE OR DISTRIBUTION ■■ An analog cam angle meter to display the cam angle, points resistance and condenser capacitance and condition ■■ A vacuum pump© system Jones which & Bartlett includes the Learning, motor- LLC © Jones & Bartlett Learning, LLC pump, gauge andNOT regulator FOR control SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION ■■ An ohmmeter for measuring pickups and modules ■■ Selector switching for testing electronic ignitions with and without coils, as well as standard systems ©with Jones and without & Bartlett coils Learning, LLC © Jones & Bartlett Learning, LLC ■■ NOTSelector FOR positions SALE are ORalso providedDISTRIBUTION testing modules, NOT FOR SALE OR DISTRIBUTION coils and pick-up coils This distributor tester helps to sort out any trouble that you may have with the ignition system of your motor- © Jones &cycle. Bartlett After checking Learning, and reconditioning LLC the distributor,© JonesFIGURE & Bartlett 3-55 Alternator Learning, test bench. LLC NOT FORand SALE perhaps OR synchronizing DISTRIBUTION a multiple breaker system onNOT FOR SALE OR DISTRIBUTION the test bench, put the distributor on the engine again, set the initial timing to manufacturer’s specifications FIGURE 3-54 . Battery Chargers There are many different types of battery chargers, and Using an Alternator© Jones Test Bench& Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTIONeach is designed for a particularNOT purposeFOR SALE and applica OR DISTRIBUTION- An alternator test bench is normally compact and should tion. Fast chargers have high current output to charge be easy to use for fast and accurate testing of a wide a battery quickly. Slow chargers take longer to charge range of alternators and starter motors. The test bench a battery and have lower current outputs; they put can be operated at two speeds, ensuring thorough test- less stress on the battery, which is ideal if time is not ing both© Jones at higher & andBartlett lower Learning,speeds. It can LLC also include a consideration.© Jones Smart & Bartlettchargers Learning,incorporate LLCmicro- vacuumNOT testing. FOR SALE OR DISTRIBUTION processorsNOT to monitor FOR SALEand control OR DISTRIBUTIONthe charge rate so A good test bench should have many of the specific that the battery receives the correct amount of charge features, such as built-in power source, thus eliminat- according to its state of charge. These types of charging the need for external batteries. It must be capable of ers are becoming more popular; they ensure that the © Jones &testing Bartlett 12-volt Learning, and 24-volt LLCsystems with digital ammeter/© Jonesbattery & receivesBartlett the Learning, optimal charge, LLC thus promoting NOT FORvoltmeter SALE ORFIGURE DISTRIBUTION 3-55 . NOTlonger FOR batterySALE life.OR DISTRIBUTION

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Even though a motorcycle battery is typically 12 volts, © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC it stores a lot of energy. The high-current supply from a NOT FORbattery SALE can OR be veryDISTRIBUTION dangerous. Remember, batteries haveNOT FOR SALE OR DISTRIBUTION to deliver enough power to crank over a cold engine. They also produce enough power to melt a metal rod resting across the terminals. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC Battery Safety NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Batteries give off hydrogen gas while they are being charged, and for some time afterward. Hydrogen is a light and highly explosive gas that is easily ignited by a simple spark. Batteries are filled with sulfuric acid, so © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC if the hydrogen does explode, the battery case can then ruptureNOT and FOR spray SALEeverything OR and DISTRIBUTION everyone nearby with NOT FOR SALE OR DISTRIBUTION this dangerous and corrosive liquid. FIGURE 3-56 Switch off the charger before connecting it to or disconnecting it from the battery. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALETECHNICIAN OR DISTRIBUTION TIP NOT FOR SALE OR DISTRIBUTION Always remove your hand, wrist and neck jewelry anything that stays on when the motorcycle is not run- before working with batteries and electrical systems. If jewelry comes into contact with the battery terminals ning drains the battery. or power wire, it can© cause Jones a short & circuit.Bartlett You Learning,will LLCSlow-charging a battery is© less Jones stressful & Bartletton the battery Learning, LLC than fast-charging so, if possible, slow-charge a battery receive painful skin burnsNOT from FOR the SALEvery rapid OR heating DISTRIBUTION NOT FOR SALE OR DISTRIBUTION of the metal you are wearing, or even flash burns from instead of fast-charging it. Removing the negative bat- an arcing current. A wristwatch or ring is much harder tery terminal while changing a battery reduces the risk to take off when it is red- or white-hot and burned of burning up any electronic devices on the motorcycle, onto your skin! especially with modern, electronically intensive motor- © Jones & Bartlett Learning, LLC cycles. However,© Jones disconnecting & Bartlett the Learning,motorcycle’s LLCbattery NOT FOR SALE OR DISTRIBUTION risks losingNOT information FOR SALEsuch as ORradio DISTRIBUTION presets and other learned data. Use a memory saver (memory minder), Be very careful not to create a spark when you are con- which provides backup power to retain electronic mem- necting or disconnecting battery cables or hooking up a ory settings in the motorcycle’s computer systems. charger to the battery terminals. Switch off the charger Manufacturers install multiple batteries in some appli- © Jones &before Bartlett connecting Learning, and disconnecting LLC them from the bat©- Jonescations & to Bartlett provide additional Learning, battery LLC power when needed. NOT FORtery SALE FIGURE OR 3-56 DISTRIBUTION. NOTKnowing FOR SALE how theOR batteries DISTRIBUTION are connected together will Do not try to charge a battery faster than the battery determine how to connect a battery charger properly. manufacturer recommends, and never use a battery Batteries can be connected in series (connected in line load tester immediately after charging a battery. This with each other, with the positive of one connected to is because both charging© Jones and rapidly& Bartlett discharging Learning, a LLCthe negative of the other) or© parallel Jones (connected & Bartlett side Learning, by LLC battery generate heatNOT and hydrogen.FOR SALE If you OR load-test DISTRIBUTION side, with positive connectedNOT to positive FOR andSALE negative OR toDISTRIBUTION a battery after charging it without waiting for it to negative). Two 12-volt batteries connected in series have cool down, you will increase the risk of distorting the the positive terminal of one battery connected to the nega- plates inside the battery, as well as increase the risk tive terminal of the second battery. The output voltage of explosion. will be equal to the sum of the voltages of the individual © Jones & Bartlett Learning, LLC batteries and© Jonesis taken from& Bartlett the negative Learning, terminal LLC of one ChargingNOT FOR a Battery SALE OR DISTRIBUTION battery andNOT the positive FOR terminalSALE OR of the DISTRIBUTION other battery. For Batteries go dead for a variety of reasons. A common example, two 12-volt batteries connected in series will cause is the rider forgetting to turn off the headlights have a nominal output voltage of 24 volts across the most when leaving the motorcycle. Or maybe the owner went negative and most positive battery terminals. If you have © Jones &on Bartlettholiday for Learning, a month and LLC the battery discharged slowly© Jonesa 24-volt & Bartlett battery charger, Learning, you can LLC charge both batteries at NOT FORover SALE that ORtime. DISTRIBUTION Because the battery only stores charge,NOT the FOR same SALE time by OR connecting DISTRIBUTION the battery charger to these

056754_CH03_p056-105.indd 97 3/12/14 9:37 PM 98 CHAPTER 3 Care and Use of Tools Applicable to the Trade

same terminals. If you have only a 12-volt charger, you posts of either battery. For example, two 12-volt batteries © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC have to either charge one battery at a time, or reconnect connected in parallel have an output voltage of 12 volts. NOT FORthem SALE so they OR areDISTRIBUTION connected in parallel. Just make sureNOT In FOR this situation, SALE OR a 12-volt DISTRIBUTION charger may be used to charge you charge both batteries fully, which could take more both batteries at the same time while the batteries are than 12 hours each, if slow-charging. connected together. But it is likely to take about twice as Batteries connected in parallel have the negative ter- long as it would if charging only one battery. minals of both batteries© Jones connected & Bartlett to each otherLearning, and LLCAfter charging and reinstalling© Jones the battery, & Bartlett it is good Learning, LLC the positive terminalsNOT of each FOR battery SALE connected OR DISTRIBUTION to each practice to clean the batteryNOT terminals FOR SALE and posts. OR ToDISTRIBUTION other. The output voltage will be equal to the voltage of charge a battery using battery charging equipment, fol- one battery and is taken from the positive and negative low the guidelines in PROCEDURE 3-6 .

© Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION PROCEDURE 3-6 Charging a Battery Using Battery Charging Equipment © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR4 Verify SALE that the OR charger DISTRIBUTION is unplugged from the wall and turned off. Connect the red lead from the charger to the positive battery terminal. Connect the black lead from the charger to the negative battery terminal.

© Jones & Bartlett Learning, LLC 5 Check the settings on the ©charger Jones and verify& Bartlett that they Learning, LLC NOT FOR SALE OR DISTRIBUTIONare correct for what you areNOT charging. FOR SALE OR DISTRIBUTION 6 Turn the charger on and select the automatic setting, if equipped. Select the rate of charge. A slow charger usually charges at a rate of less than 5 amperes. A © Jones & Bartlett Learning, LLC fast charger© Jones charges &at aBartlett much higher Learning, ampere rate LLC depending on the original battery state of charge; NOT FOR SALE OR DISTRIBUTION a fast-chargeNOT should FOR be SALE carried outOR only DISTRIBUTION under constant supervision.

7 Verify that the voltage and amperage the charger is putting out is proper. 1 Determine the voltage of the system that needs © Jones & Bartlettcharging. Learning, If you are charging LLC a 12-volt battery, use the© Jones & Bartlett Learning, LLC 8 Once the battery is charged, turn the charger off. NOT FOR SALE12-volt OR settingDISTRIBUTION on the charger. NOT FORDisconnect SALE theOR black DISTRIBUTION lead from the negative battery terminal and the red lead from the positive battery 2 Identify the positive and negative terminals. Never simply use the color of the cables to determine the terminal. positive or negative terminals; use the + and—or the 9 Allow the battery to stand for at least five minutes “Pos” and “Neg”© marks. Jones & Bartlett Learning, LLCbefore testing the battery. ©Using Jones a load tester& Bartlett or Learning, LLC NOT FOR SALE OR DISTRIBUTIONhydrometer, test the chargedNOT state FOR of the SALEbattery. OR DISTRIBUTION 3 Inspect the battery by carrying out a visual inspection of the battery to ensure there are no cracks, holes or damage to the casing.

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© Jones & BartlettTECHNICIAN Learning, TIPLLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Alternators are not generally designed to charge a fully discharged battery while running several accessories. If a battery is discharged enough that the battery must be jump-started, it is always best to recharge the battery© using Jones a battery & Bartlettcharger. That Learning, way LLC © Jones & Bartlett Learning, LLC the alternator will notNOT have FORto work SALE so hard. OR Some DISTRIBUTION NOT FOR SALE OR DISTRIBUTION technicians say it only takes 15 minutes to burn up an alternator when charging a fully discharged battery.

When connecting jumper leads, a spark will almost FIGURE 3-57 Some examples of lifting equipment are always occur on the last connection you make. That is vehicle hoists, floor jacks, jack stands, engine and component why it is critical that you make the last connection on hoists, chains, slings and shackles. © Jones & theBartlett engine blockLearning, away from LLC the battery and any other © Jones & Bartlett Learning, LLC NOT FOR SALEflammables. OR DISTRIBUTIONA spark also occurs when you disconnect NOT FOR SALE OR DISTRIBUTION the first jumper lead connection, so that also needs to be the connection at the engine block. within its capacity. Using lifting equipment incorrectly may lead to equipment failure that can cause serious © Jones & Bartlett Learning, LLCinjury and damage. © Jones & Bartlett Learning, LLC Vehicle hoists raise whole vehicles off the ground NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Lifting Equipment so that a technician can more easily work on those parts that are accessible only toward ground level or There are many different types of generic lifting equip- from underneath FIGURE 3-58 . There are a number of ment used in a workshop. Some examples include vehicle different designs and they come in a range of sizes hoists,© floorJones jacks, & Bartlett jack stands, Learning, engine and LLC component and configurations© Jones to & meetBartlett the particular Learning, needs LLC of the hoists,NOT chains, FOR slings SALE and ORshackles DISTRIBUTION FIGURE 3-57 . Lifting workshop. NOTFor instance, FOR SALE there are OR hoists DISTRIBUTION that are mobile, equipment is designed to lift and securely hold loads. hoists that are designed for use where the ceiling height Each piece of lifting equipment is designed for a specific is limited. purpose and has an operating capacity. The operating capacity is usually expressed as the safe working load © Jones &(SWL) Bartlett. For Learning,example, if theLLC SWL is 1 ton, the equip©- Jones & Bartlett Learning, LLC NOT FORment SALE can OR safely DISTRIBUTION lift up to 1 ton, or 2,000 lbs. WhenNOT FOR SALE OR DISTRIBUTION using lifting equipment, never exceed its capacity and always maintain some reserve capacity as an extra safety margin. Each piece of lifting© equipment Jones & shouldBartlett be usedLearning, only LLC © Jones & Bartlett Learning, LLC for the purpose for which it is designed. For example, NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION a vehicle hoist should be used only to lift motorcycles

TECHNICIAN TIP © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC WhenNOT multiple FOR pieces SALE of liftingOR DISTRIBUTIONequipment are used, NOT FOR SALE OR DISTRIBUTION the SWL is limited to the lowest-rated piece of equipment. For example, if a chain with an SWL of 2 tons is used with a 5-ton SWL shackle and a 3-ton SWL engine hoist, then the maximum amount of © Jones & weightBartlett that Learning,can be lifted is LLC 2 tons. © JonesFIGURE & Bartlett 3-58 A typical Learning, four-post hoist. LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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A single-post hoist raises the vehicle on a platform © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC TECHNICIAN TIP supported by a single solid shaft located centrally under NOT FOR SALE OR DISTRIBUTION NOTthe FOR vehicle. SALE This OR type DISTRIBUTION of hoist is very compact in the Manufacturers supply operating information for lifting workshop and leaves the perimeter of the vehicle very equipment, including the equipment’s SWL. Check the accessible, but the central post obscures part of the under- SWL of the lifting equipment and never exceed the SWL. side of the vehicle. © Jones & Bartlett Learning, LLCOther types of hoist include:© Jonesscissor lifts; & Bartlett parallelogram Learning, LLC NOT FOR SALE OR DISTRIBUTIONlifts; and mobile or specialtyNOT lifts. FOR SALE OR DISTRIBUTION The most common types of hoist in general use are ■■ Safety locks. Every workshop hoist must have a known as two-post and four-post hoists: locking device built into it so that the hoist can be secured at the chosen height after the motorcycle has ■■ Four-post hoist. A four-post hoist is very easy to © Jones & Bartlett Learning, LLC been raised.© Jones This locking& Bartlett device Learning, prevents the LLCmotor- use. The vehicle is driven between the four posts cycle from being accidentally lowered, and holds the NOTso that FOR the wheels SALE are OR resting DISTRIBUTION on two long and nar- NOT FOR SALE OR DISTRIBUTION motorcycle in place, even if the lifting mechanism row platforms, one on each side of the vehicle. The fails. Technicians should never physically go under platforms are then raised up, taking the vehicle with a raised motorcycle for any reason unless the safety them. The underside of the vehicle is accessible, locking mechanism has been activated. © Jones & Bartlettbut it is Learning, resting on its LLC wheels, so these cannot be© Jones & Bartlett Learning, LLC NOT FOR SALEremoved OR DISTRIBUTIONwhile the vehicle is on a four-post hoist.NOT FOR■■ Ratings SALE and OR inspections. DISTRIBUTION All hoists are rated for a particular weight and/or type of motorcycle, and ■■ Two-post hoist. A two-post hoist requires careful should never be used for any task other than that positioning of the padded ends of four short arms recommended by the manufacturer. In particular, a so that they are under appropriate lifting points, two hoist should never be used to lift a motorcycle that on each side of the vehicle. The workshop manual © Jones & Bartlett Learning, LLC is heavier than its rated© limit. Jones & Bartlett Learning, LLC for the vehicle willNOT detail FOR where SALE those ORlifting DISTRIBUTION points NOT FOR SALE OR DISTRIBUTION are so that the vehicle can be raised without caus- In most countries, there are regulations that require ing structural damage. A two-post hoist leaves the hoists to be periodically inspected and certified as fit for underside of the vehicle very accessible, and also use—usually annually. Before you use a hoist, check the allows a technician to remove the wheels while the identification plate for its rating, and make sure that is ©vehicle Jones is raised. & Bartlett Learning, LLC has a current© Jonesregistration & Bartlett or certification Learning, label. LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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© Jones & BartlettVocabulary Learning, BuilderLLC and Review© Jones Questions & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Vocabulary Builder club hammer The club hammer is like a small mallet, with two square faces made of high-carbon steel. air drill A compressed air–powered drill. © Jones & Bartlett Learning, LLCIt is the heaviest type of ©hammer Jones that & Bartlettcan be used Learning, LLC air hammer A tool powered by compressed air with one-handed. NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION various hammer, cutting, punching or chisel attachments. combination pliers A type of pliers for cutting, grip- Also called an air chisel. ping and bending. air impact wrench An impact tool powered by com- combination wrench A type of wrench that has an open pressed air designed to undo tight fasteners. end on one end and a box-end wrench on the other. air nozzle© Jones A compressed-air & Bartlett Learning, device that LLC emits a fine © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION crankshaft NOTA motorcycle FOR SALE engine componentOR DISTRIBUTION that transfers stream of compressed air for drying or cleaning parts. the reciprocating movement of pistons into rotary motion. air ratchet A ratchet tool for use with sockets powered cross-arm A description for an arm that is set at right by compressed air. angles or 90 degrees to another component. Allen wrench A type of hexagonal drive mechanism cross-cut chisel A type of chisel for metal work that © Jones &for Bartlett fasteners. Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOTcleans FOR out SALE or cuts OR key DISTRIBUTION ways. angle grinder A portable grinder for grinding or cut- curved file A type of file that has a curved surface for ting metal. filing holes. aviation snips A scissor-like tool for cutting sheet metal. dead-blow hammer A type of hammer that has a cush- ball-peen (engineer’s) hammer A hammer that has a © Jones & Bartlett Learning, LLCioned head to reduce the amount© Jones of head & Bartlett bounce. Learning, LLC head that is rounded on one end and flat on the other; NOT FOR SALE OR DISTRIBUTIONdepth micrometers A micrometerNOT FOR that SALE measures OR the DISTRIBUTION designed to work with metal items. depth of an item such as how far a piston is below the battery A device that converts and stores electrical surface of the block. energy through chemical reactions. diagonal-cutting pliers Cutting pliers for small wire battery charger A device that charges a battery, reversing or cable. the discharge© Jones process. & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION dial bore gaugeNOT FORA gauge SALE that ORis used DISTRIBUTION to measure the bench grinder (pedestal grinder) A grinder that is fixed inside diameter of bores with a high degree of accuracy to a bench or pedestal. and speed. bench vise A device that securely holds material in jaws dial indicators A dial that can also be known as a dial while it is being worked on. gauge, and as the name suggests, has a dial and needle © Jones &blind Bartlett rivet ALearning, rivet that can LLC be installed from its inser©- Joneswhere & measurements Bartlett Learning, are read. LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION tion side. diestock A handle for securely holding dies to cut bolt cutters Strong cutters available in different sizes, threads. designed to cut through non-hardened bolts and other double flare A seal that is made at the end of metal small-stock material. tubing or pipe. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC bottoming tap A thread-cutting tap designed to cut drift punch A type of punch used to start pushing roll threads to the bottomNOT of a blind FOR hole. SALE OR DISTRIBUTIONpins to prevent them from spreading.NOT FOR SALE OR DISTRIBUTION box-end wrench A wrench with a closed or ring end to drill chuck A device for securely gripping drill bits in grip bolts and nuts. a drill. chassis dynamometer A machine with rollers that drill press A device that incorporates a fixed drill with © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC allows a motorcycle to attain road speed and load while multiple speeds and an adjustable worktable. It can be sittingNOT still FORin the workshop.SALE OR DISTRIBUTION free-standingNOT or fixedFOR toSALE a bench. OR DISTRIBUTION circlip pliers A pair of pliers for installing and removing drill vise A tool with jaws that can be attached to a drill internal or external circlips. press table for holding material that is to be drilled. cleaning gun A device with a nozzle controlled by a fast chargers A type of battery charger that charges bat- © Jones &trigger Bartlett fitted Learning, to the outlet LLCof pressure cleaners. © Jonesteries &quickly. Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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feeler gauges Also called feeler blades; flat metal strips mandrel The shaft of a pop rivet. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC used to measure the width of gaps, such as the clearance NOT FOR SALE OR DISTRIBUTION NOTmandrel FOR SALE head ORThe headDISTRIBUTION of the pop rivet that connects between valves and rocker arms. to the shaft. finished rivet A rivet after the completion of the rivet- measuring tape A flexible type of ruler and a common ing process. measuring tool. flare-nut wrench A type of box-end wrench that has a © Jones & Bartlett Learning, LLCmechanical fingers Spring-loaded© Jones fingers & Bartlett atthe end Learning, of LLC slot in the box section to allow the wrench to slip through a flexible shaft that pick up items in tight spaces. a tube or pipe. Also calledNOT a FOR flare-tubing SALE wrenchOR .DISTRIBUTION NOT FOR SALE OR DISTRIBUTION memory saver (memory minder) Battery backup device flashback arrestor A spring-loaded valve installed on for motorcycle computer systems. oxyacetylene torches as a safety device to prevent flame micrometers Precise measuring tools designed to meas- or sparks from entering the torch hoses. © Jones & Bartlett Learning, LLC ure small distances© Jones and & are Bartlett available Learning, in both inch LLC(0) and flat-nosed pliers Pliers that are flat and square at the millimeter (mm) calibrations. end ofNOT the nose.FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION Morse taper A tapered mounting shaft for drill bits and flat-tip screwdriver A type of screwdriver that fits a chucks in larger drills and lathes. straight slot in screws. needle-nosed pliers Pliers with long tapered jaws for forcing screw The center screw on a gear, bearing or gripping small items and getting into tight spaces. © Jones &pulley Bartlett puller. Learning, Also called LLCa jacking screw. © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOTnippers FOR SALE Pliers ORdesigned DISTRIBUTION to cut protruding items level four-post hoist A type of hoist that the vehicle is with the surface. driven onto that uses two long, narrow platforms to lift offset screwdriver A screwdriver with a 90-degree bend the vehicle. in the shaft for working in tight spaces. G-clamp A clamp shaped like the letter G; it comes in offset vise A vise that allows long objects to be gripped various sizes and can ©clamp Jones various & Bartlett items. Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTIONvertically. NOT FOR SALE OR DISTRIBUTION gasket scraper A broad, sharp, flat blade to assist in open circuit A circuit that has a break that prevents removing gaskets and glue. current from flowing. gear puller A tool with two or more legs and a cross-bar open-end wrench A wrench with open jaws to allow with a center forcing screw to remove gears. © Jones & Bartlett Learning, LLC side entry to© aJones nut or bolt.& Bartlett Learning, LLC grinding wheels and discs Abrasive wheels or flat discs outside micrometer A micrometer that measures the fittedNOT to bench, FOR pedestalSALE ORand portableDISTRIBUTION grinders. NOT FOR SALE OR DISTRIBUTION outside dimensions of an item. grounds A term often used in conjunction with shorts oxyacetylene torch A gas welding system that combines and is usually a reference to a short to ground. oxygen and acetylene. high resistance The resistance of a component or cir- parallax error A visual error caused by viewing meas- © Jones &cuit Bartlett relative Learning,to a low resistance. LLC It can also refer to ©a Jones & Bartlett Learning, LLC urement markers at an incorrect angle. NOT FORfaulty SALE circuit OR where DISTRIBUTION a section or component has excessNOT FOR SALE OR DISTRIBUTION unwanted resistance. peening A term used to describe the action of flattening a rivet through a hammering action. hollow punch A punch with a center hollow for cutting circles in thin materials such as gaskets. Phillips screwdriver A type of screwdriver that fits a head shaped like a cross in screws; also called Phillips impact driver A tool© that Jones is struck & Bartlettwith a blow Learning, to pro- LLC © Jones & Bartlett Learning, LLC head screwdriver. vide an impact turningNOT force FOR to remove SALE tight OR fasteners. DISTRIBUTION NOT FOR SALE OR DISTRIBUTION pin punch A type of punch in various sizes with a inside micrometer A micrometer that measures the straight or parallel shaft. inside dimensions of an item. pliers A hand tool with gripping jaws. intermediate tap One of a series of taps designed to cut an internal© Jones thread. & BartlettAlso called Learning, a plug tap. LLC pop-rivet gun© Jones A hand & tool Bartlett for installing Learning, pop rivets. LLC lockingNOT pliers FOR A SALEtype of plierOR whereDISTRIBUTION the jaws can be set power toolsNOT Tools FOR powered SALE by electricity OR DISTRIBUTION or compressed air. and locked into position. pressure washer/cleaner A cleaning machine that magnetic pickup tool An extending shaft, often flex- boosts low-pressure tap water to a high-pressure output. ible, with a magnet fitted to the end for picking up metal prick punch A pinch with a sharp point for accurately © Jones &objects. Bartlett Learning, LLC © Jonesmarking & Bartletta point on Learning, metal. LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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pry bar (also known as a crowbar) A high-strength square file A type of file with a square cross-section. © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC carbon-steel rod with offsets for levering and prying. NOT FOR SALE OR DISTRIBUTION NOTsteel FOR ruler SALE A ruler OR thatDISTRIBUTION is made from stainless steel. pullers A generic term to describe hand tools that straight edge A measuring device generally made of mechanically assist the removal of bearings, gears, pul- steel to check how flat a surface is. leys and other parts. straight grinder A powered grinder with the wheel set punches A generic term to describe a high-strength © Jones & Bartlett Learning, LLCat 90 degrees to the shaft. © Jones & Bartlett Learning, LLC carbon-steel shaft with a blunt point for driving. Center sulfuric acid A type of acid that when mixed with pure and prick punches areNOT exceptions FOR and SALE have ORa sharp DISTRIBUTION point NOT FOR SALE OR DISTRIBUTION water forms the basis of battery acid or electrolyte. for marking or making an indentation. tap A term used to generically describe an internal ratchet A generic term to describe a handle for sockets thread-cutting tool. that allows the user to select direction of rotation. It can turn ©sockets Jones in restricted& Bartlett areas Learning, without the LLC user having tap handle© A Jones tool designed & Bartlett to securely Learning, hold taps LLC for to removeNOT the FOR socket SALE from OR the fastener.DISTRIBUTION cutting internalNOT threads. FOR SALE OR DISTRIBUTION ratcheting screwdriver A screwdriver with a selectable taper tap A tap with a taper; it is usually the first of three ratchet mechanism built into the handle that allows the taps used when cutting internal threads. screwdriver tip to ratchet as it is being used. telescoping gauge Gauge used for measuring dis- © Jones &rattle Bartlett gun The Learning, most common LLC air tool in a motorcycle© Jonestances & in Bartlett awkward Learning, spots like LLCthe bottom of a deep NOT FORworkshop, SALE OR also DISTRIBUTION called the air impact wrench or impact gunNOT. cylinder. FOR SALE OR DISTRIBUTION reserve capacity A standard used to specify the time thread repair A generic term to describe a number of in minutes that a battery will supply a load of 25 amps processes that can be used to repair threads. at 27ºC without its voltage dropping below 10.5 volts. tin snips Cutting device for sheet metal, works in a safe working load (SWL)© Jones The &maximum Bartlett safe Learning, lifting LLCsimilar fashion to scissors. © Jones & Bartlett Learning, LLC load for lifting equipment.NOT FOR SALE OR DISTRIBUTIONtube-flaring tool A tool thatNOT makes FOR a sealingSALE flare OR DISTRIBUTIONon sand or bead blasters A cleaning system that uses high- the end of metal tubing. pressure fine particles of glass bead or sand. tubing cutter A hand tool for cutting pipe or tubing screw extractor A tool for removing broken screws or squarely. bolts.© Jones & Bartlett Learning, LLC twist drill© A Jones hardened & steelBartlett drill bitLearning, for making LLC holes shortNOT circuit FOR A conditionSALE OR in whichDISTRIBUTION the current flows in metals, plasticsNOT FOR and wood. SALE OR DISTRIBUTION along an unintended route. two-post hoist A type of motorcycle hoist that uses two single flare A sealing system made on the end of metal parts (one on each side of motorcycle) and four arms to tubing. lift the motorcycle. © Jones &sliding Bartlett T-handle Learning, A handle LLC fitted at 90 degrees to the© JonesV blocks & Bartlett Metal blocks Learning, with a V-shaped LLC cutout for hold- NOT FORmain SALE body OR that DISTRIBUTION can be slid from side to side. NOTing FOR shafts SALE while OR working DISTRIBUTION on them. Also referred to as vee blocks. slow charger A battery charger that charges at low current. vernier caliper An accurate measuring device for inter- smart charger A battery charger with microprocessor- nal, external and depth measurements that incorporates controlled charging rates and times. fixed and adjustable jaws. socket An enclosed metal© Jones tube commonly & Bartlett with Learning, 6 or 12 LLC © Jones & Bartlett Learning, LLC volatile organic compounds (VOCs) Evaporative emis- points to remove and NOTinstall FOR bolts andSALE nuts. OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION sions that motorcycles emit. solvent tank A tank containing solvents to clean motor- wad punch A type of punch that is hollow for cutting cycle parts. circular shapes in soft materials such as gaskets. speed brace A U-shaped socket wrench that allows high- warding file A type of thin, flat file with a tapered end. speed© operation. Jones & Also Bartlett called aLearning, speeder handle LLC. © Jones & Bartlett Learning, LLC water-pump pliers Adjustable pliers with parallel jaws splitNOT ball gaugeFOR SALE (small holeOR DISTRIBUTION gauge) A gauge that is NOT FOR SALE OR DISTRIBUTION that allow you to increase or decrease the size of the jaws good for measuring small holes where telescoping gauges by selecting a different set of channels. cannot fit. wrenches A generic term to describe tools that tighten spray-wash cabinet A cleaning cabinet that sprays sol- and loosen fasteners with hexagonal heads. © Jones &vent Bartlett under pressure Learning, to clean LLC motorcycle parts. © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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4. Tech A says pressure compression gauges are used to © Jones Review& Bartlett Questions Learning, LLC © Jones & Bartlett Learning, LLC measure the compression pressures inside an engine NOT FOR 1.SALE Tech AOR says DISTRIBUTION that you would use an outside micromNOT- FORcylinder. SALE Tech OR B DISTRIBUTION says pressure compression gauges eter to measure the bottom of a cylinder. Tech B says can identify overall condition and pressure leakage that you would use a telescoping gauge to measure situations that could be caused by a range of engine the bottom of a cylinder. Who is correct? faults. Who is correct? a. Tech A © Jones & Bartlett Learning, LLCa. Tech A © Jones & Bartlett Learning, LLC b. Tech B NOT FOR SALE OR DISTRIBUTIONb. Tech B NOT FOR SALE OR DISTRIBUTION c. Both A and B c. Both A and B d. Neither A nor B d. Neither A nor B 2. Tech A says to use nippers to cut through soft metal. 5. Tech A says the most commonly used pair of pliers Tech© Jones B says to& useBartlett an Allen Learning, wrench. Who LLC is correct? in the ©workshop Jones is& theBartlett needle-nosed Learning, plier. LLCTech B a.NOT Tech FOR A SALE OR DISTRIBUTION says theNOT most FOR common SALE is the OR circlip DISTRIBUTION plier. Who is b. Tech B correct? c. Both A and B a. Tech A d. Neither A nor B b. Tech B © Jones & 3. Bartlett A screw orLearning, bolt with aLLC cross-shaped recess requires© Jonesc. & Both Bartlett A and Learning,B LLC NOT FOR SALEa Phillips OR headDISTRIBUTION screwdriver. NOT FORd. NeitherSALE AOR nor DISTRIBUTION B a. True b. False

056754_CH03_p056-105.indd 104 3/12/14 9:37 PM © Jones & Bartlett Learning, LLC © Jones & Bartlett Learning, LLC NOT FOR SALE OR DISTRIBUTION NOT FOR SALE OR DISTRIBUTION

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