Screwdrivers Common or Standard

Should not be used as a punch, chisel, pry-bar, or nail puller

The blade size should be close to the screw slot width, and the blade thickness should fit as tightly as possible in the screw head slot

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Phillips The tip of a Phillips screwdriver is rounded The tip should fit snugly into the screw head

Frearson Also known as a Reed and Prince The tip comes to a point rather than rounded Any Frearson screwdriver will fit any Frearson screw However, do not use a Frearson screwdriver in place

of a Phillips

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Torx Torx screws have a six point star pattern Require a Torx driver to properly drive them Do not use an Allen wrench in place of a Torx driver

Tamperproof Torx Also called security Torx A star shaped screw just like a regular Torx except

there is an additional hole in the middle Must use a tamperproof Torx driver to remove these

screws

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Square Also called a Robertson drive A hexagonal shaped driver for driving screws with

square holes Hammers

Common Have forged steel heads Sizes vary in weight from 4 ounces to 2 ½ pounds

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Types of common hammers are:• Claw hammer – used for driving and pulling nails• Ballpeen hammer – used for metalwork preening

operations or for tapping punches and chisels• Soft hammers (mallets)

Used to form soft metals or drive closely fitting parts together

Since they are made of soft material they should not be used for hard work such as driving punches, nuts, or bolts

• Two types: soft-faced and true malletOn a true mallet, the soft head is composed of rubber,

brass, bronze, lead, or plasticOn a soft-faced hammer, only the surface of the head is

composed of these materials

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Safety Precautions Misuse of a hammer may cause damage to the

hammer, the equipment, or the user Make sure the work ares is clean Make sure your hands are clean and dry Never use a hammer or mallet with a loose head;

most accidents involving hammers are caused by loose heads

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Chisels Classified according to their type of point

Flat (cold) – most common, used for cutting sheet metal, chipping, cutting heads off rivets or screws, and all general cutting procedures

Cape – used to cut grooves, slots, and chipping flat surfaces too narrow for a flat chisel

Half-roundnose – cuts round (concave) grooves Diamond Point – cuts V-shaped grooves

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Proper use Hold the chisel cutting edge precisely at the point

you wish to make the cut Choose an angle that will allow it to follow the

desired finished surface After each hammer blow, set the chisel to the

correct position for the next cut Always wear safety glasses when using any type

of chisel since pieces of the item being chiseled and pieces of the chisel itself may fly

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Proper care Chisels should always be kept sharp by

sharpening the cutting edge at a 60° angle Chisel heads that have mushroomed from

hammer blows should be ground back into the original shape

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Punches The type of punch will depend upon the type of

job you are trying to accomplish There are three general types:• Pin punch

Has a straight shaftUsed to remove a straight pin or taper pin after it has

been loosened with a starting punch, which can take more stress

• Starting punchA modified pin punchHas a tapered shaft used to loosen or set straight or

tapered pins

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Prick punchPrimarily used for timing marks and making small

indentationsUsed in metal work to make small indentations that act

as guides for a twist-drill Drift punch

Often called a drift pinUsed for aligning holes in two pieces of material to

simplify inserting bolts, rivets, pins, etc.

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Pliers Intended for holding small objects and bending or

cutting thin soft wire or metal strips Should never be used as a tongs Most common types:

Adjustable combination (standard) pliers Adjustable water pump (Channel Locks) pliers Locking pliers (Vise Grips)

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Long-nose (needle nosed) pliers Diagonal cutter

A soft wire cutting tool only; has no gripping jawsWhen cutting wire, place the wire as close to the pivot

point as possible Side-cutting pliers

Also called linemans or electricians pliersHeavy duty pliers that combine the gripping jaw of the

combination pliers and the cutting surface of the diagonal cutters

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Wrenches Used to apply a turning force to bolt heads, nuts,

and screws; also for gripping round material such as pipes, studs, and rods

Precautions• Each type of wrench has a specific purpose and must

be utilized properly or you may injure yourself or damage the equipment

• Always pull on a wrench, never push on it• Always make sure the wrench opening fits the nut

exactly

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Types Open wrench

Most common type Usually vary in size from 3/16 to 1 inch More sturdily constructed than boxend or adjustable

wrenches

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Adjustable (Crescent) wrench• Should be restricted to light work• Should only be used for odd-sized nuts and bolts

Box wrench• Better than open-end or adjustable wrenches for

working in close quarters• Less likely to slip off nut or bolt• More torque can be applied• Come with either six or twelve points• A 6 point is less likely to strip the nut or bolt head• A 12 point can be used to loosen or tighten a nut

with a minimum handle travel of 30°

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Socket wrenches• Come in both standard and metric sized openings• Come in both 6 and 12 points• Come in differing drive sizes such as 1/4”, 3/8”, and

1/2” Torque wrench• Actually a special handle for a socket wrench• Used when the torque of a nut or bolt is critical• Torque wrenches are calibrated in inch-pounds or

foot-pounds

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Two types: Indicating - indicates the amount of torque being

applied either on a dial or a pointer Brakeaway - automatically releases when a

predetermined amount of torque is reached

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Hex (Allen) wrench Come in both standard and metric Used on setscrews and cap screws with

recessed heads Not designed for high torque Very common in medical Equipment

Pipe wrench Designed for use on pipes or round metal The jaws of the wrench have teeth that bite into the

round material to grab in one direction only Moving the wrench in the opposite direction allows the

wrench to be repositioned for additional pulling similar to a ratcheting action

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Files A hardened high-carbon-steel tool used for

cutting, removing, smoothing, or polishing metal The cutting teeth are made up of diagonal rows of

chisel cuts along the file face They come in various shapes and sizes and range

in length from 3 to 24 inches

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Files are categorized by name and/or cut and grade

Grade refers to the distance between the parallel cuts (coarseness)

The order of coarseness is• Curved• Coarse• Bastard• Second cut• Smooth• Dead smooth

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Selecting the correct file: Use a large, coarse, double-cut file for heavy, rough

cutting Use a second-cut, or smooth, single-cut file when

finishing cuts Use and care

Apply pressure on the forward stroke only Do not exceed 30 to 40 strokes per minute (may

ruin the file and the work)

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Always use a file handle to prevent cuts and punctures from the filings

When filing soft metals or narrow surfaces be sure to clean it regularly with a brush or pin to avoid pinning (small particles of the work getting clogged in the file teeth)

Saws Cross-cut and rip saws are used to cut wood

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Hacksaws are used for cutting all types of metal• Two types of frames – solid and adjustable• Two types of blades – all-hard or flexible• The all-hard blade is hardened throughout and is used for

sawing brass, tool steel, cast iron, and other stock with a heavy cross section

• On a flexible blade only the teeth are hardened, so the blade does not break as easily under bending stress; it is used for sawing hollow shapes and metals with a light cross section such as tin, copper and aluminum

• Blades are made with pitches (teeth per inch) of 14, 18, 24, and 32

• Install the blade with the teeth pointed away from you• Pressure is applied on the forward stroke only

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Special tools Screw extractor (Easy Out)

Used to extract broken screws and bolts The tool is tapered and has sharp ridges (similar to

left-hand threads) that grip the sides of the hole drilled into the broken part so it can be backed out of the hole

To perform an extraction:Drill a hole in the broken part slightly smaller than it’s

diameter taking care not to drill into the threadsInsert the screw extractor into the drilled hole, lightly

tap the extractor to seat it, and turn it counter-clockwise to remove

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Taps and dies – used to cut thread in holes and outside threads on rods or bolts or to repair threads with minor damage• Taps – used for cutting threads inside of holes of metal,

fiber, or other material • They range in size from 0 to 30 (i.e. a 10-24 tap will

thread a hole for a #10 screw with a threads per inch [tpi] count of 24)

• There are three types of taps:Taper tap – used to start all threads and finish the

threading if it can be run entirely through the work Plug tap – used when one end of the hole is pluggedBottoming tap – used when it is necessary to cut a full

thread to the bottom of a closed hole

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TappingFirst determine what screw size you are using by

utilizing a pitch gauge.Next, choose the proper drill size by using a tapping

tableDrill a hole in the material you want to thread ensuring

the hole is straightLubricate the tap with oil to both cool the work and help

clear away chipsMount the tap wrench on the square shank of the tap

and turn it in a clockwise directionUse sufficient downward pressure to start the tap cutting

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Once the cutting begins, do not apply any additional pressure

The safest procedure is to take a half turn forward and then a quarter turn back, then a half turn forward, etc., until the work has been completed

The normal procedure for tapping a closed hole is to use each of the three types of taps (taper, plug, bottoming) in succession

When the tap won’t turn and you notice a springy feeling, stop immediately and clear away the chips

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Dies – cut outside threads on round stock Preparation

Clamp the material to be threaded tightly in a viseAdjust the screw in the die to expand it, then place the

die in the die stockExpansion of the die is required to prevent cutting too

deeply on the first cutFailure to expand the die could cause the die threads to

shatterUse cutting oil for lubrication

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Cutting threadsPlace the die on the work and, while applying pressure,

turn the die stock clockwiseMake sure the die has started straightIf not, straighten it by applying pressure on one sideTurn the die clockwise half a turn, then back it up

counter-clockwise a quarter turn to eliminate shavingsOnce the die has started cutting threads, downward

pressure is no longer requiredContinue cutting threads until at least two threads

extend past the die or until the desired thread length is reached

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To produce good threads, make two cuts with a dieOn the second cut, remove the die from the stock and turn

the adjusting screw one quarter turn to allow the die to contract slightly

Repeat this procedure until you get the desired fit for the second cut

The second cut is used to produce finished threads

Measurement tools Used for checking thickness and sizes of parts

and materials In the maintenance area you should find

gauges for checking the size of twist drills, wire, screw thread count or pitch, and thickness

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Drill gauge A metal plate with holes corresponding to the various

twist drill sizes, each marked to indicate the size Use a gauge for checking the size of a twist drill or

for separating an assortment of unknown sizes Screw thread gauge

Contains several blades with teeth that correspond to the various screw thread counts

Each blade is stamped with a number indicating the threads per inch

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Gap gauge Measures the space between two objects Contains hardened steel blades groundto a definite thickness, usually from .001 to .03 inches Often called a “feeler gauge”

Micrometer or dial caliper A device for precisely measuring the thickness or

length of an object Often used when a ruler or other measuring device is

not convenient or not sufficiently accurate

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Tool safety Don’t hold the work in your hand If the tool slips it may cut or pierce your hand Always place the work on a bench or in a vise Using the wrong size or type of tool may

damage the equipment May strip a nut or bolt by using pliers instead of

a proper fitting wrench Using the wrong sized screwdriver may strip the

head of the screw making the job much more difficult

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General precautions for tool use Keep your bench, work area, and tool kit neat,

clean, and orderly Always protect cutting edges Keep all tool handles and working surfaces free of

oil or liquids “Right tool for the job”

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