Lesson 2: Shop Facilities and Maintenance Equipment

Lesson 2: Shop Facilities and Maintenance

Equipment

Introduction:

There are many types of equipment used in the shop. This

equipment can create many different hazards in the shop.
Objectives:

At the completion of this lesson the student will be able to identify

and use the different types of equipment and cleaning chemicals used
in the shop.

Materials:

Shop area and typical chemicals used in the shop.

Unit 1 1-2-2 Caterpillar Service Industry
Lesson 2

Fig. 1.2.1 Shop Air System

Shop Air System

The shop air system separate components are: the air compressor, the
control unit, the after cooler, the moisture separator (it is used to take
water out of the air), the automatic drain trap, the air inlet filter and
silencer, the safety shutoff controls, the air receiver, the air lines and
the service couplers. Automatic controls activate the air compressor.
Safety shut off controls are used to turn off the system in an
emergency. Every shop technician must know the location of the
safety shut off controls. The air lines are flexible rubber hoses with
quick disconnect couplings at each end. One end of the hose
connects to the steel air lines and the other end to the air tool.
The shop air system is used for the pneumatic tools and the
equipment that is used to clean parts. The shop air system can be
used to remove dirt and solvent off parts. The shop air system needs
a constant pressure of 90-100 psi (621-690 kPa). The compressor
puts the air under compression and sends it to the aftercooler and
moisture separator. The water which has been taken out of the air
goes out through the automatic drain trap or through the air receiver.
The air receiver is a storage tank to remove fast changes (surges) in
pressure. To connect a pneumatic tool, the quick disconnect coupler
at the end of the hose needs to be pushed on to (rapidly move
together with) the quick disconnect coupler on the tool.
Always wear eye protection. There are several safety controls
available which will stop the compressor to prevent damage after a
Unit 1 1-2-3 Caterpillar Service Industry
Lesson 2

failure. Failures in the system cause high air temperature at the

outlets, low oil pressure, high water temperature in the aftercooler,
and vibration. A control, which will turn off the system if there is
high air temperature at the outlets, is probably the best control since
most failures cause an increase in the air temperature at the outlets.

Fig. 1.2.2 and 1.2.3 Shop Electric System

Shop Electric System

The shop electric system components are: the safety control box, the
power lines, the electrical outlets, and electrical plugs. Fuse boxes
and circuit breakers are the safety control boxes, and control the
amount of current which can go through a line. The power lines are
probably made of copper and are measured by their diameter (gauge).
There are different sizes of electrical outlets and plugs according to
the amount of power which can go through them. Plugs and outlets
with three wires (three-pronged plugs and outlets) are the only ones
to be used in a shop because one of the three wires is for safety.
With the larger electric lines, there are caps on the outlets and plugs.
The shop electric system is used to distribute electric power safely in
the shop area. Usually there are several outlets available in the shop
area. The electric circuit is closed when the tool, machine or some
other electronic application is put into the outlet. The higher power
outlets have the larger outlet and plug. The three-pronged plug is
used so that the tools and machines will be grounded (to connect to a
conductor which is electrically connected to the earth). To connect
the tool to the outlet, the three-pronged plug is put into the outlet as
far as it can go. The operator must not come in contact with the
wires in the plug.
Unit 1 1-2-4 Caterpillar Service Industry
Lesson 2

Never use an adapter that will cause the tool to not be grounded.
Always check the plastic or rubber on the lines from the tool and
from the source for cuts. Do not let the lines go through oil, water,
grease or other liquids which are on the floor. Do not stand in water
when an electric tool is disconnected, connected, or used. If a fuse
breaks the circuit, find the reason for the increase in current before a
new fuse is put in or before the circuit breaker is turned on. Do not
feel the wires of the power lines without protection on your hand.

Fig. 1.2.4 Shop Lubricant System

Shop Lubricant System

The components of the shop lubricant system are the storage units,
the lubricant pumps, the control unit and junction box assembly, the
line control, the ready light, the fluid lines, the line strainer, the
terminal box assembly, the fluid flow meters at the end of the fluid
lines, and a separate hose system for each type of fluid. In the
manual drum system, the storage units can be drums as small as 55
gallons (210 liters), which can be put at each work area. The ready
light, the separate hose system for each type of fluid, and the fluid
flow meters at the end of the fluid lines are at the work area. The
fluid lines are flexible rubber lines. A lever in each line is used to
control the flow of fluid.
Unit 1 1-2-5 Caterpillar Service Industry
Lesson 2

The shop lubricant system is used to install lubricants in a safe, clean,

and easy way for all applications of the lubricant. To activate the
shop lubricant system, the technician tells the control operator the
type and amount of fluid needed. The control unit operator starts the
pump for that product. The ready light near the technician turns on to
tell him that the lubricant is ready for application. The technician
operates the lever to control the flow of fluid. After the technician
has finished, he pushes the off control to close the system. For the
manual drum system, the technician manually pumps the fluid from
the drum and into the application. Air power pumps can also be
used.
Always wear eye protection when the system is in use. Hold the
lines tight when the lubricant is put into the machine. Relief valves
are in the fluid lines to control a sudden increase in pressure.

Fig. 1.2.5 Pressure Water Washer

Shop Equipment Cleaning
Water Washers
There are three main kinds of pressure water washers. These are the
high pressure washer with cold water, the high pressure washer with
hot water and detergent, and the steam cleaner. Most pressure water
washers use a positive displacement pump and the nozzle controls
the pressure of the flow. Pressure water washers are made up of
components. The components are the power unit, the pump, the
Unit 1 1-2-6 Caterpillar Service Industry
Lesson 2

heater, the hoses, and the nozzle. The nozzle is controlled by the
technician with a lever or valve. The hoses are flexible lines so that
they can be moved around easily. Usually the spray nozzle has two
handles for the technician to hold onto.
Water washers with high pressure are the best method to clean dirt
off machines before they are to be worked on in the shop. The
pressure and rate of flow are different for different types of jobs. The
water supply to the pump must be enough in volume to always have
a positive head at the inlet to the pump. To use the pressure water
washer, the technician must check the supply of water to the pump.
The power unit must then be turned on. The technician must hold
the spray nozzle with two hands and then point the spray nozzle
towards the machine to be cleaned. The technician must stand away
from the machine. The nozzle must be close enough to the machine
for good cleaning.
Always wear eye protection when the water washer is in use. Do not
get to close to the object when the spray gun is in use. Use an
extension if necessary. Do not let dirt get into the tip of the spray
gun. A spray gun with good safety controls is necessary with a high
pressure pump. If there is a failure in the spray gun, the safety
control must let only low pressure water flow from the spray gun.
Other safety systems will stop flow at the tip of the spray gun and
cause the water to go back to the pump.

Fig. 1.2.6 Parts Cleaner (Agitating)

Ultrasonic Parts Cleaner

The ultrasonic parts cleaner is a tank filled with a water and a
cleaning detergent. The theory of ultrasonic operation depends on
cavitation. Cavitation is the rapid formation and violent collapse of
minute bubbles or cavities in a cleaning fluid. This agitation by
countless small and intense imploding bubbles creates a highly
effective scrubbing of both exposed and hidden surfaces of parts
immersed in the cleaning solution.
Unit 1 1-2-7 Caterpillar Service Industry
Lesson 2

Cavitation is produced by introducing high frequency (ultrasonic),

high intensity sound waves into a liquid. Consequently, the three
essential components of any ultrasonic cleaning system are: a tank to
contain the cleaning liquid, a transducer to convert electrical energy
into mechanical energy, and an ultrasonic generator.
Ultrasonic cleaning is faster than any conventional cleaning method
in the removal of soil and contamination from parts. Entire
assemblies can be cleaned without disassembly. Often, its labor
saving advantages make ultrasonics the most economical way of
cleaning.
It is recommended that rubber work gloves be used while operating
the machine.

Fig. 1.2.7 Solvent Tank

Solvent Tank
A solvent tank uses solvent as its cleaning fluid. There are many
types of solvent tanks. The lowest efficiency solvent tank is a drum
filled with solvent and a brush. The highest efficiency solvent tank
uses a sink tank on top of another tank which is in the shape of a
cylinder (drum tank). The solvent is inside the drum tank and a
pump is used to lift the solvent from the drum tank to the sink tank.
The part is cleaned in the sink tank. A control for the light and pump
is on the back of the cover. The light is connected to the back of the
cover is lifted up, the light will be in the correct position. A drain for
the solvent is in the bottom of the sink tank.
Unit 1 1-2-8 Caterpillar Service Industry
Lesson 2

The solvent tank is used to clean small metal parts. To use the high
efficiency solvent tank, the electric plug must be connected to the
electric outlet. The parts are put into the cleaning sink tank and the
pump is activated. The solvent flows through a flexible line which
has its position adjusted by the technician. The technician moves the
part or the flexible line to clean the part. Many times a brush or
pieces of cloth are used to clean the solvent off the part. A metal
plate with holes in it (strainer) is over the drain to keep large particles
of dirt out of the drum tank. If large particles get into the drum tank,
they can get into the pump and cause it to not operate correctly.
Always wear eye protection when the solvent tank is in use. Be sure
you have a good grip on the part when it is moved under the solvent.
Be sure the flexible line keeps the solvent inside the cleaning tank.
Do not let large particles of dirt fill the holes in the strainer. This
will not let the solvent flow back to the drum tank. Do not move the
drum tank or cover while the light is on and the solvent is flowing
out of the flexible line. Rubber gloves are recommended but are not
necessary to hold the part under the solvent.

Fig. 1.2.8 Glass Bead Cleaner

Glass-Bead Cleaners
There are two main types of glass-bead cleaners, the wet type and the
dry type machines. The difference between the wet and dry type
machines is the method in which the glass particles (beads) go to the
outlet of the hose (gun). Dry type machines use air pressure alone to
move the glass beads, while the wet type uses a water and glass-bead
mixture along with air pressure. The size of the glass beads must be
between 50 and 100 microns. Do not use aluminum oxide or silicon
oxide in the glass bead cleaner.
Unit 1 1-2-9 Caterpillar Service Industry
Lesson 2

The tank stands on legs and is made to open from the top or end. A
hole in the cover has a piece of clear plastic or glass so that the
operator can see the part while it is cleaned.
Glass-bead cleaners are good for removal of carbon and corrosion
from pistons, valves, cylinder heads and other parts. The glass beads
will not damage most metal surfaces, including aluminum, unless the
air pressure is too high or glass beads clean one spot for too long a
time. The impact of the glass beads removes the deposits. To use
the glass-bead machine, the air supply must be at a high enough
pressure but not more than 80 psi (552 kPa). The part is put inside
the tank and the cover is closed. Gauntlets (hand and arm protection)
are connected to the cover so that the technician can control the
operation of the gun and hold the part inside the tank. A flexible
rubber hose is used to send the glass beads to the gun. A valve at the
gun controls the flow of glass beads. A switch runs a fan and light.
Always wear eye protection when you use the glass-bead cleaner. Be
sure that the cover is closed before the control for the beads is used.
Do not point the gun at the glass cover and operate the control for the
beads. Be sure that the drain will let the used glass beads go back to
the separator. The gun can be moved as close to the part as
necessary as long as it does not cause a restriction to the flow.
Unit 1 1-2-10 Caterpillar Service Industry
Lesson 2

Fig. 1.2.9 Sandblast Cleaner

Sandblast Cleaner
There are two main types of sandblast cleaners, the wet and dry type
machines. The difference between the wet and dry type machines is
the method by which the sand goes to the outlet on the end of the
hose (spray gun). Wet type machines use a water and sand mixture
while the dry type uses only sand. Sandblast cleaners are made up of
components. The components are the power unit, the pump or air
compressor, the sand hopper, and the spray gun with the hoses. The
hoses are flexible. The spray gun on the end of the hose does not
have a lever to control the flow of sand. To control the flow of sand,
there is a lever at the air compressor and/or sand hopper. The sand
hopper holds the sand that will be used.
Sandblast cleaners are used to remove salt deposits, corrosion and
other hard-to-remove deposits from parts and machines. When you
use the sandblast cleaner on machines, the sand can get by the seals
and get into the oil and grease compartments. After the sandblast
cleaner is used, the machine must be completely disassembled and
cleaned of sand. To use the sandblast cleaner, the sand hopper must
be filled with sand (silicon oxide). The air compressor must be
started to get the necessary pressure. Hold the flexible hose with two
hands and point the spray gun at the work. With some models, the
technician can control the flow with a lever on the spray gun handle.
Always wear protection over the hands, arms, face, and upper body
when you are the operator of the sandblast cleaner. The protection on
your body must be heavy enough to prevent the impact of any sand to
be felt by the body. Do not get too close to the part or machine. Use
Unit 1 1-2-11 Caterpillar Service Industry
Lesson 2

an extension if necessary. Do not let sand and dirt get into the tip of
the gun and prevent it from correct operation. A safety spray gun
must be used with a high pressure pump. If there is a failure, only
low pressure will flow from the spray gun.

Fig. 1.2.10 Stands, Racks, Carts

Engine Stand
The engine stand has four vertical supports. These can be adjusted
along two channel beams to fit different engine widths. These
supports are fitted with screw locks. The two channel beams are
connected by two pipes, one inside the other (telescopic). These
pipes have holes and two locking pins. The engine stand can be
made longer or shorter to fit different length engines. When the
holes are in alignment, the locking pins are put in to hold the pipes in
position (specific length). There are two threaded supports which
can be adjusted to four positions and held in place with lock pins.
The threaded portion can be adjusted through the full length of
threads. One channel beam is fitted with wheels so that the engine
stand can be moved with a wheel dolly.
This equipment is used as a support for an engine while it is worked
on. The engine can be cleaned, disassembled and assembled while
held by the engine stand. The engine stand can also be used during
dynamometer testing.
Make sure that all engine supports are locked into position with
screw locks or lock pins. Make sure that the engine is solidly held
by all engine supports. Before an engine is moved on a stand, fasten
the engine to the engine stand with chain. A rough shop floor can
cause an engine to fall off of its stand.
Unit 1 1-2-12 Caterpillar Service Industry
Lesson 2

Fig. 1.2.11 Engine Stand (Lift Truck)

Lift Truck Engine Stand

The engine stand for four and six cylinder engines has one vertical
support. An adapter tube is held at the top of the vertical support. At
one end of the adapter tube is a handle to turn the adapter tube.
There is also a lock pin to hold the adapter tube in position. The
other end of the adapter tube has a flat plate on which the engine is
held with bolts. An adapter plate must be used between the engine
and the engine stand. The vertical support is held with two
horizontal box section beams. These beams are fitted with three
wheels. One wheel can be retracted to keep the engine stand from
moving while it is in use. The maximum rated capacity of this engine
stand is 1000 lb. (450 kg).
This equipment is used as a support for a four or six cylinder engine
while it is worked on. The engine can be cleaned, disassembled and
assembled while held by the engine stand. An adapter plate must be
fastened with bolts to the engine. The adapter plate is then fastened
with bolts to the engine stand. While on the engine stand the engine
can be turned and held in eight positions. With the use of a universal
mounting group the engine stand can be used to support steering
axles and differential housings of lift trucks.
Make sure that the adapter plate is held solidly with four bolts to the
engine and the adapter plate is held solidly with four bolts to the
engine stand. Do not use damaged bolts to fasten the engine to the
engine stand. The adapter tube must be fastened to the engine near
its center of gravity to cause a minimum of weight shift during
rotation.
Unit 1 1-2-13 Caterpillar Service Industry
Lesson 2

Fig. 1.2.12 and 1.2.13 Transmission Stand

Transmission Stand
The transmission stand has four vertical supports. These supports
(swivel mounting shoes) can slide from the center to the four corners
on top of the transmission and be held in place by bolts. One end of
the transmission stand is fitted with wheels so that it can be moved
with a wheel dolly.
This equipment is used to support transmissions in the vertical
position for disassembly and assembly. This stand can be used to
support a:
• Power shift transmission.
• Range transmission.
• Direct drive transmission.
• Torque converter.
• Flywheel clutch.
With modification the transmission stand can be used to support
differentials and marine gear input shafts.
Make sure that the transmission is solidly held by the swivel
mounting shoes. Fasten the transmission to the swivel mounting
shoes with bolts before moving the transmission stand.
Unit 1 1-2-14 Caterpillar Service Industry
Lesson 2

Fig. 1.2.14 and 1.2.15 Parts Cleaning and Storage Racks (Transmission)
Parts Cleaning and Storage Racks
The parts cleaning and storage rack has steel mesh sides and bottom.
One type of parts cleaning and storage rack has separate
compartments for the different internal parts of a transmission. These
compartments can be changed to fit different types of transmissions.
A second type of parts cleaning and storage rack has no
compartments. The sides and bottom of this rack are also steel mesh.
There is a lifting eye in each corner of the parts cleaning and storage
rack. A vertical support in each corner of the rack will hold a second
rack above the first. There is a separate bottom (base) assembly that
has wheels at one end and can be moved with a wheel dolly.
This equipment is used to hold transmission parts for cleaning and
storage. One rack can hold all the internal parts of one transmission.
The parts cleaning and storage rack will fit into a parts cleaner tank.
It is not necessary to remove transmission parts from the rack during
the cleaning process. All parts of one transmission can be cleaned in
a single cycle. Parts cleaning and storage racks can be put into a
single column for storage. The correct use of these parts racks will
stop damage to components after disassembly.
Make sure that all parts cleaning and storage racks are held solidly by
the supports under each corner. When these racks are put into a
single column for storage, keep the total height of the column at a
safe level. Move no more than two parts cleaning and storage racks
at one time with a single wheel dolly.
Unit 1 1-2-15 Caterpillar Service Industry
Lesson 2

Fig. 1.2.16 Engine Parts Rack (Internal and External Component)

Engine Parts Rack

The engine parts rack for internal components is made of metal bars
and mesh. One side of the engine parts rack is fitted with crankshaft
holders. The engine parts rack for external components has flat
compartments with metal mesh bottoms. There are three of these flat
compartments held between two vertical supports. Both engine parts
racks have wheels fitted to the bottoms. A modification to the engine
parts rack will let the wheels be fastened to a separate bottom
assembly. With the modification, the engine parts rack can be
removed from the bottom assembly and put into a parts cleaning
tank. There is a handle assembly (which can be removed) at one end
of the engine parts rack. This equipment is used to hold both internal
and external engine components during engine disassembly and
assembly. The internal engine parts rack will hold all the internal
components. The external engine parts rack will hold lines, pans,
pumps, and housings. It is not necessary to remove internal engine
parts from the engine parts rack during the cleaning process if the
bottom assembly has been made.
Make sure that all heavy engine components are held solidly in the
engine parts rack. Be careful not to overload the engine parts rack.
There are different sizes of parts racks for different sizes of engines.
Unit 1 1-2-16 Caterpillar Service Industry
Lesson 2

Fig. 1.2.17 Oil Drain Cart

Oil Drain Cart

The oil drain cart is an open tank with low sides. A cover made of
metal mesh is put over the top opening. This cover will stop the oil
drain plug if it falls. The inside of the cart is divided by vertical
plates to reduce fluid movement. There are holes in the vertical
plates so the oil level is the same in all compartments. There is a
drain valve on one end of the oil drain cart. This valve can be used
as a gravity drain for the oil drain cart. The oil drain cart has wheels
and a long handle so that it can be moved easily. The maximum
capacity of the oil drain cart is 55 gal (210 L).
This equipment is used as a tank into which waste oil from heavy
equipment is drained. The oil drain cart is put into position under the
oil drain plug which is to be removed. The oil drain plug is removed
and the waste oil will flow into the oil drain cart. When full, the oil
drain cart can be moved to the waste oil reservoir.
Remove any oil from the floor of the shop immediately. Do not let
the oil level in the cart get above the metal mesh. Empty the oil
drain cart after use. The oil drain cart must be put in storage away
from heat. With oil in the drain cart there is the existing danger of
fire.
Unit 1 1-2-17 Caterpillar Service Industry
Lesson 2

Fig. 1.2.18 Fluid Removal Unit

Fluid Removal Unit

The fluid removal unit is generally a large tank in the shape of a
cylinder. The tank is held in the horizontal position. Fluids are
moved into and out of the tank through flexible hoses. The valves for
control of the fluid removal unit are on the top of the tank. An air
hose is used to connect the large tank to the shop air system. The air
hose is also connected on the top of the large tank. There is a
separate fixture for suction or discharge that can be connected to a
flexible hose. Some units have filters in the discharge section. Some
units also have a second tank which is small and has low sides and an
open top. The small tank is connected to the large tank by a flexible
hose. This small tank fits into brackets on the bottom of the large
tank for storage. There is a drain fixture at the bottom of one end of
the large tank. The fluid removal unit has wheels fitted to the bottom
of the large tank so that it can be moved easily. The maximum
capacity of the large tank is approximately 100 gal (380 L).
This equipment is used to remove oil from oil pans and hydraulic
tanks. The suction hose can be put directly into the filler opening of
a hydraulic tank. With the air valves in the vacuum position, the
hydraulic oil will flow through the hose from the hydraulic tank to
the fluid removal unit. A second method is to use a small tank with
low sides and an open top. This small tank is put into a position
below the drain plug on a hydraulic tank or oil pan. When the drain
plug is removed, the oil will flow into the small tank. The small tank
is connected to the fluid removal unit by a flexible hose. With the air
valves in the vacuum position, the oil will flow through the hose
from the small tank to the fluid removal unit. When it is desired to
discharge the contents of the fluid removal unit, either one of two
methods can be used. The cap on the gravity drain fixture on the end
Unit 1 1-2-18 Caterpillar Service Industry
Lesson 2

of the large tank can be removed. This will cause the contents to
flow out of the fluid removal unit by the force of gravity. The second
method is to connect the flexible hose to the discharge fixture on the
top of the large tank. Put the air valve in the discharge position. The
contents of the fluid removal unit will be pushed out of the large tank
and through the hose. The fluids are forced to flow through the hoses
by a difference in air pressures. The difference in air pressures is
made possible by the shop air system. One large advantage of the
fluid removal unit is that oil that is in good condition can be used
again. Good oil can be discharged through filters back into oil tanks.
Remove any oil from the floor of the shop immediately. Remove oil
from the surface of the equipment used. Follow the safety
procedures for the use of shop air systems. Be careful in the storage
of oil because of the existing danger of fire.
Unit 1 1-2-19 Caterpillar Service Industry
Lesson 2

Fig. 1.2.19 Portable Stand (Work)

Portable Stand
The portable stand is generally made of metal beam and tube
materials. There are ladder steps that go up to a flat support at the
top of the portable stand. The flat support at the top is generally the
same size as or larger than the ladder steps. There are wheels fitted
to the bottom of the portable stand so that it can be moved easily.
This equipment is used as a stand for a person to work from. It
permits a person to work at a higher vertical height than his normal
capacity. The portable stand can be put into position by one person.
When the portable stand is put into position, the wheels must be held
so that the stand will not move during use. Some portable stands are
equipped with locks that automatically hold the wheels when the
stand is in use.
Unit 1 1-2-20 Caterpillar Service Industry
Lesson 2

Fig. 1.2.20 Portable Work Bench

Portable Work Bench

The portable work bench is generally made of sheet metal. There
is an opening on the front of the portable work stand to use for
storage. Some have fixtures that can be closed over these
openings. The top of the portable work bench is flat. A support
can be fitted to the end for the addition of a tool box. The bottom
of the portable work bench has wheels so that it can be moved
easily.
This equipment is used as a work stand and for storage. The flat
top is used as a support for small components and materials while
they are worked on. The bottom section is used for storage of
tools, instruments, test equipment, and materials for the technician.
A support on the end of the portable work bench will hold a tool
box with the standard set of tools used by the technician. Make
sure that this tool box will not cause the work bench to tip.
Unit 1 1-2-21 Caterpillar Service Industry
Lesson 2

Fig. 1.2.21 Drill Press

Drill Press
The drill press is similar to a portable drill held by a vertical support.
The drill press has a much larger capacity than the portable drill and
has better accuracy. The drill head is held at top of the vertical
support. The drill head is made of the:
• Electric motor
• Power transmission (gear or belt driven)
• Spindle
• Components for control of operation
Tool holders fasten to the spindle. The spindle turns as a result of the
motor and transmission arrangement. The vertical support also holds
a horizontal support (work table) below the drill head. The work
table on many drill presses can be adjusted to any vertical height
below the drill head. Vertical movement of the drill bit is controlled
by the operator through the use of a hand lever or wheel. Some drill
presses can be made to drill automatically at a specific rate. A depth
gauge on the drill head can be adjusted to permit the drill to cut no
lower than a specific depth.
Unit 1 1-2-22 Caterpillar Service Industry
Lesson 2

This equipment is used to cut round holes in solid material. The hole
can be cut to a specific depth or completely through the material.
The material to be drilled must be held solidly on the work table.
This can be done with stops and clamps. Small materials can be held
in a vise. The drill speed must be adjusted to the minimum needed
for the specific job. The drill speed is controlled by the type of
material to be drilled and the diameter of the drill bit used. These
same factors control the speed at which the drill bit is lowered into
the material that is to be drilled. A cutting fluid can be used to cool
the drill bit and a hard material that is to be drilled.
Make sure that no loose material comes into contact with the drill or
the spindle. Make sure that the operator has safety protection for his
eyes. The drill can throw pieces of sharp shavings during operation.
Keep the work table and the floor area clean. Make sure that all of
the access covers on the drill press are in place. The drill bits must
be sharp and held tight by the drill press. Remove the chuck key
from the chuck before the drill press is operated. Never clean the
drill press while the spindle turns. Never use a hand to stop a
spindle. Make sure that the drill speed is adjusted correctly before
the drill press is operated. After adjustments have been made, make
sure that all locks are tight.
Unit 1 1-2-23 Caterpillar Service Industry
Lesson 2

Fig. 1.2.22 and 1.2.23 Bench Grinder

Bench Grinder
The bench grinder has a horizontal electric motor. An abrasive wheel
is fastened to each end of the motor spindle. There is a cover (wheel
guard) fitted around each abrasive wheel. The wheel guard is open
only at the working area at the front of the abrasive wheel. At the
bottom of the opening in the wheel guard is a horizontal support
(work rest). The work rest can be adjusted to keep a minimum of
distance between the work rest and the abrasive wheel. The bench
grinder can be fastened to a work bench or to a stand fastened to the
floor.
This equipment is used to grind a solid material with a abrasive
wheel. In this application, the bench grinder can be used to make
tools sharp; make surfaces smooth; give shape to parts; or get
material ready for welding. The work rest must be adjusted to 1/16
in (2 mm) from the abrasive wheel. Turn the abrasive wheel one
complete revolution before operation of the bench grinder. This is to
make sure that the abrasive wheel does not hit the work rest. The
wheel rotation will be down against the work rest. The material
being worked is held against the work rest with the opposite end held
up a little. Pliers are used to hold small materials. When materials
are hand held, fingers must be in position on the front edge of the
tool rest. The operator must be careful not to let materials get too hot
while being worked on the bench grinder.
Never use too much force against the abrasive wheel. Make sure that
no loose material comes into contact with the abrasive wheel or the
bench grinder spindle. The operator must have safety protection for
his eyes. Do not operate the bench grinder unless all wheel guards
are in position. The maximum speed at which an abrasive wheel can
be used is found on the side of the abrasive wheel. Make sure that
Unit 1 1-2-24 Caterpillar Service Industry
Lesson 2

the bench grinder does not turn faster than the maximum safe speed
of the abrasive wheel being used. Inspect the abrasive wheel before
operating the bench grinder. Never work in a position where the
hands can come into contact with the abrasive wheel. Keep the work
rest and the abrasive wheel distance as small as possible to keep
material from being pulled down between the work rest and the
abrasive wheel.

Fig. 1.2.24 Pedestal Grinder

Pedestal Grinder
The pedestal grinder is similar to the bench grinder. The pedestal
grinder is heavier than the bench grinder and it is fastened directly to
the floor. The spindle is driven by belts connected to an electric
motor. Some grinders are driven directly by an electric motor. Each
end of the spindle holds an abrasive wheel.
This equipment is used for the same purpose as the bench grinder.
The pedestal grinder can hold a larger abrasive wheel than the bench
grinder. The surface speed of the grinding wheel must be constant.
Larger grinding wheels must have a slower rotation than smaller
grinding wheels.
Unit 1 1-2-25 Caterpillar Service Industry
Lesson 2

Fig. 1.2.25 and 1.2.26 Abrasive Wheels

Abrasive Wheels
The abrasive wheel is made of a hard rough material. There are
basically two types of abrasive wheels. One type is called
"Alundum." This abrasive wheel is used to work on materials with
high tensile strength and for all types of steel. The second type is
called "Crystolon." This abrasive wheel is harder than "Alundum" and
is used to work on hard materials which are not made of iron. The
type of abrasive is found on the side of each abrasive wheel.
This equipment is made to be fastened to a grinder to be used to
make tools sharp, make surfaces smooth, give shape to parts, or get
material ready for welding. The abrasive wheel does its job by being
held in contact with a material while being turned at a high rate of
speed. It is important to use the correct type of abrasive wheel for a
specific job.
Test an abrasive wheel for cracks before using. Cracks can be found
by visual inspection. A second way to find cracks is to hang an
abrasive wheel vertically and hit it easily with a piece of wood. If the
wheel makes a clear light sound, it is free of cracks. If it makes a
short low sound, it is cracked and is to be thrown away. A cover
(guard) is to be fastened around an abrasive wheel before it is used.
This way the operator will have protection if a piece of the abrasive
wheel breaks off. The operator must have safety protection for his
eyes. Material is to contact only the edge of the abrasive wheel.
Never use the side of the abrasive wheel in contact with a material.
Unit 1 1-2-26 Caterpillar Service Industry
Lesson 2

Fig. 1.2.27 Bench Vises

Bench Vise
The bench vise has two jaws which face each other. A screw is used
to adjust the distance between the two jaws. A handle on the front of
the bench vise is used to turn the screw. The jaws are generally 3 to
6 in (7.5 to 15 cm) wide. They can generally open to a maximum of
4 to 9 1/2 in (10 to 24.5 cm) from each other. The body of the bench
vise is made of high carbon steel. Some types of bench vises can be
turned on their bottom support and held in position with a lock.
Some types of bench vises have an area that can be used as a support
for a material while it is hit with a hammer. This area is generally on
top of the body behind the jaws.
The bench vise is used to hold materials while they are worked on.
A material is put between the jaws of the bench vise. The jaws are
closed when the screw is turned with the handle on the front of the
bench vise. When the jaws close tight on a material, it is held solidly
in position. A bench vise can be used when any small material must
be held tight. Soft metal covers can be put on the jaws of the vise.
These covers can prevent damage to parts held in the vise. Some
bench vises will turn (rotate) on a stationary base.
When a material is put into the bench vise, make sure that it is held
tight enough so that it will not move while it is worked on. Do not
hit the vise handle with a hammer to tighten the jaws.
Unit 1 1-2-27 Caterpillar Service Industry
Lesson 2

Fig. 1.2.28 and 1.2.29 Arbor Press (Mechanical)

Arbor Press
The arbor press has a vertical support on the back side. The top of
the vertical support holds a straight bar (press bar) with a rack of gear
teeth. The press bar is held vertically. Close to the press bar are the
adjustment fixtures. When the adjustment fixtures are operated, the
press bar moves axially up and down. Generally one adjustment
fixture moves the press bar rapidly and the other moves the press bar
slowly with more force. At the bottom of the vertical support is a
horizontal flat support. This support will hold the material while it is
worked on. The arbor press is made in a large range of sizes. Arbor
presses can be fastened to work benches or held on the floor
according to size.
This equipment is used to push one component into or out of a
second tight fitted component; for example, to push the shaft out of a
gear or bearing. The material to be installed on or removed from the
shaft is put on the horizontal support. The shaft is put into alignment
with the press bar. There is a hole in the horizontal support which is
in vertical alignment with the press bar. This hole is to give
clearance between the shaft and the horizontal support. The press bar
is lowered until it comes into contact with the shaft. When alignment
is correct, the press bar will push the shaft to the desired position.
The force of the operator is multiplied by the mechanical advantage
of the arbor press.
Unit 1 1-2-28 Caterpillar Service Industry
Lesson 2

Be careful not to let components hit the operator when they are
pushed out by the arbor press. Make sure that material is held solidly
on the horizontal support before the press bar is lowered. Do not let
material fall to the shop floor once it is pushed free by the arbor
press.

Fig. 1.2.30 Hydraulic Press

Hydraulic Press
The hydraulic press is made of steel channel beams. Two vertical
channel beams are connected at the top by two horizontal channel
beams. The top channel beams hold a hydraulically operated press
bar. Two more horizontal channel beams are used as supports below
the hydraulic press bar. The ends of these supports are held by the
two vertical channel beams with lock pins. These lower horizontal
supports can be moved up and down and held at the different
positions with the lock pins. A hand crank on the side of the
hydraulic press is used to move the horizontal support up and down.
There are also forged steel bars to use as supports for material while
it is worked on the hydraulic press. The hydraulic press bar is a
hydraulic cylinder. This hydraulic cylinder can be moved
horizontally to any position between the two vertical channel beams.
Unit 1 1-2-29 Caterpillar Service Industry
Lesson 2

This equipment is used to push one component into or out of a

second tight fitted component. The hydraulic press is used in the
same type of applications as the arbor press. The primary difference
is that more force can be given by the hydraulic press. The
movement of oil to the hydraulic cylinder is caused by a pump. The
pump is driven by hand, an electric motor, or compressed air. Special
attachments can be fitted to the press bar for assistance in specific
jobs. Horizontal movement of the hydraulic cylinder lets the operator
easily make the final alignment of the press bar and the material to be
worked.
Keep hands away from the press bar while the hydraulic press is
operated. Keep all safety protection equipment in position for
operation. Be careful not to let components hit the operator when
they are pushed out by the hydraulic press. Make sure that the
operator has protection if a material that is worked on a hydraulic
press were to break. Material must be held solidly on the horizontal
support before the press bar is lowered. Check lock pins and holes
for damage and wear before the hydraulic press is used. Do not let
components fall to the floor when they are pushed out by the
hydraulic press. Follow the safety procedures for hydraulic systems.
NOTES