Safety & Tools(Ch 2)

2

Small Engine Safety

• Never operate an engine in an enclosed area.

• Work in a space with room for maneuvering.

• Engines should be operated only by qualified personnel.

• Do not have open flame near flammables.

• Allow engine to cool before refueling.

• Take care of spilled gas• Be familiar with engine shut off

procedures.

• Do not operate an engine with the air cleaner removed.

• Do no operate an engine with out a muffler.

• Disengage an engine from driven equipment before starting.

• Never leave an operating engine unattended

• Do not operate an engine at excessive speeds.

• Avid contact with hot engine parts.• Keep feet, hands, and clothing away from

moving engine and equipment components.

• Do not attempt to crank an engine with the spark plug removed

• Always have an approved fire extinguisher near the work area.

3

Safety and Product Standards

• Government agencies

• Standards Organizations

• Technical Societies

• Private organizations

• Trade associations

• Training Organizations

• Student Organizations

4

Government Agencies

OSHA Occupational Safety and Health Administration

CFR Code of Federal Regulations:

NIOSH National Institute for Occupational Safety and Health:

EPA Environmental Protection Agency:

DOD Department of Defense:

DOT Department of Transportation

CPSC Consumer Product Safety Commission

5

Standards Organizations.

ANSI American National Standards Institute:

CSA Canadian Standards Association:

ISO International Organization for Standardization:

6

Technical Societies

ASABE American Society of Agricultural and Biological Engineers

SAE Society of Automotive Engineers

ASTM American Society for Testing Materials

7

Private Organizations

UL Underwriters Laboratories

NFPA National Fire Protection Association

8

Trade Associations

OPEI Outdoor Power Equipment Institute

API American Petroleum Institute

Trade Organizations

EETC Equipment and Engine Training Council

OPEESA Outdoor Power Equipment and Engine Service Association

AED Associated Equipment Distributors

9

Student Organizations

FFA

SkillsUSA-VICKA

10

Fire Safety

• Small gas engine facilities commonly have flammable materials in the area.

• Flammable materials must be used and stored correctly.

A fire must have oxygen, heat and fuel, and these must be in sufficient quantities to cause a chemical reaction.

Removal of any one of the four items will stop a fire.

11

Portable Fire Extinguishers

• Use a portable fire extinguisher when the fire is confined to a small area, such as a wastebasket, and is not growing; everyone has exited the building; the fire department has been called or is being called; and the room is not filled with smoke. (NFPA)

• To operate a fire extinguisher, remember the word PASS:

– Pull the pin. Hold the extinguisher with the nozzle pointing away from you, and release the locking mechanism.

– Aim low. Point the extinguisher at the base of the fire.

– Squeeze the lever slowly and evenly.

– Sweep the nozzle from side-to-side.

12

Fire Extinguishers

• Fire extinguishers are rated for the class of fire.

• Classes of fire.– A– B– C– D

Combustibles such as paper, wood, cloth rubber, plastics, refuse and upholstery.

Combustible liquids such as gasoline, oil, grease, and paint.

Electrical equipment such as motors, appliances, and wiring.

Combustible metals such as magnesium, potassium, sodium, titanium, and zirconium.

13

Types of Fire Extinguishers

Pressurized WaterABC Dry Chemical

Carbon Dioxide

14

Safety Principles

Flammable Liquid: A liquid with a flash point below 100o F.

Flash Point: the lowest temperature at which a liquid gives off sufficient vapor to sustain combustion.

oF Liquid oF Liquid

-36 Gasoline 100 Kerosene

-4 Acetone 104 Mineral spirits

50 Ethyl alcohol 125 Diesel fuel (No. 2)

Flash Point

Flammable liquids should be stored in a safety can.

Safety cans should be stored in a safety cabinet.

Rags and paper contaminated with a flammable liquid should be placed in an oily waste can.

15

Safety Principles-cont.

Combustible liquid: A liquid with a flash point at or above 100o F.

Testing flash point

Spontaneous combustion: Self-ignition caused by chemical reaction and temperature buildup in waste materials.

Carbon Monoxide: A toxic gas produced by

incomplete combustion.

CO is slightly lighter than air.

Humid conditions may cause it to remain

stationary.

16

PPE (Personal Protective Equipment)

Every occupation and every activity has PPE that should be worn.

The appropriate PPE is a function of the hazards.

Small gas engines PPE:

Clothing

Eye

Ear

Respiratory

Hand

Foot

Back

Hazard: anything that has the potential to cause an accident.

Prevent injury and provide a professional appearance.

Required when there is a reasonable probability of flying particles, molten metal, chemical liquids or gases, radiant energy or a combination of any or all of these.

Engines and tools produce loud noises. Loss caused by intensity and duration of exposure.

Required when exposed to chemical hazards, any chemical that is toxic when inhaled, absorbed, or ingested.

Required to prevent injuries from burns, cuts and the absorption of chemicals.

Typical injury caused by an 65 pound object falling less than 4 feet.

Anyone that does anything will hurt their back someday. Most back injuries are the result of improper lifting.

17

NFPA Hazard Signal System

Health Hazard4 Deadly3 Extreme danger2 Hazardous1 Slightly hazardous0 Normal material

Specific HazardOX OxidizerACID AcidALK AlkaliCOR CorrosiveW Use no water Radiation hazard

Fire Hazard (Flash Points)4 Below 73 oF3 Below 100 oF2 Below 200 oF1 Above 200 oF0 Will not burn

Reactivity4 May detonate3 Shock & heat may detonate2 Violent chemical change1 Unstable if heated0 Stable

18

Tools

19

Tool Safety

• 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

• Use the tool for its

designed use.

• Secure small work in a

clamp or vise.

• Repair or replace

damaged tools.

• Report any injuries to

the supervisor.

20

Categories of Tools

• Hand• Power• Test

21

Hand Tools

• 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.

• Measuring tools– Micrometer

– Rules

– Thickness gauges

• Fastening tools– Wrenches

– Screwdrivers

– Pliers

• Cutting tools– Hacksaws

– Files

– Chisels

• Driving tools– Hammers

– Mallets

– Punches

Tools that are powered by hand

22

Power Tools

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.

23

Test Tools

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 safetyUse tool according to manufactures instructions.Store properly

Measuring Tools

25

Introduction

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

26

Direct Reading Measuring Tools

Small engines use two types of direct reading measuring tools:1. Micrometers2. Calipers

Micrometers

28

Micrometer Introduction• A micrometer is a mechanical device

designed to measure distances as small as 1/10,000 of an inch (0.0001 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:1. Micrometer caliper2. Inside micrometer3. Depth gauge micrometer

Micrometer calipers are available in mechanical and digital models.

29

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.

30

Reading Micrometer Caliper-parts

• The first step in being able to read a micrometer is learning the names of the parts.

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..

31

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.

32

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).

1

10 4 =

1

10 x

1

4

=1

40 0.025

33

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 0.001 inch.

34

Micrometer Caliper Example• Determine the reading for the micrometer caliper in the

illustration.

1. Smallest whole unit 0.0002. Tenths of an inch 0.3003. Twenty five thousands ( 0.025 x 2 ) 0.0504. Thousands 0.015 Sum (measurement) 0.365

35

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

36

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.

37

Inside Micrometer Example

Read the 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

38

Inside Micrometer Example 2• Inside micrometers use extensions to change the range of

measurements.• Adding an extension increases the minimum measurement.

Smallest whole unit 2.000Tenths 0.200Twenty five thousands 0.075Thousands 0.001 Reading 2.276

In this example a 1/2 inch extension has been added.

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.

39

Depth Gauge Micrometer• 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.

Thimble

Spindle

40

Depth Gauge Micrometer Example

Smallest whole unit0.000

Tenths0.800

Twenty Five Thousands0.050

Thousands0.017

Sum (reading)0.867

Read the depth gauge micrometer in the illustration

Calipers

42

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

43

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.

44

Vernier Scale

• 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.

• A Vernier is a mechanical means of magnifying the last segment on the main scale so addition subdivisions can be made.

45

Vernier Caliper-practice

• Smallest whole unit 1.000• Tenths of an inch 0.200• Twenty five thousands 0.000• Vernier scale 0.011 Sum (measurement) 1.211

LOC

Read the Vernier caliper in the illustration.

46

Dial Caliper

A dial replaces the Vernier. This makes the caliper easier to read.The reader must still determine the units and graduations.

Measurement Transferring Tools

48

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

49

Spring Calipers

• Spring calipers are used to transfer measurements.

• Three types of spring calipers– Outside– Inside– Hermaphrodite

50

Dividers

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

51

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.

52

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.