1. Tools

2. Tool Safety Use the tool for its designed use. Wear proper PPE
Secure small work in a clamp or vise.
Repair or replace damaged tools.
Report any injuries to the supervisor.
Wear proper PPE
Secure hair and loose clothing.
Work in areas with good lighting.
Make sure all personnel are at a safe distance before using the tool.
Deep tools free of oil, grease, and foreign matter

3. Categories of Tools
Hand
Power
Test

4. Hand Tools Tools that are powered by hand Measuring tools
Micrometer
Rules
Thickness gauges
Fastening tools
Wrenches
Screwdrivers
Pliers
Cutting tools
Hacksaws
Files
Chisels
Driving tools
Hammers
Mallets
Punches
Hand tool safety
Keep sharp and in proper working order
Point cutting tools away from the body during use.
Grind excess metal from mushroomed chisels.
Organize tools to protect and conceal sharp cutting surfaces.
Never use a hammer on another hammer.
Do not carry tools a a pocket.
Remove fasteners by pulling the tool toward the body or pushing the tool away from the face.
Wooden handles shall be keep free of splitters and cracks.

5. Power Tools Small engine power tools Power tool safety
Tools that are electrically, pneumatically, hydraulically or engine powered.
If capable of being held in the operators hands they are called portable power tools.
Large power tools that are not hand held are call stationary power tools.
Small engine power tools
Grinders
Drill press
Air chisels
Impact wrenches
Battery chargers
Portable drills
Power tool safety
All tools should be operated according to the manufactures instructions.
Insure electrically powered tools are properly grounded.
Metal case electrical portable power tools should have a three prong cord.
Do not use electrical tools on damp ground..
Floors must be kept clean, dry and free of debris.
Stand to one side when starting grinders.
Keep all guards in place.

6. Test Tools Test tools Test tool safety Store properly
A test tool is a measurement tool used to test the condition or operation of an engine component or system.
Test tools
Multimeter
Spark tester
Compression tester
Cylinder leakdown tester
Test tool safety
Use tool according to manufactures instructions.
Store properly

7. Tools
Tools for engine maintenance and repair can be divided into three (3) categories:
Special engine
General purpose
Measuring

8. Tools – Special Purpose Engine Tools
Valve spring compressor
Spark tester
Spark plug gauge
Tang bending tool
Tachometer
Feeler gages
Torque wrench
Starter clutch wrench
Oil evacuator pump
Flywheel puller
Flywheel strap wrench
Multimeter
Piston ring compressor
Valve lapping tool
Plug gauge
Seal protector
Impact wrench

9. Tools – SE – Valve Spring Compressor
Used to compress the valve spring in L-head engines so the key hole type of valve spring retainer can be removed.
Key hole valve
spring retainer
Lever style works well with B & S engines.

10. Tools – SE – Spark Tester
Spark testers are used to determine if the ignition system is producing sufficient energy to fire the spark plug.
The spark plug wire is attached to the terminal on the tester and the clamp is attached to a good ground on the engine.

11. Tools – Small Engine - Spark Plug Gauge
Used to set the gap between the two electrodes on spark plugs.
Wire types are also used.

12. Tools – Small Engine – Tang Tool
Used to adjust the governor spring tang. The tang is bent to fine tune the engine speed.

13. Tools – Small Engine - Tachometer
Tachometers are used to measure engine speed.
Briggs & Stratton recommends the Tiny Tach.
The wire is attached to the spark plug lead.
When engine is running it gives rpm, when engine is off it reads hours of use.
Virbatachs are also useful when managing small engines.

14. Tools – Small Engine – Feeler Gage
Use to measure or set small clearances.
Each blade is a different thickness.
Most have both English and metric measurements on the blades.

15. Tools – Small Engine – Torque Wrench
Used to tighten bolts and nuts to a specific torque.
Torque = lb-ft
Older style uses a flexible beam.
Newer style clicks when the desired torque is applied.

16. Tools – Small Engine – Starter clutch Wrench
Used to take off the starter clutch.
The starter clutch holds on the flywheel.

17. Tools – Small Engine – Flywheel puller
Small engine flywheels are mounted on a tapered section of the crankshaft.
A flywheel puller is used to remove the flywheel from the crankshaft.

18. Tools – Small Engine – Flywheel Strap Wrench
Strap wrenches are used to keep the flywheel from turning when removing the flywheel nut or clutch.
They have replaced the older style of flywheel holder.

19. Tools – Small Engine – Multimeter
Required to troubleshoot electrical problems.
Measures amps, volts and Ohms.

20. Tools – Small Engine – Piston Ring compressor
Used to compress the rings on the piston when installing the piston into the cylinder.

21. Tools – Small Engine – Valve Lapping Tool
The valves seal the combustion chamber.
To have a good seal the contact line on the valve face must be uniform width and darkness.
If the contact line on a valve taken out of an engine is not uniform in width and darkness, it should be lapped.
New Valve
Lapped Valve

22. Tools – Small Engine – Plug Gauge
Used to determine if wear is acceptable for valve guides.
May also be used for main bearings.
Must have the correct number of gauge for the engine model.

23. Tools – Small Engine – Seal Protectors
Should be used when assembling the sump plate/crankcase cover to the block.
Protects the crankshaft seal from damage.

24. Tools – Small Engine – Impact Wrench
Used to apply high amounts of torque to a nut or bolt with minimum effort.
Power has traditionally been compressed air, but electric impact wrenches are also available.
Note: An impact wrench is not the same tool as an impact drill.

25. Tools – General Purpose Engine Tools
General purpose tools for small engines can be divided into three (3) categories.
Turning
Gripping
Driving

26. Tools – GPE Tools - Turning
Wrenches
Screwdrivers
Ratchet & Socket

27. Tools – GPE Tools – Turning Tools - Wrenches
Open end wrench
Standard wrench has a different size on each end.
Available in English and metric sizes.
Many variations.
Wrenches for specific implements
Single Open End

28. Tools – GPE Tools – Turning Tools - Wrenches
Box end wrench
Preferred over open end wrench because less chance of stripping of the corners of the nut or bolt head.
Available in fractional and metric sizes.

29. Tools – GPE Tools – Turning Tools - Wrenches
Combination wrench
Combination of open end wrench and box end wrench.
Usually both ends are the same size.
Available in fractional and metric sizes.

30. Tools – GPE Tools – Turning Tools - Wrenches
Ratchet box end wrench
Newer style that is gaining popularity because the reduce the amount of time required to remove a nut or bolt.
Available in fractional and metric sizes.

31. Tools – GPE Tools – Turning Tools - Wrenches
Adjustable wrench
Available in different sizes.
Size determined by handle length.

32. Tools – GPE Tools – Turning Tools - Wrenches
Hex wrench
Has a hexagonal cross section to match bolts and screws with a hexagonal socket in the head.
Also available with a screw driver handle, folding and several other configurations.

33. Screw Drivers

34. Tools – GPE Tools – Turning Tools – Screw Drivers
Screwdrivers are designed to turn/hold wood and metal screws.
Screw drivers are available in many different lengths, style of handles and drive points.

35. Tools – GPE Tools – Turning Tools – Screw Drivers
The drive points are designed to match the different types of screw heads.
Six (6) drive points are:
Each type of screw driver is available in different sizes.

36. Tools – GPE Tools – Turning Tools – Screw Drivers
Slotted screwdrivers are sized by blade width.
Slotted
Tip Width
Screw Gauge
3-32
3/16
1-7
8-9
5/16 10
3/8
11-20
Philips Size
Screw Gauge
0-1 1
2-4 2
5-9
2 or 3 10 3
11-16 4
18-20
Phillips screwdrivers are sized by number.

37. Tools – GPE Tools – Turning Tools – Bit Driver
Screws can also be installed and removed using a bit driver and interchangeable bits.
Bit driver
Bits for different screw patterns

38. Ratchet and Socket

39. Tools – GPE Tools – Turning Tools – Ratchet & Socket
Ratchet wrench
Used to turn sockets.
Different size of drives are used.
1/4, 3/8,& 1/2 inch are most common.

40. Tools – GPE Tools – Turning Tools - Ratchet & Socket
Ratchet sockets
Many variations in sockets are available.
They can be taller-deep sockets.
They can have different number of points, usually ranging from 4 to 12.
They can have swivels attached.
Available in fractional and metric sizes.
Deep Sockets
4 point
12 point
Swivel sockets

41. Tools – GPE Tools – Turning Tools - Ratchet & Socket
Ratchet extensions
Extensions are used to extend the distance between the ratchet and the socket.
Available for the different drive sizes.
Multiple lengths

42. General Purpose Tools--Gripping

43. GPT- Gripping - Pliers Pliers are used for holding or turning.
Many different types and sizes are available.
Common types used for small engines include:
Slip joint
Diagonal (side cutters)
Needle nose
Tongue and groove
Locking

44. GPT- Gripping – Pliers – Slip Joint
Slip joint pliers get their name from the have the capability of slipping the hinge joint to increase the size of object that can be gripped.
Slip joint pliers are sized by their length.
Most brands also have a wire cutter.

45. GPT- Gripping – Pliers – Diagonal Cutters
Used for cutting wire.

46. GPT- Gripping – Pliers – Needle Nose
Needle nose pliers have long narrow jaws that allow them to reach into small or crowded areas.
Needle nose pliers are sized by their length.
Many variations are available.
Long nose
Bent nose

47. GPT- Gripping – Pliers – Tongue & Groove
These pliers have serrated jaws that are angled to the handles.
The lower jaw can be moved into different grooves, which changes the effective gripping size, without increasing the distance between the handles.
Size is determined by the length of the handles.

48. GPT- Gripping – Pliers – Locking
Locking pliers use a thumb wheel to adjust to range of sizes and an over center lever action to lock the handles in place.
Locking pliers are sized by their length.
They are available with a variety of jaws.

49. Measuring Tools

50. Introduction
Measuring tools for small engines are divided into three categories.
Direct reading
Measurement transferring
Reject gages

51. Direct Reading Measuring Tools
Small engines use two types of direct reading measuring tools:
Micrometers
Calipers

52. Reading - Micrometer
A micrometer is a mechanical device designed to measure distances as small as 1/10,000 of an inch ( in).
Micrometers are only one (1) inch long.
The micrometer is used with different types and sizes of frames to provide precise measurements of many different objects.
Small engines uses three (3) types of micrometers:
Micrometer caliper
Inside micrometer
Depth gauge micrometer
Micrometer calipers are available in mechanical and digital models.

53. Reading - Micrometer Caliper
A micrometer caliper uses a frame that allows the micrometer to measure the thickness of objects.
For small engine use, different frame sizes are used to provide a wider measurement range.
One inch
Two inch
Etc.

54. Reading - Micrometer Caliper-parts
Frame
Lock
Barrel or sleeve scale
Reading point
Thimble
Friction or ratchet stop
Thimble scale
Barrel or sleeve
Spindle
Anvil

55. Reading - Micrometer Caliper--information
The face of the anvil and the face of the spindle are the contact surfaces.
The spindle and thimble turn together.
The ratchet/friction stop improves the repeatability of measurements for beginners.
A micrometer caliper is read at the point were the edge of the thimble crosses the barrel scale
Insure the lock is released before trying to turn the thimble..

56. Reading Micrometer Caliper-barrel
A micrometer caliper is read just like an ruler.
Start by determining the smallest whole unit, and then determine the values of each sub division.
The smallest whole unit is determined by the frame size.
One (1) inch frame = 0.0 smallest whole unit
Two (2) inch frame = 1.0 smallest whole unit.
Etc.
The micrometer barrel scale is one (1) inch long and is divided into ten (10) sections.
Each number on the barrel scale = 1/10 or 0.1 inch.

57. Reading Micrometer Caliper-barrel
Each 1/10 of an inch on the barrel scale is divided into 4 segments.
Each short line = 0.25 inches (25 thousands of an inch).

58. Reading Micrometer Caliper-thimble
The last step is reading the value on the thimble scale.
The thimble scale subdivides the last segment on the barrel scale.
The smallest segment on the barrel is 25 thousands (0.025).
The thimble is divided into 25 segments = 1/1,000 or inch.

59. Micrometer Caliper Example
Determine the reading for the micrometer caliper in the illustration.
Smallest whole unit 0.000
Tenths of an inch 0.300
Twenty five thousands ( x 2 ) 0.050
Thousands 0.015
Sum (measurement) 0.365

60. Micrometer Caliper-digital
Most measuring tools are available with a digital readout.
Advantages
Easier to read.
Can be interfaced with data collection devices for automatic recording.
Easy to convert between English and metric units.
Disadvantages
Requires battery
More expensive

61. Inside Micrometer
Inside micrometers have been replaced by dial calipers and other tools for small gas engines.
The principles for reading are the same.
The primary difference is determining the smallest whole unit.
The physical size of the micrometer limits the smallest whole unit to 1 or 1-1/2 inch.
Extensions are added to set the minimum size to the desired range.

62. Inside Micrometer Example
Read a inside micrometer in the illustration.
Smallest whole unit 1.500
Tenths 0.200
Twenty Five Thousands 0.025
Thimble 0.014
Sum (reading) 1.734

63. Inside Micrometer Example 2
Inside micrometers use extensions to change the range of measurements.
Adding an extension increases the minimum measurement.
In this example a 1/2 inch extension has been added.
Smallest whole unit 2.000
Tenths 0.200
Twenty five thousands 0.075
Thousands 0.001
Reading 2.276
Note: when the zero on the thimble is close to the reference line and a 25 thousands line is close to the edge of the thimble, it may be difficult to determine if the last line that should be counted. If the thimble zero is above the reference line the line is not counted. If it is below it should be counted.

64. Depth Gauge Micrometer
Thimble
Depth gauge micrometers are used to measure the depth of blind holes, slots, key ways, etc.
The spindle length can be changed to set the micrometer for the desired range of measurement.
To read a depth gauge micrometer you must visualize the distance that has been covered by the thimble.
Spindle

65. Depth Gauge Micrometer Example
Read the depth gauge micrometer in the illustration
Smallest whole unit 0.000
Tenths 0.800
Twenty Five Thousands 0.050
Thousands 0.017
Sum (reading) 0.867

66. Calipers

67. Introduction
Calipers can be direct reading or measuring transferring tools.
Direct reading calipers are capable of a wider measurement range than micrometer calipers.
Six (6), eighteen (18) and twenty four (24) inch are popular.
Three common designs of direct reading calipers;
Vernier
Dial
Digital

68. Vernier Caliper
Vernier Caliper
Vernier calipers are an old tool that has been mostly replaced by dial and digital calipers.
They are manufactured with decimal scales, metric scales and fractional scales.
The Vernier scale is still used on many mechanical measuring tools.

69. Vernier Scale
A Vernier is a mechanical means of magnifying the last segment on the main scale so addition subdivisions can be made.
The reference point is the 0 on the Vernier scale.
To read a Vernier, the line of coincidence must be located.
The line of coincidence (LOC) is the line on the Vernier that coincides with a line on the main scale.
Illustration LOC = 19
In theory only one LOC is possible, but usually when reading the Vernier it appears several exist. When this occurs pick the middle line.

70. Vernier Caliper-practice
Read the Vernier caliper in the illustration.
LOC
Smallest whole unit 1.000
Tenths of an inch 0.200
Twenty five thousands
Vernier scale 0.011
Sum (measurement) 1.211

71. Dial Caliper On a dial caliper a dial replaces the Vernier.
The caliper easier to read.
The reader must still determine the units and graduations.

72. Measurement Transferring Tools

73. Introduction
Measurement transferring tools are tools that collect a measurement, but do not have a scale to read the measurement.
Common tools are:
Spring calipers
Dividers
Telescoping gauges
Ball gauges

74. Spring Calipers Spring calipers are used to transfer measurements.
Three types of spring calipers
Outside
Inside
Hermaphrodite

75. Dividers
Dividers are very useful for laying out several equal distances or transferring a distance measurement when other measuring devices cannot be used.

76. Telescoping gages
Telescoping gages are used to measure inside diameters.
One or both ends are spring loaded so they can be retracted and inserted into the hole being measured.
The measurement is made with a caliper or micrometer.

77. Ball Gauges
Ball gauges are use to transfer measurements that are too small for telescoping gauges.
The ball is split and a tapered wedge is used to increase and decrease the diameter of the ball halves.