HANDY HINT;Well maintained power toolswill reduce the likelihood of
accidents or injury.
HANDHELD ENGINEERING POWER TOOLS INFORMATION SHEETS MEL02INF2396
HEALTH & SAFETY REQUIREMENTS
RECORDING REQUIREMENTS: Record the results of your work on Task Worksheet MET02TWS13REFERENCES: This document relates in part to the requirements of Unit Standard 2396
ADVANTAGES OF POWER TOOLS
Power tools are labour saving devices; they are designed and built to quickly and accurately do work that would normally take us muchlonger if we were to use hand tools. This in turn enables us to be more productive and produce less expensive, better quality products.
Safety Boots are mandatory in most engineering environments and usually offer toe protection from crushing or falling objects.Most safety boots have heavy-duty construction, and a choice of non-skid, chemical resistant and/or electrically insulated soles.
Overalls are mandatory in most engineering environments, and usually provide arm as well as leg and body protection from dirt, dust andoil contamination, and light abrasion.
Safety Glasses are mandatory in most engineering environments to protect the wearer from eye injury and impact caused by low velocity,low mass flying objects.
Visors are designed to offer protection from impact caused by low velocity, low mass flying objects in the assembly environment.Visors are usually constructed from light-weight, heavy-duty plastics and incorporate a head band with a clear flip-down face shield.
Ear Muffs are designed to provide hearing protection from workplace noise. Hearing protection is required for exposures above 85decibels (dBA) over an 8 hour working day, but as a general rule, hearing protection should be used where any discomfort is experienced.
Leather Gloves are used to provide hand protection from abrasion, as well as minor impact and variations in temperature.
Dust and particle masks are designed and rated to provide protection by filtering fine solids or liquid particles from inhaled air.
Hard Hats are designed to prevent head injury due to impact from flying, falling or suspended objects.Some types of hard hat can be modified by adding face-shields, visors, chin-straps and hearing protection.
Personal Protective Equipment
Normal street and office clothing is not usually adequate for protecting people while working withpower tools in a mechanical engineering environment. Items such as ties, jewellery, loose fittingclothing or even long hair may become caught in machinery or equipment, leading to serious harm or loss.
Overalls should be worn to protect and confine exposed skin and personal clothing
Jewellery should be removed to prevent amputation of body parts
Hair ties or a hair net should be used to confine long hair
To remain safe when assembling mechanical components, the correct personnel protective equipment (PPE) must be worn.Some items of PPE are mandatory, while other types need to be used to ensure protection during specific activities.
POWER TOOL HAZARDS AND SAFETYPower tools a designed to do work at very high speeds andthey are much more powerful than hand tools.Consequently, they can very quickly do muchmore damage than hand tools.Common power tool hazards include;
Avoiding injury or damage can be as simple as choosing the right power tool for the job, and using it correctly.
Don't use damaged or broken power tools
Don't use a tool that is designed for a different job
Always work carefully and methodically-don't rush
Don't use incorrect, damaged or broken attachments or accessories
If you don't know which tool to use, or how to use a power tool properly; STOP and ASK!
HANDY HINT;ALWAYS follow the manufacturers instructions
when maintaining and using power tools.
MAINS-SUPPLY POWER HAND TOOLSAdvantages
Powerful and robust
Wide range of equipment types available
240 volt AC mains power is commonly available
DisadvantagesLess portable than battery powered hand tools
Usually requires an extension cordCannot be used in wet environments
Cannot be used in hazardous environments
Restricted to nearest 240 volt AC local mains supply
Safety Requirements
Before starting work, check that the electric power tool is currently certified and tagged.Always use mains powered electric tools with each of the following;
Either a residual current device (RCD) protection, or an isolating transformer, or connected to a monitored-earth circuit
Certified or test-tagged extension cordsPersonal Protective Equipment (PPE)
Care, Maintenance and Storage
Check and clean the tools and equipment with a clean dry ragto remove dirt, dust, water or oil.
Return to the tool chest, shelf or storage box at the completionof the job, or at the end of the work day.The following problems require repair by a qualified personand should be reported to your supervisor;
Damage to the tool casing or switchNicks and cuts on the cord insulation
Rough-running spindle bearings
Worn or seized mechanismsLoose or missing guards
Broken or damaged accessories or attachments
Reversible Drills can be used todrill a wide range of materialssuch as metal, wood, and plastic.
Angle Drills are handy forworking in tight spaces.
Disk Grinders are commonlyused for grinding and cutting steelcomponents and welded joints, as
well as buffing and polishing finished jobs.
HANDY HINT;Regularly check the mechanisms of the
power tool for smooth and free movement.
IMPORTANT NOTE;The casings of double insulated tools are identified
with this symbol and do not to require a safetyconnection to an electrical earth.
Abrasive Wheel
Metal Guard
Die Grinders are used for finishgrinding small amounts of metal frommachined and cast components.
Jig Saws can be fitted withdifferent blades to cut a wide range
of thin section material such as plastics,woods, composites and metals.
IMPORTANT NOTE;Despite its obvious convenience, personal
contact with electricity can be fatal.ALWAYS test the RCD before starting work.
Wide range of equipment types availableLightweight and portable
Interchangeable tools and batteries
Self-powering (no external source required)No extension cords or pressure hoses required
240 volt mains power is commonly available for charging
DisadvantagesLess powerful than most other types of powered hand tools
Batteries require regular charging and have a limited life span
Batteries require specialised disposal and recycling processesNot recommended for use in wet or hazardous environments
Safety Requirements
Before starting work, check that the battery charger for the power tool is currently certified and test-tagged.
Always wear the appropriate Personal Protective Equipment (PPE) when using battery powered tools.
HANDY HINT;Battery powered tools have enabled engineersto provide greater flexibility when responding to
urgent requests for service .
Reversible Pistol-drills are usuallyfitted with an adjustable clutch can beused to drill a wide range of materialssuch as metal, wood and plastic.
Hammer Drills are usedto drill masonry anchorholes in concrete floorand machine foundations.
Battery Powered Disk Grinderscan be used for grinding and cuttinglight gauge steel components andsmall welded joints, as well asbuffing and polishing finished jobs.
Battery Powered Jigsaws can be usedfor cutting engineering material such asplastics, woods, composites and metals indifficult, hard to reach locations.
Battery Powered Screwdriversare used for rapidly assembling
quantities of small fasteners intomechanical devices.
HANDY HINT;Spare batteries should always be charged–up and be placed
in the job bag before going to work in remote locations.
Rechargeable batteries arecommonly available in eitherNickel Metal-Hydrate (Ni-MH)or Lithium-ion (Li-ion).
Battery Chargershave dedicated cradles
with switching systems designed to monitorthe status of the battery while it is charging.
Care, Maintenance and Storage
Check and clean the tools and equipment with a cleandry rag to remove dirt, dust, water or oil.
Check and charge-up the batteries before returning theequipment to the tool chest and storage area at thecompletion of the job, or at the end of the work day.
The following problems require repair by a qualifiedperson and should be reported to your supervisor;
Damage to the tool casing or switch
Nicks and cuts on the cord insulation
Rough-running spindle bearingsWorn or seized mechanisms
Loose or missing guards
Broken or damaged accessories or attachments
PNEUMATIC (AIR) POWERED HAND TOOLSAdvantages
No extension cords or direct electrical supply
Wide range of equipment types availableInterchangeable tools and hose connections
Small, lightweight, fast and comparatively powerful
Simple, light and robust designsTough, durable construction for long service
Can be used in wet environments
Suitable for restricted use in some hazardous environments
Disadvantages
External power source required (powered compressor)
Requires medium pressure compressed air supply hoses and connectionsSome tool types can be comparatively noisy
Safety RequirementsBefore starting work, check that the electrical supply to the compressor is fitted with either a residual current device (RCD) protection,or an isolating transformer, or connected to a monitored-earth circuit. Any extension cords should be checked for test-tagging.
Check the air hoses are free from damage, deterioration or leaks, and that the connections are secure.Check, set and drain the regulator/filter/oiler setup, and the compressor vessel.
Always wear the appropriate Personal Protective Equipment (PPE) when using air powered tools.
Duster-Guns are used forblowing down componentsduring cleaning and assembly.
High-speed Die Grinders areused for precision finishing ofhigh-spec components.
High-speed Angle-Drills areused for precision drilling of verysmall holes in difficult locations.
Disk-sanders are often fitted with smalldiameter self-adhesive or Velcro pads to allowquick changing of sanding and polishing disks.
Pneumatic Impact Wrenches or “rattle-guns”are used when working with large fasteners whichmay become seized or need to be “torqued –up”.
High-speed Air Wrenches are used whenworking on large or complex mechanismswhere there are large quantities of fasteners.
Pneumatic Tools such as this buffingwheel and pistol-drill are recommendedfor their consistent power and lightweight, and most importantly, their long-lasting, heavy-duty construction.
Care, Maintenance and Storage
Check and clean the tools and equipment with a clean dry rag to remove dirt, dust, water or oil.Check and drain the compressor before returning the equipment to the tool chest and storage area atthe completion of the job, or at the end of the work day.
The following problems require repair by a qualified person and should be reported to your supervisor;Broken, damaged or leaking tools or equipment
Nicks, cuts or leaks in the air hoses
Worn or seized mechanismsLoose or missing parts
HANDY HINT;Check the air lines and hoses
for condensation beforeconnecting-up the tools.
HANDY HINT;Pneumatic tools are designed to be fitted with attachments
and accessories such as sockets, screwdrivers, drills, burrs,buffing-wheels and orbital sanding heads.
HANDY HINT;Hydraulic power tool kits use a comprehensiverange of high pressure tools, typically for lifting
and moving heavy engineering machinery.
HYDRAULIC POWERED HAND TOOLSAdvantages
No extension cords or direct electrical supplyEquipment includes hand or powered pumps
Interchangeable tools and hose connections
Very powerful and efficient tools and equipmentSimple, robust designs with tough, durable construction
Can be used in wet environments
Suitable for restricted use in some hazardous environments
Disadvantages
External power source required of some pumping equipment
Requires high-pressure hydraulic oil, supply hoses and connections
Some tool types can be very heavy and difficult to handleLimited range of equipment types available
Safety RequirementsBefore starting work, check that the electrical supply to the power-pack pump is fitted with either a residualcurrent device (RCD) protection, or an isolating transformer, or connected to a monitored-earth circuit.Any extension cords should be checked for current test-tagging.Check the hydraulic hoses are free from damage, deterioration or leaks, and thatthe connections are secure. Always wear the appropriate Personal ProtectiveEquipment (PPE) when using hydraulic tools.
Care, Maintenance and Storage
Check and clean the tools and equipment with a clean dry rag to remove dirt, grime and oil.Clean up any oil spills with oil-absorbent material. Check and top-up the oil in the hydraulic pump before returningthe equipment to the tool chest and storage shelf at the completion of the job, or at the end of the work day.The following problems require repair by a qualified person and should be reported to your supervisor;
Broken, damaged or leaking tools or equipment
Nicks, cuts or leaks in the hydraulic hose
Worn or seized mechanismsLoose or missing parts
IMPORTANT NOTE;Hydraulic equipment uses very high pressures.
Care should be taken to avoid sudden movementof heavy parts or the crushing of limbs.
HANDY HINT;Compressors allow engineers to operate awide range of powerful air powered, light-
weight tools from one central power source.
Air Tool Power SourceThe quality of the air being delivered from the compressor ismaintained by the sequential arrangement of a filter-separator,a regulator and pressure gauge, and an air-oiler.
Clean compressed Air is then piped to the work areas via a network ofplastic or galvanised pipework and valves, and then to the individual airtools via flexible hoses and quick-disconnect couplings.
