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[object Object],[object Object],[object Object],[object Object],OBJECTIVES: After studying Chapter 10, the reader should be able to:
[object Object],KEY TERMS:
AIR COMPRESSOR ,[object Object],The larger the storage tank, expressed in gallons, the longer an air tool can be operated in the shop without the compressor starting. Figure 10–1 A typical shop compressor. Placed out of the way, yet accessible to provide for maintenance to the unit.
[object Object],Figure 10–2 A typical air nozzle. Always use an air nozzle that is OSHA approved. All OSHA approved air nozzles have vents drilled around the main discharge hole. Air pressure used by a nozzle (blow gun) must be kept to 30 psi (207 kPa) or less.
AIR AND ELECTRICALLY OPERATED TOOLS ,[object Object],Figure 10–3 A typical 1/2-inch drive impact wrench. Continued
Figure 10–4 This impact wrench features a variable torque setting using a rotary knob. The diameter of rotation can be changed by pressing the button at the bottom. The air-operated 1/2-inch drive impact wrench is the most commonly used unit. Rotation direction and diameter are controlled by switches. Continued
[object Object],Figure 10–5 A typical battery-powered 3/8-inch drive impact wrench. Continued
In one busy shop, it was noticed by several technicians that water was being pumped through the air compressor lines and out of the vents of air impact wrenches whenever they were used. It is normal for moisture in the air to condense in the air storage tank of an air compressor. One of the routine service procedures is to drain the water from the air compressor. The water had been drained regularly from the air compressor at the rear of the shop, but the problem continued. Then someone remembered that there was a second air compressor mounted over the parts department. No one could remember ever draining the tank from that compressor. After that tank was drained, the problem of water in the lines was solved. The service manager assigned a person to drain the water from both compressors every day and to check the oil level. The oil in the compressor is changed every six months to help ensure long life of the expensive compressors. The Case of the Rusty Air Impact Wrenches Continued
Figure 10–6 A black impact socket. Always use impact-type sockets whenever using an impact wrench to avoid the possibility of shattering the socket, which can cause personal injury. Continued CAUTION:   Always use impact sockets with impact wrenches, and be sure to wear eye protection in case the socket or fastener shatters. Impact sockets are thicker walled and constructed with premium alloy steel. They are hardened with a black oxide finish to help prevent corrosion and distinguish them from regular sockets.
Figure 10–7 An air ratchet is a very useful tool that allows fast removal and installation of fasteners, especially in areas that are difficult to reach or do not have room enough to move a hand ratchet wrench. ,[object Object]
Figure 10–8 This typical die grinder surface preparation kit includes the air-operated die grinder, as well as a variety of sanding discs for smoothing surfaces or removing rust. Die Grinder   A  die grinder  is a commonly used air-powered tool, which can also be used to sand or remove gaskets and rust.
Air Drill   An  air drill  is a drill that rotates faster than electric drills (up to 1,800 rpm). Commonly used in auto body work when many holes need to be drilled for plug welding. Air Blow Gun   An  air blow gun  is used to clean equipment and other purposes where a stream of air would be needed. Air-Operated Grease Gun   Uses shop air to operate a plunger to force to grease a grease cartridge. Most use a 1/4-inch air inlet and operate on 90 psi of air pressure. Battery-Powered Grease Gun   More expensive than air-operated guns but offer the convenience of not having an air hose. Many use rechargeable 14- to 18-volt batteries and standard grease cartridges.
TROUBLE LIGHTS ,[object Object],WARNING:   Do not use incandescent trouble lights around gasoline or other flammable liquids. The liquids can cause the bulb to break and the hot filament can ignite the flammable liquid. LED Trouble Light   Light emitting diode (LED)  trouble lights are excellent because they are shock resistant, long lasting, and do not represent a fire hazard. Some are battery powered and can be used in places where an electrical cord could present problems.
Figure 10–9 A fluorescent trouble light operates cooler and is safer to use in the shop because it is protected against accidental breakage where gasoline or other flammable liquids would happen to come in contact with the light. ,[object Object],Trouble lights are usually attached to retractors which hold 20 to 50 feet of electrical cord.
BENCH/PEDESTAL GRINDER ,[object Object],[object Object],[object Object],Continued
[object Object],A bench grinder is a very useful piece of shop equipment and the wire wheel end can be used for the following: ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Continued
Figure 10–10 A typical pedestal grinder with a wire wheel on the left side and a stone wheel on the right side. Even though this machine is equipped with guards, safety glasses or a face shield should always be worn when using a grinder or wire wheel. CAUTION:   Always wear a face shield when using a wire wheel or a grinder. Keep the part support ledge (table) close to the stone. Only use a steel wire brush on steel or iron components. If a steel brush is used on aluminum or copper-based metal parts, it can remove metal from the part.
BENCH VISES ,[object Object],The vise jaws can damage parts or components being held. Pieces of wood or other soft material between the steel jaws and workpiece help avoid damage. Many vises are sold with optional aluminum jaw covers.  When finished using a vise, be sure to close the jaws and place the handle straight up and down to help avoid personal injury. Figure 10–11 Vise mounted to a workbench.
HYDRAULIC PRESSES ,[object Object],Figure 10–12 A hydraulic press is usually used to press bearings on and off on rear axles and transmissions. Continued
Whenever pressing on a bearing or other component, use an old brake drum over the shaft and the bearing. In the event the bearing shatters during the pressing operation, the drum will prevent parts of the bearing from flying outward where they could cause serious personal injury. Cover Work While Pressing
PORTABLE CRANE AND CHAIN HOIST ,[object Object],Figure 10–13 A typical portable crane used to lift and move heavy assemblies, such as engines and transmissions. Continued
[object Object],CAUTION:   Always follow the instructions from the manufacturer regarding proper use and care of the equipment.
ENGINE STANDS ,[object Object],Continued Safe Operation of an Engine Stand   When mounting an engine, be sure the engine is supported by a portable crane. Ensure attaching bolts are grade 5 or 8 and the same thread size as the holes in the block. Be sure all attaching bolts are securely tightened before releasing the weight of the engine from the crane. Cautiously loosen the rotation retaining bolts. The engine could rotate rapidly, causing personal injury.
Figure 10–14 Two engines on engine stands. The plastic bags over the engines help keep dirt from getting onto these engines and engine parts.
Figure 10–15 An engine stand that grasps the engine from the sides rather than the end. ,[object Object],On larger engines, such as the 5.9 Cummins inline six-cylinder diesel engine, the engine mounts to the stand using the engine mounting holes in the block.
[object Object],CARE AND MAINTENANCE OF SHOP EQUIPMENT ,[object Object],[object Object],CAUTION:   Always follow the instructions from the manufacturer regarding proper use and care of the equipment.
[object Object],Continued
[object Object],( cont. ) Continued
[object Object],Continued
[object Object]
SUMMARY ,[object Object],[object Object],[object Object],Continued
SUMMARY ,[object Object],[object Object],[object Object],[object Object],( cont. )
end

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Chapter 10

  • 2.
  • 3.
  • 4.
  • 5.
  • 6.
  • 7. Figure 10–4 This impact wrench features a variable torque setting using a rotary knob. The diameter of rotation can be changed by pressing the button at the bottom. The air-operated 1/2-inch drive impact wrench is the most commonly used unit. Rotation direction and diameter are controlled by switches. Continued
  • 8.
  • 9. In one busy shop, it was noticed by several technicians that water was being pumped through the air compressor lines and out of the vents of air impact wrenches whenever they were used. It is normal for moisture in the air to condense in the air storage tank of an air compressor. One of the routine service procedures is to drain the water from the air compressor. The water had been drained regularly from the air compressor at the rear of the shop, but the problem continued. Then someone remembered that there was a second air compressor mounted over the parts department. No one could remember ever draining the tank from that compressor. After that tank was drained, the problem of water in the lines was solved. The service manager assigned a person to drain the water from both compressors every day and to check the oil level. The oil in the compressor is changed every six months to help ensure long life of the expensive compressors. The Case of the Rusty Air Impact Wrenches Continued
  • 10. Figure 10–6 A black impact socket. Always use impact-type sockets whenever using an impact wrench to avoid the possibility of shattering the socket, which can cause personal injury. Continued CAUTION: Always use impact sockets with impact wrenches, and be sure to wear eye protection in case the socket or fastener shatters. Impact sockets are thicker walled and constructed with premium alloy steel. They are hardened with a black oxide finish to help prevent corrosion and distinguish them from regular sockets.
  • 11.
  • 12. Figure 10–8 This typical die grinder surface preparation kit includes the air-operated die grinder, as well as a variety of sanding discs for smoothing surfaces or removing rust. Die Grinder A die grinder is a commonly used air-powered tool, which can also be used to sand or remove gaskets and rust.
  • 13. Air Drill An air drill is a drill that rotates faster than electric drills (up to 1,800 rpm). Commonly used in auto body work when many holes need to be drilled for plug welding. Air Blow Gun An air blow gun is used to clean equipment and other purposes where a stream of air would be needed. Air-Operated Grease Gun Uses shop air to operate a plunger to force to grease a grease cartridge. Most use a 1/4-inch air inlet and operate on 90 psi of air pressure. Battery-Powered Grease Gun More expensive than air-operated guns but offer the convenience of not having an air hose. Many use rechargeable 14- to 18-volt batteries and standard grease cartridges.
  • 14.
  • 15.
  • 16.
  • 17.
  • 18. Figure 10–10 A typical pedestal grinder with a wire wheel on the left side and a stone wheel on the right side. Even though this machine is equipped with guards, safety glasses or a face shield should always be worn when using a grinder or wire wheel. CAUTION: Always wear a face shield when using a wire wheel or a grinder. Keep the part support ledge (table) close to the stone. Only use a steel wire brush on steel or iron components. If a steel brush is used on aluminum or copper-based metal parts, it can remove metal from the part.
  • 19.
  • 20.
  • 21. Whenever pressing on a bearing or other component, use an old brake drum over the shaft and the bearing. In the event the bearing shatters during the pressing operation, the drum will prevent parts of the bearing from flying outward where they could cause serious personal injury. Cover Work While Pressing
  • 22.
  • 23.
  • 24.
  • 25. Figure 10–14 Two engines on engine stands. The plastic bags over the engines help keep dirt from getting onto these engines and engine parts.
  • 26.
  • 27.
  • 28.
  • 29.
  • 30.
  • 31.
  • 32.
  • 33.
  • 34. end