Hand & Power Tools : Using electric power tools

Using electric power tools:
   Using an angle grinder
   Using a bench grinder
   Using pressure washers & cleaners

Using an angle grinder

Part 1. Preparation and safety

Objective

• Show the correct operating procedure for using an angle grinder.

Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:

• Work clothing - such as coveralls and steel-capped footwear
• Eye protection - such as safety glasses and face masks
• Ear protection - such as earmuffs and earplugs
• Hand protection – such as rubber gloves and barrier cream
• Respiratory equipment – such as face masks and valved respirators

If you are not certain what is appropriate or required, ask your supervisor.
Safety check

• Always wear impact-resistant protective glasses, ear protection and a full-face shield when using an angle grinder.
• Disconnect the power supply when changing any grinding attachments or discs.
• Wear safety shoes, leather gloves and an apron to protect your body from flying metal chips. Make sure the blade guard is firmly secured.
• Use the correct type of disc.
• Make sure the guard handles are secure.
• Use the correct flange or spindle nut for the type of disc being used. If you don't, the disc can shatter at high speed and injure you.
• Angle grinders, like all portable grinding tools, need to be equipped with safety guards to protect you from flying fragments in case the disc breaks apart.
• Always follow the manufacturer's recommendations to make sure the spindle wheel does not exceed the abrasive wheel specifications.
• Make sure there are no obvious defects or damage to the disc before you install it.
• Everyone who uses an angle grinder must receive training and instruction in safe work procedures.
• Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.

Points to note

• The angle grinder uses an electric motor to drive an abrasive disc at high speed.
• The grinder disc is turned at speeds that range from 5,000 rpm to 12,000 rpm.
• The turning disc is used to grind or cut metal.
• The grinder size relates to the diameter of the cutting disc. This can range from 100 mm to 230 mm (4 inches to 9 inches). The size of grinder you use depends on the type of job you are doing.
• The smaller the grinder, the higher the speed it turns.
• Sanding discs and wire wheels can be fitted on the grinder, making it a versatile electric tool.

• An extra handle is provided that is attached to the grinder head. This can be fitted to either the left, right or top of the head to make it easy to use for left-handed as well as right-handed people.
• The abrasive disc or cutting wheel is attached to the grinder by a flange and nut. The nut is specially designed to fit in a recess in the center of the pad or wheel. It is tightened by a spanner that is provided with the grinder when purchased. Do not lose this wrench because it is the only tool that can tighten the nut properly.
• When using cutting discs you should always use the edge of the disc rather than the face.
• Do not confuse a grinder with a sander/polisher. The sander/polisher turns at lower speeds, typically 600 to 3,000 rpm. They are commonly used to sand and polish paint. The pads these tools use cannot be turned at high speed. If the polish pad were attached to an angle grinder, the higher rotational speed would cause the polishing pad to burn the paint and cause the polish pad to fly apart.

---

Part 2: Step-by-step instruction

1. Position the disc
   Hold the face of the disc against the work, not the edge.
2. Work carefully
   Be careful that the motor’s torque does not cause the grinder to slip out of your hand. Do not press too hard. Let the grinder do the work.
3. Select the correct disc
   Use special discs for cutting, in places where a hacksaw can’t be used. With cutting discs, use the edge of the wheel, not the face.

Using a bench grinder

Part 1. Preparation and safety

Objective

• Set up, adjust and use a bench grinder.

Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:

• Work clothing - such as coveralls and steel-capped footwear
• Eye protection - such as safety glasses and face masks
• Ear protection - such as earmuffs and earplugs
• Hand protection – such as rubber gloves and barrier cream
• Respiratory equipment – such as face masks and valved respirators

If you are not certain what is appropriate or required, ask your supervisor.
Safety check

• Stand to the side of the grinder when starting the electric motor.
• Always wear full-face protection, ear protection, leather gloves and a leather apron.
• Use the safety shield fitted to the grinder. If it has been damaged, replace it.
• Do not grind on the side of the wheel because it may cause the wheel to shatter.
• Make sure you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are not sure of what these are, ask your supervisor.

Points to note

• The bench grinder turns an abrasive wheel or wire brush wheel at high speed. These wheels are used to remove metal from a work piece, sharpen tools and clean parts.
• The type of wheel you use will depend on the type and the hardness of the material.
• Whether you are grinding or polishing, use the correct wheel for the material you are grinding or buffing.
• Ask your supervisor to demonstrate the differences between grinding wheels for soft and hard materials and wire brush wheels.
• As the abrasive wheel wears down, the gap between the wheel and the tool rest will increase.
• Make sure the tool rest is as close as possible to the grinding wheel, but not touching it. It needs about a 1/16th of an inch (1.5 mm) gap.
• The face of the abrasive wheel must be kept square. This is done with a dressing tool, which removes some of the abrasive compound.
• If the abrasive wheel is not square, ask your supervisor to demonstrate the use of the dressing tool.
• When grinding metal, it must not overheat. This will affect its hardness. If the metal becomes too hot and is allowed to cool slowly, it may become soft. If it is cooled quickly (quenched), it may become brittle.
• As you shape the metal, dip it into the water pot attached to the bottom of the grinder. This will prevent the metal from getting too hot.
• Some bench grinders are not supplied with a water pot. If this is the case, you will need to have a water pot located near the grinder so that you can cool the piece you are grinding.

Component identification

• Some parts of this illustration are labeled. It is important to learn the names of these equipment components.

---

Part 2: Step-by-step instruction

1. Set up the bench grinder
   Before you start using the bench grinder, it’s vital that you set it up correctly. When operating, the abrasive wheel turns at high speed and produces dangerous and hot flying particles and sparks. Make sure the grinder is both switched off and disconnected from the power supply before you attempt to adjust it.
2. Use the correct safety equipment
   Certain safety attachments MUST be in place before operating the grinder. They are the wheel guard, the see-through safety shield, the tool rest, a water pot and a full-face protector.
3. Use the correct wheel
   The grinder may have abrasive grinding wheels for removing metal, a wire wheel to clean parts, or both. Make sure the wheel you’re using is appropriate for the job.
4. Adjust the tool rest
   With the correct wheel fitted to the grinder, adjust the tool rest. Position it so there’s at least 1/16th of an inch gap between the wheel, and the tool rest and that it is the same height as the center of the wheel. To adjust the tool rest, locate the adjusting bolt and loosen it with a box wrench. Set the tool rest at the right height and distance from the wheel and then tighten the adjusting bolt. If you are unsure of how to do this, ask your supervisor.
5. Safely use the grinder
   Connect the grinder to the power supply. Adjust your face protector, stand to the side of the wheel and switch the grinder on. Once the grinder is up to speed, move to the front of the wheel, hold the part firmly onto the tool rest, and move it slowly and gently forward until it comes into contact with the wheel. The grinding wheel removes the metal it contacts. Occasionally dip the part into the water to keep it cool.
6. Shut down
   When you have finished, turn off the power and unplug the grinder.

Using pressure washers & cleaners

Part 1. Preparation and safety

Objective

• Safely use pressure washers and cleaners in the workshop.

Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:

• Work clothing - such as coveralls and steel-capped footwear
• Eye protection - such as safety glasses and face masks
• Ear protection - such as earmuffs and earplugs
• Hand protection – such as rubber gloves and barrier cream
• Respiratory equipment – such as face masks and valved respirators

If you are not certain what is appropriate or required, ask your supervisor.
Safety check

• Wear protective gloves whenever using cleaning agents or solvents.
• Always wear a facemask and gloves when using cleaning and washing equipment.

• Always wear safety shoes when using any washing equipment to prevent slips on slippery surfaces.
• Always be aware of the location of safety switches located on equipment and of eyewash and first aid stations should an accident occur.
• Do not place your hand, or any other part of your body in the stream of water from the high-pressure wand
• Do not aim the high-pressure wand at another person.
• Always test the temperature of the wand and the hose before you pick it up. The handle of the pressure wand is insulated to protect the user from heat, but the wand extension and the hose are not.
• If the pressure cleaner uses a heating element, turn the heater off and allow water to flow through the wand until is has cooled before you turn the unit off.
• If you are unfamiliar with a solvent or a cleaning agent refer to the MSDS for information about its correct use and applicable hazards.

• Always wear protective clothing and the appropriate safety equipment.
• Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.

Points to note

• Pressure washers and cleaners used in automotive applications are available in a range of makes and types depending on application. There are fixed washers for cleaning components and mobile pressure washers that can be used to wash vehicle systems and engine bays.
• Make yourself familiar with the equipment prior to use; incorrect handling can result in damage to the vehicle or components that you are cleaning in addition to health risks to yourself and your workmates.
• The biggest advantage of using fluid to clean vehicles, components and workshops is that it wets the dirt or contaminants, so no dust is created. However, the waste products must be caught and disposed of properly in either a tank or sullage pit. The waste materials must not be released into a storm water drain.
• Component washers have to incorporate either an in-built waste recovery system or can only be used where the contaminated washer fluids can be captured to enable disposal in an environmentally friendly manner. They are normally designed to run on low pressure and use a range of chemicals and solvents as the cleaning agent.
• A low-pressure air blower is normally provided to remove the fluid from the component into the tray area and then back to the tank by gravity.
• Always follow recommended safety procedures. Some washers use very dangerous chemicals and others use very high pressure water to clean away the contaminants.
• It is imperative that the user read the instructions beforehand and be familiar with the operation of the pressure washer. When cleaning exterior paintwork, extreme care must be taken to ensure that the pressure does not damage or remove paint. If in doubt, clean the area manually using a clean sponge using fresh clean water.
• It is very important to note the type of solvent being used as some vehicle components can be damaged by some solvents and should only be cleaned in wash tanks containing the correct cleaning fluid.
• When using high pressure washers, it is always important not to use the high pressure spray in areas where the ingress of water and water based solvents can have a detrimental effect on electrical equipment such as fuse boxes and relay units. If you are required to use a pressure washer in an adjacent area of the vehicle, take precautionary measures to protect the units from high-pressure water damage. The damage sometimes does not become apparent for some time after the cleaning process, but can have a catastrophic effect on the vehicle, causing system failures, which are difficult to diagnose.
• If the washer has been used on the braking system, ensure that the vehicle is driven for a small distance with the brakes slightly applied to dispel any residual water from the system through heat transfer and subsequent evaporation of the water.
• On completion of the job, the correct disposal of contaminated materials is an absolute priority. Operatives of equipment may be subject to prosecution for the incorrect disposal of waste materials.

• Familiarize yourself with the equipment prior to use, as misuse can cause damage.
• Avoid using solvent when cleaning components as it contaminates friction materials and may cause seals to swell. Water is a good cleaning agent for brake components.
• Never use Kerosene as a general cleaning agent to clean brake components as it does not clean away brake fluid, can be absorbed into lining materials and can cause seals to swell.
• Whenever using a pressure washer or tank type cleaner with solvents and cleaners make sure there is adequate exhaust ventilation. Wear appropriate breathing apparatus and eye protection.

---

Part 2: Step-by-step instruction

1. Choose the correct washer
   Use the correct washer for the task you are performing, and always refer to the manufacturers manual for specific operating instructions. Before using the equipment locate the position of safety switches and put on a facemask and gloves. Note the location of the eyewash and first aid stations within the workshop. Use a component washer to clean items that can be safely contained within the cleaning tray. Use a pressure washer to clean vehicles, engines and engine bays.
2. Use a component washer
   Make sure that all the washing fluid is contained within the cleaning tray and returns to the reservoir. Washing solvents must not enter the environment. Before using the component cleaner, make sure the solvent is compatible with the component to be cleaned. Put on a facemask and gloves and lift the component to be cleaned into the wash tray. Make sure the waste drain is not blocked and the low-pressure air blower is operational.
3. Clean and dry the component
   Using a stiff brush, paint the solvent over the components to both wet and clean the components and remove contaminants. Use the low-pressure air blower to dry excess solvent from the component,
   and make sure the waste materials are caught in the cleaning tray and strained back into the tank below.
4. Use a high-pressure washer
   Follow the manufacturers instructions and connect the pressure washer hose to the mains pressure water supply, and the electrical plug to an earth leakage protected power outlet. Make sure electrical connections and adjacent areas are protected from water spray by using appropriate protective shields. Put on a facemask and gloves and turn on the water supply but not the electrical power. Make sure that water is flowing through the washer unit by testing the flow through the pressure wand before turning the power on. It should flow freely but not at high pressure.
5. Turn the power on
   Turn the power on and you will hear the motor engage. Point the wand toward the ground and test that the water now flows at high pressure.
6. Use a degreaser
   It may be necessary to apply a degreasing agent with a hand brush to penetrate and remove excess dirt before you operate the washer.
7. Clean the component
   Pull the trigger and using a circular motion direct the high-pressure water onto the area to be cleaned to remove the contaminants. Avoid getting the high-pressure spray on the exterior paintwork of the vehicle by placing the wand close to the area to be cleaned. When the contaminants have been removed, release the trigger and then remove the wand from the cleaning area. Turn the electrical power off then turn the water supply off.
8. Check vehicle operation
   Use an air blower to disperse any residual water from electrical components that have come into contact with the cleaning fluids, and then start the vehicle. Let the vehicle run for a few moments to dry, and then remove any residual water lying in the engine bay area. Clean up any residual material and place in a bin or an environmental waste container.