Automotive Electrical & Electronics Tools PDF

Automotive Electrical & Electronics Level – I Using Tools, Equipment and Measuring Instruments 1 Hand Tools Have no power source, other than the physical force applied by the user 2  HAND TOOLS  Sc...

Automotive Electrical & Electronics Level – I Using Tools, Equipment and Measuring Instruments 1 Hand Tools Have no power source, other than the physical force applied by the user 2  HAND TOOLS  Screwdrivers  Pliers  Hammers  Wrenches  Socket wrench sets  Special tools 3  Screwdrivers Phillips Flat Blades Torx a screwdriver is directly proportional to the size (diameter) of the handle Blade should fit the slot as tightly as possible 4 Screwdrivers Slotted/Flat Phillips/Reed Torx 5  Pliers Combination Side cutters Slip joint Long nose 6  Pliers available with standard, Locking and slip joint Handles Slip-joint Pliers Needle nose Pliers Side cutter Water pump Pliers C-clip Pliers Vice grips 7 Pliers 8  Pliers  Diagonal (Side) Cutting Pliers Used to cut wires, tie wraps, plastic tubing, hoses, etc. Available in straight and angled jaws. 9 Specialty Pliers  Battery pliers  Hose clamp  Grease cup  Tin snips  Many other types 10  Hammers Used for striking various components. 1.Ball peen hammer 2. Engineers hammer 3. Soft faced 4. Rubber mallet 5. Dead blow 6. Brass 7. Leather 11  Hammers Ball peen Hammer Rubber mallet Dead blow Hammer Sledge Hammer 12 Hammers 13  Wrenches Used to install and remove nuts and bolt  The 5 types of Wrenches are Open-end Box-end Combination Flare nut or line Allen 14  Wrenches Open ends Box end 15 Wrenches 16  Flare Wrench Flare wrench is a special wrench that is used on fuel and brake lines 17  More Wrenches Flare nut Distributor wrench Alignment wrench wrenches Ratcheting box wrench Tubing wrenches Curved wrench 18  Crescent Wrenches Adjustable end wrench (Crescent wrench) Bulky Not precise Rounds of the fastener head. Do not make it your favorite tool. 19  Pipe Wrench Is used to hold cylindrical stock. Can wreck the surface of the object. Not a common tool in automotive industry. 20  Socket Wrenches ocket wrenches: is basically a box-end wrench designed used on a socket handle Classified by their drive size. Three drive sizes are commonly used in the automotive trade. ¼”, 3/8”, ½” I.e: the size of the square 21  Socket Wrench Drivers Ratchet Speeder Nut driver Breaker bar T-handle Breaker bar ½’’ Drive, 3/8 ’’ Drive 1/4 ”22 Driv  Sockets (Metric & Imperial) Deep & Shallow 6 Point & 12 Point Hex size 23  Specialty Sockets Impact sockets Spark plug sockets Universal sockets O2 sensor socket 4 & 8 point sockets Impact Sockets (Used with impact Impact & Standard Sock 24  Spark Plug Socket 5/8” & 13/16” Rubber insert to protect the spark plug. 25  Extensions Different drives & different length (1”, 3”,6”, 9” &1’) Adapters ¼” to 3/8” or 3/8” to ¼” 3/8” to ½” or ½” to 3/8” Universal swivels. Breaker Bar 26  Torque Wrenches  Beam  “Click” Older and not very When the handle reaches accurate. the preset torque, the wrench clicks.  Dial A dial indicates the amount of torque exerted.  Digital read out Is usually the most accurate design. 27  Torque wrench Foot pound / Newton meter Zero before putting it away. Dial torque wrench. 28  Specialty Hand Tools Magnet, Pick-up Ring compressor, tool, Pullers: damper, Valve lifter tool, oil slide bar, pitman filter wrench, brake arm, wheel and Spoon, ring battery terminal. 29  Cutting Tools  Hack saws  Files  Chisels  Taps & Dies  Drills  Grinders  Da Torch 30  Hacksaws  Use to saw through metal.  Needs a special blade depending on thickness of metal.  Blades come in 18, 24, or 32 teeth per inch. 31  Files  Commonly used to shape or smooth metal edges and surfaces.  They only cut when you push.  For removing small amounts of metal.  They vary in size and coarseness depending on the shape and material being filed. 32  Chisels  Used for cutting metal when driven by a hammer. Can be used to shear off bolt and rivet heads. Scraper 33  Punchers  Punches Used for driving out pins, rivets, or shafts; aligning holes in components; and marking the starting point for drilling a hole.  If the end is mushroomed, grind it before using. 34  Threading Tools  Cut threads  Taps cut internal threads.  Dies cut external threads.  Used in automotive service to repair threads. 35  Hand Tool Safety  Use the proper tool for the job.  Use the correct size wrench or socket.  Use box-end wrench or socket whenever possible.  Always pull on a wrench. 36  Power Tools  Impact wrenches  Air ratchets  Drills  Blow guns  Grinders  Cutting tools 37  Compressed-Air System Air tools are driven by the compressed-air system Components include: air compressor air lines pressure regulator filter and lubricator 38  Air Tool  Air (impact) Wrench  Air Ratchet  Air Hammer (Chisel)  Blowgun  Solvent Gun  Air drill  Rotary Brush  Abrasive Pad  Rotary File 39  Air (Impact) Wrench Provides a very fast means of installing or removing threaded fasteners 3/8”, 1/2”, and 3/4” drive sizes are used 40  Air Ratchet Impact wrench designed to work in a limited space usually found in 1/4” and 3/8” drive 41  Impact Sockets & Extensions  Must be used with air wrenches  Case hardened, thicker, and much stronger than conventional sockets and extensions  Impact tools are flat black, instead of chrome  Using a chrome tool on an impact wrench can be unsafe Impact & Standard Socke 42  Air Hammer (Chisel)  Useful during various driving and cutting operations  Capable of producing about 1000-4000 impacts per minute  Several cutting or hammering attachments are available Always wear safety glasses when using an air hammer 43  Blowgun  Commonly used to dry and clean parts washed in solvent  When using a blowgun: wear eye protection direct the blast of air away from yourself and others do not blow brake and clutch parts clean as the dust may contain asbestos Drying a part after cleaning it in solvent. May also be used to blow dust and loose dirt from 44  Solvent Gun Used to wash parts that will not fit into a cleaning tank 45  Air Drill - Power and rotating speed can be set to match the job at hand - used to drill holes, grind, polish, and clean parts46  Rotary Brush Used in a drill for cleaning off carbon deposits, rust, or old gaskets 47  Rotary File (Stone)  Used in a drill or die grinder  Handy for removing metal burrs and nicks  Maximum speed is printed on the file or stone container 48  Electric Tools  There are many electric tools that can be useful to a technician  These may include A drill press Portable drill Grinder 49  Electric Drills Used to create holes in metal and plastic parts May be portable or mounted on a workbench or the floor  Drills use drill bits, or twist drills, to drill holes in metal and plastic parts  3/8” drill the most common for general automotive work.  Made of carbon steel or high-speed steel 50  Electric Drill Used to tighten a drill Drill-Bit bit in the drill chuck High-speed steel is better because of its resistance 51  Portable Electric Drill Size of a drill is an indication of the capacity of its chuck–common sizes are 1/4”, 3/8”, and 1/2” 52  Drill Press  Large, floor-mounted or bench-mounted drill needed for drilling large holes, deep holes, or a great number of holes in several parts  Handle allows the bit to be pressed into the work with increased force 53  Drill Press Rules  Remove the key from the chuck before turning on the drill press  Secure the part to be drilled in a vise or with C-clamps  Use a center punch to indent the part and start the hole  Release pressure right before the bit breaks through the bottom of the part  Oil the bit as needed 54  Bench Grinder  Used for grinding, cleaning, or polishing  Usually has two wheels: grinding wheel–used for sharpening and deburring wire wheel–used for cleaning and polishing 55  Grinding Equipment Pedestal Grinder Valve grinding equipment Bench grinding Machine 56  Bench Grinder Rules  Always wear eye protection and keep your hands away from the wheel  Make sure the grinder shields are in place  Keep the tool rest adjusted close to the wheel  Do not use a wire wheel to clean aluminum or brass parts 57  Hydraulic Tools  Tools powered by pressurized liquid  Typical hydraulic tools used in the automotive shop: Jacks Cranes Presses 58  Floor Jack  Used to raise either the front, sides, or rear of a vehicle  To avoid vehicle damage, place the saddle under a solid part of the car such as the frame, suspension arm or axle housing 59  Floor Jack & safety Stand  Hydraulic floor jack Is used to raise vehicle off the ground. Is used with safety stands.  Safety stand Is used to support a vehicle when raised. 60  Vehicle Lifts (Hoists)  Vehicle Lifts or Hoists Can be pneumatic (air pressure) or hydraulic controlled. Most modern lifts use electric motor driven cables or screws. 61  Raising a Vehicle  Place the transmission in neutral and release the parking brake allows the vehicle to roll, preventing it from pulling off the jack  Turn the jack handle clockwise and pump the handle  After raising, secure vehicle on jack stands, shift it into park, apply the parking brake and block the wheels 62  Lowering a Vehicle  Use the jack to lift the vehicle off the jack stands  Remove the jack stands, shift the vehicle into neutral, release the parking brake, and remove the wheel chocks  Turn the handle counterclockwise slowly to release the pressure-release valve 63  Transmission Jack  Designed to hold transmissions during removal and installation  May be similar to a floor jack (low)  May use a long post that can reach high into the air for use when a car is on a lift This hydraulic stand can be extended to a height of 72” 64  Engine Crane Uses a hydraulic hand jack for raising engines and a pressure-release valve for lowering engines 65  Hydraulic Press  Used to install or remove gears, pulleys, bearings, seals, and other parts requiring a high pushing force  Hydraulic ram extends as the pump handle is worked  Ram presses the parts against a table 66  Shop Equipment Wheel balancer 67  Shop Equipment  There are various pieces of shop equipment that a technician may find useful  These include: Tire changers Stands Cleaners welders Lights and creepers 68  Tire Changer  Used to remove and replace tires on wheels  May be pneumatic or hand operated  Do not attempt to operate a tire changer without training and supervision  Follow the manufacturer’s directions 69  Cleaning Equipment  Solvent tank using mineral spirits.  Immersion cleaner using very harsh chemicals.  Steam cleaner.  Sand blaster.  Wire brushes & scrapers. 70  Solvent Tank Uses mineral spirits as a solvent. Used on oily and greasy parts. Use gloves for the solvent is harsh on skin. Don’t put any other fluids in the tank. 71  Steam Cleaner  Used to remove heavy deposits or dirt, grease, and oil from the outside of large assemblies: engines, transmissions, and transaxles  Wire brush the item to be cleaned and collect oil-soaked dirt before washing  Dispose of the oil-soaked material properly 72 High-Pressure Washer 73  Welder  Uses high current to create an electric spark, or arc  Arc is hot enough to melt and fuse metal parts together  Be sure to complete proper training before attempting to weld 74  Arc Welder MIG welder 75  Oxyacetylene Torch Used to cut, bend, weld, or braze metal parts 76  Battery Charger  Used to recharge a dead car battery  Forces current through the battery and realigns the ions  Red charger lead connects to the positive (+) battery terminal  Black charger lead connects to the negative (-) battery terminal  Connect leads before turning on the charger to avoid arcing 77  Battery Charger Battery capacity tester Jump leads Battery charger 78  Droplight  Provides a portable source of light  Light can be taken to the repair area under the vehicle or in the engine compartment  Beware of an electric shock hazard when working on a wet vehicle  Use caution when removing a fuel tank if you drop a light on the floor, a bursting bulb can ignite gasoline 79  Droplights A. Droplight B. Drop or extension cord C. Three-prong adapter with ground wire D. Fluorescent droplight 80  Pullers  Used to remove seals, gears, pulleys, steering wheels, axles, and other pressed- on parts  Always wear safety glasses when using pullers pullers exert tons of force which can cause parts to break and allow pieces to fly off 81  Pullers A Three leg puller Slide hammer puller Power puller 82  Pullers Battery terminal Steering wheel Valve spring Hub puller puller puller compressor 83  Test Equipment Scan Engine analyzer tool Timing light Digital multimeter 84  Creepers  Creeper useful when working under a car  Stool creeper allows the technician to sit while working on parts that are near the ground A. Creeper B. Stool 85  Fender Covers Placed over body sections to protect the paint or finish from nicks, scratches, and grease 86  Safety means protecting yourself and others from possible danger and injuring in the shop , 87 Venire Caliper 88 89 Micrometer 90 91 Add: Full millimetres 10.00 mm + ½ millimetres (2 × 0.50) 1.00 mm + Thimble reading 0.00 mm Final Reading 11.00 mm 92 Reading an Imperial Micrometer Add: (0 to 1 inch micrometer) 0.100 inch increments 0.200 inch + 0.025 inch increments (3 × 0.025) 0.075 inch + Thimble reading 0.000 inch Final Reading 0.275 inch 93  Using a Micrometer  Slip the micrometer back and forth over the object.  Try to rock it from side to side.  When no rocking is present and a slight drag is felt, the micrometer reading can be taken. 94  Dial Indicator  Dial indicator Is used to measure radial or axial movement, such as a shaft’s runout or end play. Indicator bases can vary from magnetic to clamp on adaptive styles. 95 Telescopic Gauge 96 Small Hole Gauge 97 Feeler Gauge 98 Screw Pitch Gauge 99 100