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CHAPTER 1 Service Information, Tools and Safety

TROUBLE LIGHTS INCANDESCENT Incandescent lights use a filament that produces light when electric current flows through the bulb. This was the standard trouble light , also called a work light for many years until safety issues caused most shops to switch to safer fluorescent or LED lights. If incandescent lightbulbs are used, try to locate bulbs that are rated “rough service,” which is designed to withstand shock and vibration more than conventional lightbulbs.

TROUBLE LIGHTS INCANDESCENT 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 which can cause personal injury or even death.

TROUBLE LIGHTS FLUORESCENT A trouble light is an essential piece of shop equipment, and for safety, should be fluorescent rather than incandescent. Incandescent lightbulbs can scatter or break if gasoline were to be splashed onto the bulb creating a serious fire hazard. Fluorescent light tubes are not as likely to be broken and are usually protected by a clear plastic enclosure. Trouble lights are usually attached to a retractor, which can hold 20 to 50 feet of electrical cord.

TROUBLE LIGHTS FLUORESCENT FIGURE 1–54 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.

TROUBLE LIGHTS LED TROUBLE LIGHT Light-emitting diode (LED) trouble lights are excellent to use because they are shock resistant, long lasting, and do not represent a fire hazard. Some trouble lights are battery powered and therefore can be used in places where an attached electrical cord could present problems.

AIR AND ELECTRICALLY OPERATED TOOLS IMPACT WRENCH An impact wrench, either air or electrically powered, is a tool that is used to remove and install fasteners. The air-operated 1/2-in. drive impact wrench is the most commonly used unit. AIR RATCHET An air ratchet is used to remove and install fasteners that would normally be removed or installed using a ratchet and a socket.

AIR AND ELECTRICALLY OPERATED TOOLS FIGURE 1–55 A typical 1/2-in. drive air impact wrench. The direction of rotation can be changed to loosen or tighten a fastener.

AIR AND ELECTRICALLY OPERATED TOOLS FIGURE 1–56 A typical battery-powered 3/8-in. drive impact wrench.

AIR AND ELECTRICALLY OPERATED TOOLS Always use impact sockets with impact wrenches, and always 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.

AIR AND ELECTRICALLY OPERATED TOOLS FIGURE 1–57 A black impact socket. Always use an impact-type socket whenever using an impact wrench to avoid the possibility of shattering the socket which could cause personal injury.

AIR AND ELECTRICALLY OPERATED TOOLS AIR RATCHET An air ratchet is used to remove and install fasteners that would normally be removed or installed using a ratchet and a socket. DIE GRINDER A die grinder is a commonly used air-powered tool which can also be used to sand or remove gaskets and rust. BENCH- OR PEDESTAL-MOUNTED GRINDER These high-powered grinders can be equipped with a wire brush wheel and/or a stone wheel.

AIR AND ELECTRICALLY OPERATED TOOLS FIGURE 1–58 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 or wrench.

AIR AND ELECTRICALLY OPERATED TOOLS FIGURE 1–59 This typical die grinder surface preparation kit includes the air-operated die grinder as well as a variety of sanding disks for smoothing surfaces or removing rust.

AIR AND ELECTRICALLY OPERATED TOOLS FIGURE 1–60 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 whenever using a grinder or wire wheel.

AIR AND ELECTRICALLY OPERATED TOOLS Always wear a face shield when using a wire wheel or a grinder.

PERSONAL PROTECTIVE EQUIPMENT Service technicians should wear personal protective equipment (PPE) to prevent personal injury. The personal protection devices include the following: SAFETY GLASSES STEEL-TOED SAFETY SHOES BUMP CAP HEARING PROTECTION GLOVES

PERSONAL PROTECTIVE EQUIPMENT FIGURE 1–61 Safety glasses should be worn at all times when working on or around any vehicle or servicing any components.

PERSONAL PROTECTIVE EQUIPMENT FIGURE 1–62 Steel-toed shoes are a worthwhile investment to help prevent foot injury due to falling objects. Even these well-worn shoes can protect the feet of this service technician.

PERSONAL PROTECTIVE EQUIPMENT FIGURE 1–63 One version of a bump cap is a molded plastic insert that is worn inside a regular cloth cap.

PERSONAL PROTECTIVE EQUIPMENT FIGURE 1–64 Protective gloves are available in several sizes and materials.

SAFETY PRECAUTIONS Besides wearing personal safety equipment, there are also many actions that should be performed to keep safe in the shop. These actions include: Remove jewelry that may get caught on something or act as a conductor to an exposed electrical circuit. Take care of your hands. Avoid loose or dangling clothing. When lifting any object, get a secure grip with solid footing. Do not twist your body when carrying a load. Ask for help when moving or lifting heavy objects. Push a heavy object rather than pull it Always connect an exhaust hose to the tailpipe of any running vehicle to help prevent the buildup of carbon monoxide inside a closed garage space. When standing, keep objects, parts, and tools with which you are working between chest height and waist height. Always be sure the hood is securely held open.

SAFETY PRECAUTIONS FIGURE 1–65 Remove all jewelry before performing service work on any vehicle.

SAFETY PRECAUTIONS FIGURE 1–66 Always connect an exhaust hose to the tailpipe of a vehicle to be run inside a building.

VEHICLE PROTECTION FENDER COVERS Whenever working under the hood of any vehicle be sure to use fender covers. They not only help protect the vehicle from possible damage but they also provide a clean surface to place parts and tools. The major problem with using fender covers is that they tend to move and often fall off the vehicle. To help prevent the fender covers from falling off secure them to a lip of the fender using a binder clip available at most office supply stores.

VEHICLE PROTECTION FENDER COVERS FIGURE 1–67 A binder clip being used to keep a fender cover from falling off.

VEHICLE PROTECTION INTERIOR PROTECTION Always protect the interior of the vehicle from accidental damage or dirt and grease by covering the seat, steering wheel, and floor with a protective covering. FIGURE 1–68 Covering the interior as soon as the vehicle comes in for service helps improve customer satisfaction.

Shop Cloth Disposal Always dispose of oily shop cloths in an enclosed container to prevent a fire. Whenever oily cloths are thrown together on the floor or workbench, a chemical reaction can occur, which can ignite the cloth even without an open flame. This process of ignition without an open flame is called spontaneous combustion.

Shop Cloth Disposal FIGURE 1–69 All oily shop cloths should be stored in a metal container equipped with a lid to help prevent spontaneous combustion.

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