CHAPTER 02
Hand and Shop Tools, Precision Tools, and Units
of Measurement
INTRODUCTION
• This chapter is intended to provide a
guide to tools for novice diesel
technicians.
• The tools are loosely divided into the
categories of hand tools, precision
measuring, and shop tools.
HAND TOOLS
• Every technician requires a basic set of
hand tools. This chapter provides some
basic guidelines, but the tools you
purchase should be determined by the
nature of the work.
• Hand tools vary considerably in price.
• Before spending large sums of money,
determine whether the cost is justified
by the amount of use to which they will
be put.
• Because of the high price of hand tools,
most technicians learn to check the
contents of their tool boxes carefully
after completing each job.
Figure 2.1 A complete tool kit.. Figure 2.2 Wrenches: (A) open end; (B and C)
combination; and (D) box end.
Open - End Wrenches
• Open-end wrenches have open jaws on
either side of the wrench, usually with
different sizes at either end and slightly
offset. (Figure 2.2A)
• The wrench should be of sufficient
quality that the jaws do not:
 spread when force is applied
 restrict access to difficult to get at
fasteners because they are too bulky
• Open-end wrenches may damage
softer fasteners(such as brass pipe nuts)
because they act on only two of the six
flats of a hex nut
Combination Wrenches
• A combination wrench is manufactured
with a boxmend and an open end both
of the same nominal size .(Figure 2.2B
and Figure 2.2C).
• There are a wide range of prices when
considering the purchase of a set of
combination wrenches.
• It makes sense to own a set of top
quality combination wrenches in sizes
up to 3 /4 in(19 mm): these tend to be
lighter and slimmer than less expensive
wrenches.
• Less costly wrenches tend to be heavier
and clumsier.
• Less expensive but fully warranted
wrenches can be considered for use on
sizes larger than 3 /4 in. (19 mm)
Box-End Wrenches
• A box-end wrench surrounds the
fastener. It may be hex(6-point) or
double-hex(12-point) as shown in
Figure 2.2D.
• Because most bolts and nuts use a hex
or 6-point design, a hex box-end
wrench grips more securely because it
acts on all six flats of the fastener.
• However, it is less versatile where
access is restricted as it can only fit on
the fastener in 6 radial positions
through a rotation rather than the 12
radial positions of the double-hex, box-
end wrench.
Adjustable Wrenches
• The adjustable wrench consists of a
fixed jaw integral with the handle and
an adjustable jaw moved by a worm
adjuster screw.
• You should probably own a couple of
these and then resolve to use them as
little as possible.
• Their advantage is versatility.
Figure 2.3 Adjustable Wrench
Line Wrenches
• A line wrench is designed to grip to a
pipe or line hex nut and act on four of
the six flats of its hex.
• It has the appearance of a box-end
wrench with a small section removed
so that it fits through the pipe to
enclose the pipe nut.
• A line wrench should be used in place
of the open-end wrench to avoid
damaging pipe nuts.
Figure 2.4 Line Wrenches
Socket Wrenches
• Diesel technicians will require
complete socket sets in 1 /4-inch, 3 /8-
inch, and 1 /2-inch drive sizes..
• A 3 /4-inch drive size may also be
useful. Complete sets of socket
wrenches will vary by manufacturer
but the following is typical.
 1/4 in. Drive : drives sockets up to
1/2 in. (12 mm)
 3/8 in. Drive : drives sockets up to
3/4 in. (19 mm)
 1/2 in. Drive : drives sockets up to 1
1/4 in. (30 mm)
• Sockets may be of the hex or double-
hex design and surround the fastener.
• The socket may be hand-rotated by a
ratchet or flex bar and power-rotated
by compressed air powered wrenches
or impact wrenches.
Types of Sockets Wrenches
• Impact sockets are manufactured out of A
softer alloys than those designed to be
turned by a ratchet or flex bar.
• Softer alloy sockets are less likely to
fracture when driven by air tools.
• Deep sockets permit access to a nut in B
which a greater length of the bolt or
stud is exposed.
• A crowsfoot socket is an open-end
wrench that can be turned by a ratchet;
C
it grips two of the six flats of a nut and
is probably mostly used for final
torquing a difficult-to-access nut.
• A line socket is the socket counterpart
to the line wrench. It grips four of the
six flats of a nut and its main use is to
deliver final torque to a pipe nut E
Figure 2.5 Typical (A) Impact sockets, (B) Softer alloy D
sockets , (C) Deep sockets, (D) Crowsfoot socket, (E) line
socket
Ratchets and Breaker/Flex Bars
• Reversible ratchets used in conjunction
with sockets are often used by any
technician. They are used to rapidly A
turn fasteners by hand and should be of
good quality because the consequence
of failure is personal injury.
• Ratchets are not designed to
accommodate high torque loads.
• A breaker bar has a grip bar and
pivoting drive square to engage with a
socket in the same way a ratchet does
so they are available in 1/4-inch, 3/8- B
inch, 1/2-inch, 3/4-inch, and 1-inch
sizes.
• A breaker/flex bar can be used to
release fasteners that require
considerably more force than could be
Figure 2.6 Typical (A) Ratchets and (B) A
safely applied to a ratchet.
breaker/flex bar
Torque Wrenches
• Torque wrenches measure resistance to
turning effort (Figure 2.7).
• Fasteners are torqued to ensure that the
correct clamping force between two
components is achieved.
• In assembling engine and fuel system
components, every fastener should be
torqued to specification.(See Figure 2.8) Figure 2.7 Types of click-type torque
wrenches.
• Studies indicate that when technicians
fail to use torque wrenches, they
overtorque fasteners to values 50
percent to 100 percent over the
specification.
• This damages fasteners and distorts
components including cylinder blocks
and heads.
Figure 2.8 Torque to overcome friction.
Types of Torque Wrenches.
A
• Click-type torque wrenches should
always be backed off to a zero reading
after use. Their calibration should be
routinely checked because they rely on
spring tension to produce a reading.
• Dial-type torque wrenches use a
B
circular dial scale and a needle to
display torque values. Dial-type torque
wrenches are usually higher priced
than click type torque wrenches and
usually require less frequent
calibration. C
• Beam-type torque wrenches use
aflexible, middle alloy steel shaft
(beam) that deflects when torque is
applied. A needle pointer is used to
indicate the torque reading. Beam-type
torque wrenches are the least costly but
have good accuracy and seldom require Figure 2.9 Typical (A) Click-type torque, (B)
calibrating. Dial-type torque , and (C) Beam-type torque
Hammers
• Mechanical technicians mostly use
ball-peen hammers in various weights.
• The specified weight of a hammer is the
head weight, which starts at 1 /2 pound
and should go up to about 4 pounds in
weight.
• The impact faces of hammers should be
inspected regularly and discarded
when the face becomes damaged. Some
examples are shown in Figure 2.9A and
Figure 2.9B.
• Hammer handles are also important,
and a hammer should not be used
when its handle is damaged.
Figure 2.10 Types of hammers (A) ball peen
• The handle may be made of hickory, in
hammer; and (B) cross peen hammer
which case it is susceptible to damage,
or steel and integral with the head with
a rubber-cushioned grip
Pliers
• Most technicians require a large
selection of pliers. They are used for
gripping and cutting. Pliers used for
working on electrical circuits should
have insulated handles.
• Pliers are named by type. Some
examples are needle-nose, slip joint,
lineman, and side cutter pliers. Figure
2.9C shows some examples.

Figure 2.11 Selection of different types of pliers.

Screw Extractors
• Fasteners occasionally fail when the
fastener head sheers.
• When methods such as welding a nut
onto a fastener that has had its hex
head sheered off have failed, a screw
extractor has to be used.
• First, the fastener has to be drilled Figure 2.12 The fastener head sheers.
dead-center to around 75 percent of its
A
depth, and then the screw extractor has B
to be driven into the drilled hole.
• Two types exist. The taper square screw
extractor is designed to bite into and
grab the bore of the drilled hole; it can
be progressively driven into the hole if
the edges round out.
• The left-hand twist screw extractor
works by self-tapping its way into the
drilled hole in the fastener as it is
Figure 2.13 Types of Screw Extractors (A) The taper
turned counterclockwise. square ; and (B) The left-hand twist
.
Stud Extractors
• Stud extractors can be used to extract a
fastener when enough of it protrudes to
grab onto its shank..
A
• Two types are used:
 Collet-type: fits over the exposed
length of the stud and locks to it as it
is rotated counter clockwise. Can be
used with air tools.
 Wedge-type: consists of a splined
circular wedge that locks to the stud
as it is rotated counter clockwise.
Should only be used with hand tools
B
as they are driven eccentrically.

Figure 2.14 Types of Stud Extractors (A) Collet-type; and (B) Wedge-type.
Taps
• Taps cut internal threads in both
standard andnmetric specifications..
A
• They can be used either to cut virgin
threads in bores or to repair damaged
threads.
B
• Three types are used:
 Taper tap: used to cut threads to a
virgin bore.
 Plug tap: used to finish cut or repair C
threads.
 Bottom tap: used to cut the final
threads in a blind hole
Figure 2.15 Types of Taps (A) Taper tap; (B)
Plug tap and (C) Bottom tap.
Dies.
• Dies cut external threads. Most are
designed with graduated teeth and a
taper, enabling them to cut threads to a
shaft..
• Technicians are most likely to use these
to repair damaged threads.
• In fact, most toolbox quality taps and
dies should not be used to cut virgin
threads in hardened steels, especially if
the fastener is critical.
 Thread pitch gauges are designed to
measure the thread pitch(angle) and
number of threads per inch (tpi) of
any thread pattern. They are used to
determine which tap, die, or fastener
is appropriate.
A

• Two types are used:

 A thread chaser is a die designed for
the sole purpose of repairing minor
damage to an existing thread. It cuts
in much the same way a die does,
but it is not designed to cut new B
threads.
Figure 2.16 Types of Dies. (A) thread chaser ;
and (B) Thread pitch gauges
Reamers
A
• Reamers are rotary cutting tools that
enlarge an existing hole to an exact
dimension.
• They are used in situations that require
a greater degree of accuracy than a
drill is capable of delivering.
• Reamers are available in several types,
two of the most common of which are:
 Adjustable: reamers that can cut B
holes through a range of sizes
 Spiral fluted taper: reamers that are
driven by air or electric power tools
and enlarge a hole accurately to a
specific size.

Figure 2.17 Types of Reamers. (A) Adjustable;

and (B) Spiral Flute Taper Reamer
Drill Bits
• Drill bits are driven by an electric or
pneumatic power tool.
• Twist drills must be machined to the
correct cutting pitch (angle) normally
by grinding on a fine abrasive wheel.
• The two cutting edges of a twist drill
must be angled identically from the
center point of the drill and have the
same radial dimension.
• A slight difference results in a larger
hole than the drill shank size.
• Drills sharpened by hand seldom
produce exact-sized holes.
• Drill speeds should be adjusted for the
material being cut and the size of the Figure 2.18 Types of Drill Bits
hole.
Hacksaws
• A hacksaw is designed to cut metals. A • Approaching the cutting task in a
hacksaw has a rigid frame and the relaxed, calm way produces fast results,
blade selected should have the whereas attempting to power through
appropriate number of teeth per the task often results in broken blades
inch(tpi) for the metal to be cut.. and lost tempers.
• The harder the metal, the more tpi
required. Better quality hacksaw blades
tend to be cost effective because they
last until they wear out. Cheaper blades
tend to break.
• Inspect the blades and replace them
when they have dulled or missing teeth.
A hacksaw should be used with a light
but firm grip.
• An even horizontal stroke with no
rocking will produce the fastest cutting
Figure 2.19 The Hacksaws
rates
Cutting Fluids
• Soluble oil is machinist’s oil mixed with
water according to the manufacturer’s
recommendations.
• Engine oil is not soluble and cannot be
used as a substitute.

Figure 2.20 Cutting Fluids

PRECISION MEASURING TOOLS
• Several precision measuring
instruments are used in a typical truck
and engine service garage. Precision
measuring tools tend to be high cost
items. They are sometimes provided by
employers but technicians who use
specific tools frequently may wish to
purchase their own.

Electronic Digital Calipers

• Electronic digital calipers (EDCs) are a
great addition to the toolbox especially
if you work on engines. They measure
dimensions. They can be used to
measure: inside, outside, and depth
measurements to within half-a-
thousandth or 0.0005 inch accuracy.
• EDCs perform with good accuracy and
Figure 2.21 Various uses of a
have the advantage of being easier to
set of digital calipers.
read than micrometers.
Standard Micrometers
• Since most of the dimensional
specifications on a metric engine are
still recorded using the standard A
system, every technician must know
how to read a standard micrometer.
• A standard outside micrometer consists
of a frame in the shape of the letter G:
on one side of the frame is a fixed anvil
and on the other is a spindle assembly.
• Figure 2.22 A shows both outside and
inside micrometers and the terminology
used to describe them.
• Study Figure 2.22 B,which shows how
B
to read a standard micrometer.

Figure 2.22 (A) Terminology and components of (a) an

outside , (b) an inside micrometer. And (B) How to read a
micrometer.
Dial Indicators

• Dial indicators are used to measure

travel or movement in values of
thousandths to one hundred
thousandths of an inch.
• Metric dial indicators are calibrated to
read in tenths to thousandths of a mili
meter.
• Dial indicators are used for many
general and job-specific functions in
the diesel engine shop.
• Figure 2-9 demonstrates dial indicator
terminology.

Figure 2.22 Dial Indicator terminology.

Dial Indicators B

Figure 2.22A (A) Dial Indicator terminology and (B)

Locations of the four readings required to measure the
TIR of a flywheel housing.
Dial Bore Gauges
• Dial bore gauges are used to measure
bore dimensions such as inside
diameter (id), taper, and out-of-round..
• They are calibrated in increments of
0.001 in. (0.025 mm) or 0.0001 in.
(0.0025 mm).
• Using a dial bore gauge is a fast way of
rapidly assessing cylinder bore
dimensions.
• The typical dial bore gauge consists of a
shaft on top of which is the dial
indicator; at the base of the shaft is a
measuring sled consisting of guides and
an actuating plunger.
• One of the three guides is located
diametrically opposite to the actuating
plunger. Figure 2.23 Dial bore gauge being used
to measure a cylinder bore.
Dial Bore Gauges

Figure 2.23 Dial bore gauge being used to measure a cylinder bore.