4-Tools and Equipments.pdf

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UNIT 1 TOOLS AND EQUIPMENT

Structure

1.1 Introduction

Objectives

1.2 Types of Tools and Equipment

1.3 General Tools

1.4 Measuring Tools

1.5 Electrical Instruments

1.6 Usage of Special Tools

1.7 Summary

1.8 Answers to SAQs

1.1 INTRODUCTION

At any point of time, it may be required to disassemble the whole or any part ofmotorcycle. Whenever a part of motorcycle malfunctions or is damaged then it may berequired to be replaced or repaired. To perform this task we need to remove it frommotorcycle body with the help of tools.

Here in this unit, we shall study about variety of tools and equipment used while servicinga motorcycle. One should also familiarize with special tools in addition to common tools,

which are used for the servicing of the motorcycle.Objectives

After studying this unit, you should be able to list various tools, measuring equipment required in a motorcycle workshop, and

identify and use appropriate tools for motorcycle service and maintenance.

1.2 TYPES OF TOOL AND EQUIPMENT

We can classify the required tools and equipment into following four categories to

understand their uses :

General tools,

Measuring equipment,

Electrical instruments, and

Special tools.

1.3 GENERAL TOOLS

General tools include spanners, screw drivers, files, pliers, vices, punches, mallets,chisels, grinders, drilling machine, oil and grease guns, etc.

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Spanners

These are used to tighten and loosen nuts and bolts. These are made according tostandard nut and bolt sizes and in vanadium steels. The following types of spannerare used :

Open-ended SpannersThese types of spanners are open from both side and used to tighten nut andbolts where low torque is required.

Ring Spanners

These are closed at both ends as they have full circular ring at ends. They donot slip and cause damage.

Combination Spanners

These are open at one end and close at other end.

Torque WrenchThese are used in special cases, where specified amount of torque is required.They are used to tighten important nuts and bolts.

Box Spanners

These may be used to tighten nuts on drums of wheels. Sometimes they arealso referred as wheel nut spanners. Figure 1.1 shows different types ofspanners used in motorcycle servicing and repairs.

(a) (b)

(c) (d)

Figure 1.1 : (a) Open End Spanners; (b) Ring Spanners;(c) Combination Spanners; and (d) Torque Wrench

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Files

Files are used to remove excess metal by cutting action. These can be classifiedaccording to their length, shape, cross-section.

Pliers

Pliers are used just for gripping or wire cutting and should never be used assubstitute for spanners. The following types of plier are used :

(a) Side cutting pliers

(b) Adjustable combination pliers

(c) (i) Flat nosed pliers

(ii) Round nosed pliers

(iii) Half round nosed pliers

Different types of plier are shown in Figure 1.2.

Figure 1.2 : Various Types of Plier

Bench Vices

Bench vice is used to hold a job on a bench. It consists of a movable jaw, a fixed jaw,spindle and a lever. Figure 1.3 shows a bench vice. The movable jaw is in the front.The spindle, carrying square threads, moves in a nut fixed inside the body of thefixed jaw. The handle is used to rotate the spindle on which movable jaw translates.

Figure 1.3 : Bench Vice

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Punches

A bar which carries a sharp point at one end and used to make a permanent mark ona part is called punch. The point is hard and tempered so that it can withstandagainst shocks. The bar can have different sizes and sections (Figure 1.4).

Figure 1.4 : Punches

Hammer/Mallet

Hammer is used to strike a job to bring it in shape or otherwise. It is made of carbonsteel. The wooden handle does not allow the shock to hand but handles made inmetal and rubber are also used (Figure 1.5).

The hammer is made up of a metallic head fitted to the end of a wooden handle. Aball peen hammer has one end spherical and other end flat. A cross peen hammerhas both ends flat. A mallet has a wooden head and is used to strike parts whichshould not be dented, such as those made of thin sheets or softer materials.

Figure 1.5 : Hammers and Mallet

Grinder

Grinders are used to sharpen the cutting edges of the tools. They are basically fastrotating grinding wheels carried at one or two ends of a shaft. The grinding wheel are

made of particles of very hard oxides or carbides of aluminum or titanium(Figure 1.6).

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Figure 1.6 : Grinder

Chisel

Chisels are used in the combination of hammer to remove metals. A set of chisels isshown in Figure 1.7

Figure 1.7 : Chisel

Scrapper

Scrappers are used to scrap gasket or other such materials from flat or irregularsurface. Scrappers of several sizes are shown in Figure 1.8.

Figure 1.8 : Scrapper

Drill Bit

This is a drilling tool used in drilling machines. The application of this tool is to makeholes. Figure 1.9 shows drill bit.

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Figure 1.9 : Drill Bit

Grease Gun

A grease gun is shown in Figure 1.10. This is used to supply semi-solid lubricant(grease) for chassis lubrication.

Oil Gun

This is used to supply fluid oil to chassis lubrication (Figure 1.11).

Figure 1.10 : Grease Gun Figure 1.11 : Oil Gun

Screw Driver

Screwdrivers of different sizes are used to tighten or loosen screws. These are madeof vanadium steels. A typical screw driver is shown in Figure 1.12.

Figure 1.12 : Screw Driver

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SAQ 1

(a) What are the types of material used for making spanners? What are the uses of

spanners?(b) Write down the uses of following tools and make neat sketches of the same :

(i) Combined Spanner

(ii) Hammer

(iii) Bench Vice

1.4 MEASURING TOOLS

Steel Rule

A steel rule is used to measure length. It has two scales in millimeters and inches.These rules are available in market in discrete lengths such as 15, 30, 60 cms. A30 cm rule is shown in Figure 1.13.

Figure 1.13 : Steel Rules

Vernier Calipers

It is used to measure internal as well as outer diameters of an object. There areseparate jaws available for inside and outside diameter measurements. It can alsomeasure the depth of a hole. Vernier caliper has two scales Main scale and Vernierscale (Figure 1.14).

Figure 1.14 : Vernier Caliper

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SAQ 2

Write down the uses of following tools and make neat sketches of the same :

(a) Vernier Caliper(b) Steel Rule

1.5 ELECTRICAL INSTRUMENTS

Multimeter

This is used to measure voltage, current and resistance of an electrical circuit(Figure 1.18).

Figure 1.18 : Mult imeter

Tachometer

This is used to measure the speed (revolutions) of an engine in revolutions perminute (RPM). This is shown in Figure 1.19.

Figure 1.19 : Tachometer

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Hydrometer

Hydrometer (Figure 1.20) is used to measure the specific gravity of battery fluid(electrolyte).

Figure 1.20 : Hydrometer

Battery Charger

As suggested by the name, it is used to charge a battery. The detailed procedure forcharging a battery is given in later units.

SAQ 3

List the uses of following tools and make sketches of the same :

(a) Hydrometer

(b) Combination spanner

(c) Multimeter

1.6 USAGE OF SPECIAL TOOLS

The common tools used in repair and maintenance of motorcycles were introduced to youin previous sections. Now, we shall learn about some special tools and their specificusages and procedure of handling them properly. The description of these special tools is

given in Appendix A. While going through the details of the special tools, you must payattention to the geometry of tools and procedure of its usage. The accompanying pictureswill help you in understanding their uses clearly. You are advised to look into the picturescarefully, while reading the procedure.

SAQ 4

(a) How should the flywheel be removed?

(b) How should the castle nut be removed from the clutch assembly?

(c) How would you set the tappet clearance?

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SAQ 5

(a) Explain the procedure of removal for valves.

(b) How should one remove valve guide from cylinder head?

(c) What is the use of piston side base?

(d) What is the use of oil pump spindle holder?

SAQ 6

(a) What is the use of ball race drive?

(b) How should one install the bottom cone race?

(c) What is the use of front fork oil seal driver body and its attachment?

(d) What is the use of crank case bearing removal?

(e) What is the use of compressor rear shock absorber?

1.7 SUMMARY

In this unit, we studied about the various tools and equipment used in service and repair ofa motorcycle and for the troubleshooting. Acquainting with these will help you to select anduse a correct type of tool. In the next unit, we shall study about servicing procedures of themotorcycle.

1.8 ANSWERS TO SAQs

Refer the relevant preceding text in the unit or other useful books/manuals available on the

topic in the workshops to get the answers of the SAQs.

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Documents

4-Tools and Equipments.pdf