C H AP TER 3 Fasteners, Sealants, and Gaskets After studying this chapter, you will be able to: + Identify fasteners used on small gas engines and implements. * Remove and install various fasteners correctly. + Repair or produce internal and external threads. ‘* Properly select and install fasteners. + Remove, select, and install gaskets correctly. Threaded Fasteners ‘Small gas engines and the implements they power are held together by fasteners. There are many kinds of fasteners. See Figure 3-1. Some are common and others are designed to perform special functions. During engine operation, these fasteners may be exposed to conditions such as heating and cooling, cyclic loading, tensile and shearing loads, corrosion, and vibration. pins retaining rings room temperature vulcanizing sealant (RTV) th screws self-tapping screws set screws square nuts taper tap tapping tensile strength thread thread pitch threading through hole toothed washers Unified National Coarse (UNC) series Unified National Fine (UNF) series wide bearing lock washer wing nuts ‘Typical threaded fasteners include screws, bolts, and nuts. The helical portion of a screw or bolt, or the helical portion in the hole or bolt that it fastens to, is called a thread. A thread is an inclined plane that circles the cylindrical bolt or hole. See Figure 3-2. The incline of the bolt or screw thread must be the same as the incline of the thread in the nut or threaded hole into which it is placed. The tightness (tension) of threaded fasteners is very important and will be discussed in the Torque section of this chapter. 53Section 1 Shop Equipment, Supplies, and Safety A thread is an inclined plane wrapped around a cylinder and is called a helix. an disassembling an engine, note the location ts, fasteners, and washers. Care should be during this process so that the parts, fasteners, Washers are put back in the correct locations ring reassembly. When fasteners are badly damaged or worn, replace them with new ones. Lightly fasteners should be cleaned with a wire brush wire wheel and examined for damage, Bolts Bolts are threaded fasteners that hold parts together by squeezing them between the head on ‘one end and a nut on the other end. See Figure 3-3. Bolt Clearance ‘bolt and nut apply great clamping force. Washers are used with nuts and botts. Note the gasket between parts. The hole the bolt passes through is not threaded There should be a small amount of clearance between the bolt and the hole so the bolt does not have to be driven through the hole. Some bolts have an unthreaded portion near the head. The unthreaded portion, or shank, of a bolt should pass through all of the top part and partially through the second component. See Figure 3-4, ‘A lock washer is often placed between the face of the nut and the part surface to prevent loos- ening caused by vibration. A flat washer is often used to provide a smooth and larger clamping surface. This is often necessary when fasteningChapter 3. Fasteners, Sealants, and Gaskets mens Figure 3-4 ‘The unthreaded portion, or shank, of a bolt should pass through all of the top part and partially through the second component. soft materials such as aluminum, plastic, or wood, Washers are covered in detail later in this chapter. ‘After being tightened, a bolt should be long enough to pass through the parts, any washers, and the nut, and protrude 1 1/2-2 threads beyond the nut. Nuts Nuts vary in shape and size depending on their intended function. Plain hexagon nuts are most common type. These nuts have six vertical sides and can be loosened or tightened with stan- dard sockets and box-end wrenches. Other types of nuts used include square nuts, jam nuts, castle nuts, acorn nuts, wing nuts, and various lock nuts. See Figure 3-5, Square nuts are not commonly used, but can be found on old implements. A jant nut is used in conjunction with a plain hexagon nut. The jam nut isa thinner nut used with a plain nut to produce a locking condition of one nut tightening against the other. See Figure 3-6. The castle nut is used on bolts that have a drilled hole through the threaded end. A cotter pin is used to prevent the castle nut from turn- ing. Cotter pins should always be installed prop- erly as shown in Figure 3-7. Castle nuts are used ‘on bolts or shafts when a component turns or pivots on it. They are also used when axial clear- ance is required, such as with axle shafts having tapered roller or ball bearings. Proper adjustment Castellated Figure 3-5, Various kinds of nuts apply clamping pressure on bolts. Plain hex nut __-sam nut GIES ‘Two nuts can be used to prevent loosening of the bolt Ends must tuck in here Cotter pin Best a A ii : Castle nut’ Acceptable B ‘Sharp, loose ‘end dangerous ell Bad c ‘Acotter pin is placed through the castle nut and bolt hole. to prevent the nut from coming off the bolt. Installation method A or B is acceptable. Method A is more dificult to produce, but eliminates sharp ends,is obtained by turning the nut until it makes light contact against the shoulder or flat washer. Back the nut off one slot aligning with the cotter pin hole. Install the cotter pin. Remember, coarse series threads will give greater axial clearance than the fine series threads. Acorn nuts are used to tighten and also cover the sharp thread end of a bolt for safety. Itisimpor- tant when using acorn nuts to be certain that the bolt end does not bottom in the nut before it tight- ens. Acorn nuts get their name from their likeness in shape to oak tree acorns and are often used to provide a smooth, neat appearance. Wing nuts are used when something needs to be frequently adjusted and can be tightened or loosened by hand. Lock nuts are designed to cr ate friction to reduce the tendency for vibration or motion to rotate and loosen the nut. Figure 3-8 illustrates some lock nuts. Bolt and Nut Terminology Bolts and nuts come in various sizes (lengths, diameters, and head size), grades (strengths), and thread types. Being familiar with these differences is important when the need arises to replace nuts and bolts. Important bolt dimensions are: * Bolt size—The major (largest) diameter of the bolt threads. * Bolt head size—The dimension across the flats of the hexagon. It is the same as the wrench size, * Bolt length—The distance from the base of the bolt head to the threaded end of the bolt. * Thread pitch—The number of threads per inch on US. customary fasteners. On metric fasteners itis the distance between each thread measured in millimeters. * Thread length—The length of the portion of the fastener with threads. Bolt Grades Bolt grades are related to the minimum tensile strength specification of the bolt. Tensile strength is the amount of tension, or pulling, force a fastener can withstand before failing, Figure 3-9 shows the tensile strength of various fasteners in pounds per square inch (psi). Bolt heads are often marked with a symbol indicating the grade of the bolt. For example, an SAE Grade 5 bolt has three marks on the head Section 1 Shop Equipment, Supplias, and Safety Palnut Asingle-thread lock ‘ut applied and tightened atter the regular nut isin place Selt-etaining ‘Threads in the section above the slot are deformed to provide a friction grip ‘Anco Esna pin impinges against A fiber collar grips the the bolt to hold the nut bolt threads. Also available in place with a metallic collar Lamson “The raised crown is distorted and heat-treated to give a spring grip on the bolt threads ‘Tinnerman Speed Nut Spin-lock Flexloc Ratchet-shaped, ‘Segments press against the serrated teeth bolt threads because the ‘embedded in the work provide a friction grip inner diameter of the upper part is slightly less than the outside diameter of the bolt Examples of common lock nuts. A Grade 6 bolt has four marks on the head. In every case, the number of marks on the head is 2 less than the grade number. Grade 1 and 2 bolts have no marks on the head. Metric bolt heads are marked with 5D, 8G, 10K, 12K. See Figure 3-9 for corresponding tensile strengths.hapter'd. Fasteners, Sealants, and Gaskets SAE Standard/Foot-Pounds Metric Standard Grade off SAE | SAE | SAE | SAE Grade of pot |1a2| 5 | 6 | 8 Bolt eo eB tO aa in Ten, [64000 | 05,000 [185000 | 150,000 Min. Ten 71.160 119.800] 142,200 170.670 Strength |PSi. [Psi esi. {esi Strength Psi (psi [Psi |Psh Size of Sie of Markings Sockat or [Markings Socket or cartons | | BD | BH | BD fever” fonts §— | D | BD | BD | BD fives Opening pening us. US. Regular ea Fy Metric Metric Foot Pounds Foot Pounds Bot Bot Jy [Bot ]usDee Bor Dia. (in) Head |“ Joa [eau Head 14 5] 7 [0 | 15 [oa [rte | emm|oace | 5s] 6 [| @ | 10 [10mm sie | 8 | [19 | 2 [ie [ane | amm|arso0 | 10 | 16 | 22 | a7 [tam 38 15 | 25 | 9 | a7 [ane [se [tonm|aeer | 10 | 31 | 40 | 49 lt7mm me || 4 | 55 | 60 [se [a4 |ramm|azo | a4 | se | 70 | 86 [10mm | 37 | 60 | es | «2 [os |rare|imm|ssie | s5 | e9 | 117 | 197 [eam one | 5 | 88 | 120 | 192 |7@ |v [vemm|easo | e9 | 192 | 175 | 200 [2amm 5 74 120 | 167 | 100 [156 [1 |1omm|7o90 | 117 | 182 | 296 | 283 [27mm a4 [120 | 200 | 260 | 296 [1-178 |1-v8|2amm|.e66; | v2 | 284 | 90¢ | 464 [sam General bolt torque chart. Torque values increase as bolt size and grade increases, ue specifications listed in Figure 3-9 are ate guidelines only and may vary depending tions, such as amount and type of lubricant, Plating on bolt, etc. It should be understood that the load applied to the bolt due to tightening (primary load) cou- pled with the external (secondary) load exerted upon it could exceed the tensile limits of the bolt, An external load could be applied as a result of pulling, lifting a load, and/or heat expansion, When a bolt reaches its load bearing limit it becomes weaker, exceeds its elastic limit, and begins to stretch plastically. When a bolt stretches plastically it does not return to its original length or shape when the load is released. A bolt that has been stretched may appear to be loose or show signs of leakage at a gasket, Unknowingly, one might try to retighten the bolt. This stretches it, weakens it more, and will result in the bolt failing in service or breaking during the tightening. Thread Types Figure 3-10 illustrates various parts of a thread. ‘There are several types, or series, of threads of com- mercial importance. Only three are of significance for the purpose of this text. The first type is the Unified National Coarse (UNC) series. Fasteners with UNC threads are for general use where they are not subjected to vibration. The second type is the Unified National Fine (UNP) series. Fasteners with UNF threads are for ‘work where vibration is a considerable factor, such as automotive and aircraft applications. UNC and UNP refer to the number of threads per inch of length on threaded fasteners. Every bolt or nut diameter will have a specific number of threads per inch of length. For example, a 1/2” diameter Uni- fied National Coarse bolt or nut will always have 13 threads per inch of length. A Unified National Fine thread of the same diameter will always have 20 threads per inch. The diameter referred to in the thread specification is always the major (largest) diameter of the thread of the bolt or nutThread depth cag Root, Crest tL angle 60° zh aa0 Bes r se8 et} elke 45° chamfer 1 Pitch = No. thds, per in. Internal Lead ~ advance for 360° External Thread terminology for external and internal threads, The third type is the metric (M) series. The metric thread is formed with a 60° angle, which is similar to the unified threads. ‘The International Standards Organization (ISO) has attempted to standardize metric threads. The ISO metric thread series has 25 thread diameters ranging from 1.6 millimeters (mm) to 100mm. ‘Threads are either right-handed or left-handed. A fastener with righthanded threads must be turned clockwise to tighten it. A fastener with left- handed threads must be turned counterclockwise to tighten it, The letter L may be stamped on the fastener with left-handed threads. of a nut or threaded hole must always be ies, size, and type as that of the bolt ing it If they are not the same, thread damage will occur. Thread Fit Some fastener applications can tolerate loose fitting threads. Other applications may require closer fitting, or tight threads. For example, the head on a gasoline engine may be held to the engine block with stud bolts, which are threaded on both ends. See Figure 3-11. One end of the stud bolt is threaded into the engine block. The other end receives a nut that tightens against Section 1 Shop Equipment, Supplies, and Safety Stud bolts are threaded at both ends. the cylinder head. It is desirable to have the stud bolt remain in the engine block when the nut is removed. The block end requires a tighter fitting thread than the nut end. If the fit of the nut is too tight, the entire stud may be removed from the block when the nut is turned with a wrench. In some cases, a UNF thread is used in the block and a UNC thread on the nut end. Unified threads are classified as external or inter- nal, and according to classification of fit as follows: * Class 1 Fit—Has the largest manufacturing tolerance. Used where ease of assembly is desired and a loose thread is not objectionable. * Class 2 Fit—Used on the largest percentage of threaded fasteners. + Class 3 FitWill be tight when assembled. Thread Designations The thread designation is a series of numbers and letters used to describe a bolt and thread. ForChapter’3. Fasteners, Sealants, and Gaskets example, the designation of 1/2-13 UNC-2A x Tis defined as follows: * 1/2—Indicates the thread diameter. In this case, the diameter is 1/2" + 13-—Indicates the threads per inch. In this case, there are 13. + UNC—Indicates the series of thread. In this case, itis a Unified National Coarse thread. The letters UNF specify a Unified National Fine thread. * 2-Indicates the class of fit.In this case, a 2 indicates a class fit. The number 1 specifies a class 1 fit and 3 specifies a class 3 fit. + A-Indicates that it is an external or internal thread. In this case, an A indicates an external thread. The letter B would indicate an internal thread, such as a nut or threaded hole, ‘+ 1This number indicates the length of the fastener in inches. In this case, the fastener is Y" long. A letter Lat the far right of thread designa- tion indicates left-handed threads. For example, 1/4-20 UNC-2A L is a left-handed thread. If the Lis not present, the thread is understood to be right-handed. Metric thread designations are slightly dif ferent. For example, the metric designation of M-10 x 1.5 x 25 is defined as follows: + M-Indicates that the thread is metric. ‘+ 10—Indicates the diameter of the thread in millimeters. In this case, the diameter is 12mm. + 1.5—Indicates the distance between threads (pitch). In this case, the pitch is 1.5mm. ‘+ 25—Indicates the length of the fastener in millimeters. In this case, the length is 25mm, Screws Screws are threaded fasteners that hold parts together by passing through one part and thread- ing into another. See Figure 3-12. The screws most commonly used in small engines and related implements have hexagonal heads that allow the use of hexagonal sockets and box wrenches for tightening and loosening. Screws with round heads require an appropriate screwdriver or Allen ‘wrench to turn them. The most common screw heads are shown in Figure 3-13. Notice that each head has a particular name that identifies the head type. Screws may be threaded all the way to the head. | ——Nonthreaded part _-Screw | Threaded part Bottom clearance Gee This screw passes through one part and threads into the mating part. Note the clearance at the bottom of the hole, PECOSS Gtuol w LU Hex Round Filister Hex Oval Flat Head Head Head Socket Head Head cE: ‘Common types of screw heads. Machine screws are externally threaded fas- teners that are used in threaded holes, but they are also used with a nut. Most machine screws have round heads that accept a screwdriver or Allen wrench. Cap screws are similar to machine screws but they often have hexagonal heads. ‘These screws are similar to bolts, but they are smaller in diameter and are often manufactured to tighter tolerances.Set screws are heat-treated, hardened alloy steel fasteners that are used to secure rotating, components, such things as pulleys and shafts, in relation to each other. See Figure 3-14. The com- mon set screw head types are square, slotted hexa- gon socket, and fluted socket. The set screw points may be flat, cup, cone, half dog, or full dog. See Figure 3-15. Flat points are used when clamping. friction alone is enough to hold the part without deforming its surface. Cup and cone point set screws cut into the surface of the shaft or part to prevent motion or rotation. Dog point set screws are designed to positively lock into a pre-drilled hole in a shaft matching the diameter of the dog. See Figure 3-16. A variety of self-tapping screws are shown in Figure 3-17. Selftapping screws are fasteners that will cut their own threads in a predrilled hole of the appropriate size. Self-tapping screws have a Recess in shaft ‘Shaft Figure 3-14, Sot screws lock pulleys and gears to shafts to prevent rotation of the shaft in the hole. Note the recessed. area on the shaft ‘Section 1 Shop Equipment, Supplies, and Safety grooved, tapered point that forms threads in the hole. Self-tapping screws are harciened steel because they perform as a cutting tool as well as a fastener. ‘Common types of set screw heads and points. Set sorews are made of hardened steel Dog point ‘The dog point of this screw fits in a hole in the shaftChapter Fasteners, Sealants, and Gaskets qV 4 For fastening For plastics. Note For metals and all types and double siot. plastics. Note coarse lead. rather than cuts, thickness of metal multiple slots. threads, For sheet metal For sheet metal For heavy gage sheet up to 18 gage, up to 6 gage, metal, castings, structural plywood, asbestos, nonferrous castings, steel, plastics, and ‘and composition plastics, plywood, plywood, materials, asbestos, and ‘composition materials. For plastics. Has. For metals. Forms, Figure 3-17. Selt-tapping screws cut, or form, their own threads. Tightening and Loosening Threaded Fasteners Aspreviously mentioned, ifa bolt, nut, or screw has right-handed threads, the direction for tighten- ing is always clockwise and the direction for loos- ening is always counterclockwise. For beginners, this can be particularly difficult to understand if, the bolt, nut, or screw is in the inverted (upside- down) position on an engine or implement. If the technician is not careful, the head of the fastener may be twisted off by attempting to turn it the wrong direction. Tightening to Specific Torque Settings Tightening bolts, nuts, and screws on engines should be done with a torque wrench. These fas- teners should be tightened to specific torque (turn- ing effort) settings. See torque charts for fractional and metric size bolts in Figure 3-9, Removing Broken Fasteners Occasionally, a bolt will break off during removal or installation. When this happens, the broken portion of the fastener that remains in the hole must be removed. If the broken fastener pro- trudes from the hole, it can sometimes be removed. using vise grips or a small pipe wrench. In some cases, a bolt that breaks off flush with the hole can be backed out of the hole by driving it counter- clockwise using a hammer and a small punch. Fasteners that break off even with or below the surface of the hole are commonly removed using a screw extractor. Before the extractor is used, a hole approximately one-half the diameter of the bolt is drilled at the top center of the broken fastener. The extractor, which has many spirals, is then tapped into the hole with a hammer. The spirals on the extractor cause it to wedge tightly in the bolt. A wrench or socket is then applied to the hex head of the extractor and the broken bolt is backed out. See Figure 3-18, Chasing Threads When threads become damaged in a nut or threaded hole, it may be necessary to recut the threads with a tool called a threading tap. See Figure 3-19. This procedure is called chasing the thread. If the hole goes all the way through, it is called a through hole. The threaded hole in a nut is, an example of a through hole. In the case of a nut, select a tap designated to fit the existing thread. If the existing thread is 1/2-13 UNC, then select a tap designated 1/2-13 UNC. This designation will be stamped on the tap shank of the tap.Removing a broken bolt. A—Drill a hole in the center of the bokeh bol, Use hammer to tep the scrast™ in he ied hoe Gao a wrengn etn fe extractor. This will back the broken boit out of the hole. < 3 a 2: 3 g 5 6 2 2 € 2 2 s = = < B = a & 2 2 = a oO a 30° A B c D Taps are tools for cutting threads in holes. For biind holes, the taper tap should be used firs, followed by the plug tap, and then the bottom tap. For a through hole, a taper tap should be used. A taper tap has a slender taper at the beginning of the tap that makes it start easier in the threads, Select a tap wrench to turn the tap. Secure the square end of the tap in the wrench. You must decide whether Section 1 Shop Equipment, Supplies, and Safety the part can be secured in a vise or whether it can be done in place. A small item can be clamped in a vise to hold it. See Figure 3-20. Add a few drops of cutting cilon the tap before beginning, This will improve the cutting action and produce better threads. Align the tap with the hole and turn it clockwise (righthanded threads) until the tap turns freely. Then, reverse the rotation until the tap can be removed. If bolt or screw threads are damaged, they can be chased witha threading die held ina die holder. Place the bolt head in a vise. Select the correct die that corresponds to the thread of the bolt. If the thread type is not known, determine it by measur- ing the major diameter of the thread, and counting, the number of threads per lineal inch. If the bolt diameter is 3/8” and there are 16 threads per inch, it is a 3/8-16 UNC thread. Select a corresponding die. Now, place the die in a die handle and secure it with the set screws. See Figure 3-21. The correct side of the die must face the threads when start- ing the die. The correct side has tapered teeth near the edge of the die. Using the correct side of the die makes starting easier and places the cutting ‘edges of the teeth cut in the proper direction. Place some cutting oil on the die teeth and on the bolt threads. Place the die on the end of the bolt and Tap wrench Keep tap square Tap with hole Use lubrication _ when required Work Taps fit into a special tap wrench. The tap must be held straight with the hole as itis tured into the work. Turn the wrench clockwise 2/3 of one turn, back it up 1/3 of one tur, and repeat the process. Use cutting fluid on the tap.Chapter Fasteners, Sealants, and Gaskeis, Die teeth, Die Stock Depression Adjustment “ screw Treading is are used to ct extemal heads. The de ‘rlnored ina wrench eae is sleck The cones Ieelnofine de shoul be started ono vod or bat ~ ~Set screw begin turning it clockwise (right-handed threads) to cutand correct the threads. Now, reverse the die rotation until it can be removed from the bolt: Internal Thread Repair When internal threads are damaged, they can often be repaired using a tap. If the threads are severely damaged, other repair methods can be used. One method involves drilling out the old threads and tapping to hole to a larger thread size, ‘Another method involves using a patented heli- cal insert to form new threads. First, the damaged threads are drilled out of the hole. Then the hole is tapped to accept the insert, Finally, the insert is installed in the tapped hole, restoring the threaded hole tots original size and condition. See Figure 3-22. Tapping New Threads Tapping is the process of cutting threads in a hole. The procedure of tapping new threads is, similar to that of chasing threads. Prior to tapping, however, a new hole must be drilled to the proper diameter. The proper diameter is obtained using an appropriate tap drill chart. Tap drill charts for both standard and metric taps are included in the appendix of this textbook Rules for Hand Tapping The following rules should be followed when tapping new threads. + Use a good cutting fluid, except when tapping, gray cast iron, which should be tapped dry. A f B c / D Ropatrng damaged threads using aheica insert. peeps tthe Samages twosde 8. Tap to hole. C—Install the insert on the supplied mandrel. D—Serew the insert into the tapped hole. + For through holes, start and end with a taper tap. + Forblind holes (holes that do not go all the way through the material), start with a taper tap or a plug tap, followed with a bottom tap. Be careful to start the tap straight in the hole. The tap wrench should be turned clockwise two-thirds of a turn then reversed one-third of a tur to break and clear the chips. Continue this through, or to the bottom of, the hole. + Never use excessive force fo turn a tap. hard and brittle, and can break when ing a broken tap can be difficult, or 1¢ smaller the tap, the easier it will break. Threading with a Die Threading is the process of making external threads on an external cylindrical surface, such as a rod, bolt, shaft, or pin. A cutting tool called a die is used in a die handle called a die stock. See Figure 3-21. The threading procedure is the same as for tapping. The diameter of the rod mustbe the same as the major diameter of the thread. Select the die. Ifthe die is of the split type, it can be opened with the adjustment screw for the first cut and then adjusted down to the desired fit in the threaded hole. Place the die in the die stock so that the set screws align with the depressions along the edge of the die. Tighten the set screws. Start the die on the correct sicle and keep it perpendicular to the centerline of the rod. A good cutting fluid should be used on the die teeth. Washers Flat washers are used to provide a wider bearing surface for a bolt or screw head and/or nut. When tightening a bolt or screw against a relatively soft material such as wood, plastic, and soft metals (like aluminum, copper, or brass), the head may gradually become embedded in the surface. This may cause the fastener to become loose during use. A flat washer tends to prevent embedding and provides a harder surface for the bolt or screw head to pull against. See Figure 3-23. Lock washers prevent loosening of bolts, screws, and nuts. There are many kinds to choose from. The most common lock washer used with nuts is the kantlink washer. It is made of spring steel and has beveled ends. The slight helix of the ‘washer tends to cut into the mating surfaces of the nut and the component. When the nut is tightened the washer is compressed flat. The tendency of the nut to reverse rotation causes the beveled ends of the washer to dig into the mating surfaces. This prevents further loosening of the fastener. ‘The wide bearing lock washer combines the characteristics of a flat washer and a kantlink lock washer. It provides the hard surface for the bolt @ Flat Kantlink Wide Bearing External Internal External-Internal, ‘Common washers of several sizes and shapes, Section 1 Shop Equipment, Supplies, and Safety or screw head to pull against, like a flat washer. It also provides beveled ends that are characteristic of the kantlink washer. Multiple toothed washers are stamped from sheet metal and have internal, external, or external- internal teeth. This type of washer is used under the heads of screws to prevent them from backing out. The teeth are twisted to resist rotation in the direction that would cause loosening of the screw. Pins Pins are used to either retain parts ina fixed posi- tion or to preserve alignment of parts. Figure 3-24 illustrates several types of pins that may be found ‘on some gasoline engines or related implements. Cotter Pins Cotter pins are sized by a nominal dimension, such as 3/32”. The hole size for a cotter pin should be slightly larger than the nominal size of the pin. Cotter pins are used to lock castle nuts and secure clevis pins. Cotter pins should be installed prop- erly as shown in Figure 3-7. Cotter pins may be made of steel, copper, brass, aluminum, or stainless steel. They can be cut to length with side-cutting pliers. They can be bent with combination, slip joint, or needle nose pliers. They can be tapped lightly with a soft hammer to form them. Ground Dowel Pins Straight Pins —} ag) E levis Pins Grooved Pins Taper Pins Cotter Pins Pins are used to hold parts together in an assembly.Chapter 3 Fasteners, Sealants, and Gaskets, \g reassembly, old cotter pins should be replaced ;new ones. Clevis Pins Clevis pins function as an axle so a part can swivel on it. It requires a flat washer and cotter pin to prevent the part from sliding off the pin. Dowel Pins Dowel pins are used for alignment and usually fit very snugly. They are heat treated and hard- ened. The dowel pin is pressed into a hole with an interference fit. The mating part has a matching, hole that fits closely to the pin but allows the part to be assembled or disassembled easily. Straight Pins Straight pins are also used for alignment. They fit closely, but are not usually an interference fit. Grooved Pins Grooved pins are driven into an interference hole. The groove cuts into the wall of the hole and secures the pin. There are several types of grooved pins. Each type hasa different shape, and each has a different size and shape of groove. See Figure 3-25. Taper Pins Taper pins havea uniform taper along the entire length of the pin. Each end is rounded slightly. Taper pins are generally used to fasten pulleys and gears to shafts, preventing rotation of the component on the shaft. Taper pins fit into tapered holes that match the two mating parts. The taper pin is held in the hole by tapping it into the tapered holes, thus wedging it tightly in place. When tapped tightly into the mating parts, the taper pin does not extend beyond the holes. The taper pin can be removed by inserting a pin punch in the small end of the hole and striking the punch with a hammer to drive the pin out. Taper pins are designated by pin size num- ber and standard lengths. Wea ee SS C=] ‘Type B Type F SS Type C = G === “ype Groove pins come in several types. Rolled Pins Rolled pins are used in similar fashion to grooved pins. Rolled pins are made of tough, spring steel. ‘They are straightand available in various lengths and fractional diameters. A 3/16” rolled pin will providea tight interference fit in a 3/16” diameter drilled hole. Rolled pins can be driven into place with an oversize pin punch and driven out with a punch equal to or slightly smaller than the pin diameter. Retaining Rings Retaining rings are circular spring steel fas- teners that fit externally or internally into a groove ina part, An external retaining ring is placed in a groove that is machined into the surface of a shaft. An internal retaining ring fits into a groove cut ina cylindrical hole. There are several types of retaining rings. See Figure 3-26. QOQE External E Type External Hole Internal Hole Internal Prong a Retaining rings may be internal or external,Retaining rings are used to prevent lateral (endwise) movement of shafts in a hole, At the same time, the retaining ring does not prevent the shaft from rotating in the hole. Most retaining rings must be installed and removed with a retaining ring tool, also known as snap ring pliers. See Figure 3-27. The tool has nibs that fit into the small holes at the ends of the rings. When Section 1 Shop Equipment, Supplies, and Safety Key, _ Keyway Keyseat _ the handles of the plier-like tool are squeezed, inter- (LTE SI nal rings are compressed inward and made smaller so they can be installed in the cylinder and. groove. External rings are forced open so they can be slid over the shaft and into the groove. The reverse action is used for removal. Retaining rings are very strong and require extreme care when installing and removing, Safety glasses with side shields must always be worn when installing or removing retaining rings. Rings can easily sip off the nibs of the tool and can fly with considerable velocity Keys Keys are used almost exclusively on shafts that have a component which fits and rotates with the shaft, The recess in the shaft is called the keyseat. The groove in the pulley, gear, or collar is the key- way. See Figure 3-28. Retaining _fing tool “Oo Retaining ring too! Gro A special plier-lke tool is required to install some retaining rings. The nibs are inserted in holes in the ring to expand or close the ring ‘The key rests in keyseat of the shatt. The keyway is located in the surrounding part. An example is the flywheel on the crankshaft of a small gas engine. The key must fit the keyseat and keyway closely to prevent motion between them. Engine flywheel keys keep the engine tim- ing correct. Several key types are used as shown in Figure 3-29. Adhesives and Sealants Many types of adhesives and sealants can be encountered when working with small engines. These products have varying properties. Both adhesives and sealants are either a liquid or semi liquid material. They can be sprayed, brushed, or spread on. Some of these adhesives and sealants set up hard, while others remain pliable. The sec- tions that follow detail some of these adhesives and sealants. Thread Adhesives Thread adhesives can be applied to the threads of nuts, bolts, or screws to prevent them from loos- ening during service. Adhesive strengths vary from light (removable) to high strength (that might require applied heat to remove). Only a drop of adhesive on the thread prior to fastening is needed See Figure 3-30. The adhesive cures once the threads are mated. This locks the mating threads together. Complete cure time may vary from 30 minutes to 24 hours. There are other uses for these adhe- sives, such as fastening bearings, bushings, gears, and sleeves on shafts.Chaptor 3 Fasteners, Sealants, and Gaskets Oe CE vp ‘Square Key Grib Head Key Pratt & Whitney Key Woodruff Key Figure 3-29. Keys used to connect a shaft to a pulley, gear, or wheal. ‘Adhesive = ‘A drop of thread adhesive can be placed on the thread to lock a screw or nut. ‘Always read health warning labels on adhesive containers. ‘Adhesives may contain chemicals that can cause injury to eyes, lungs, and other parts of the body. Always follow the manufacturer's recommended procedures. Sealants Most sealants are resistant to oil, water, gas, grease, and salt solutions. Resistance to hot and cold conditions varies. Most sealants can be used for all applications except for use on the exhaust system. Special high- ‘temperature sealants are used for exhaust systems. Form-in-place sealants can be used in place of conventional gaskets (gaskets are covered later in this chapter). This type of sealant can be used when the exact replacement gasket is not available. Room temperature vulcanizing sealant (RTV) is a form-in-place sealant that is also referred to as silicon sealant. It can be used on both flexible and rigid mating surfaces, Anaerobic sealants are similar to RTV, but they can cure in the absence of ait. This type of sealant can be used asa thread locking material or between two machined surfaces. familiar with the sealants you use. Know the ies of the sealants and their recommended uses. Antiseize Compounds Antiseize compounds are applied to threaded fasteners and metal components that are exposed to constant heat. The compound is a lubricant that prevents the metal material from being cold welded together. If a threaded fastener and its connecting, metal component are cold welded, then removal of the fastener will be impossible. The antiseize com- pounds should be applied to the threads or theSummary —— Many fasteners are used in the assembly of small gasoline engines and the implements they drive. Most, but not all, are threaded fasteners, Fasteners are exposed to conditions such as heating and cooling, cyclic loading, tensile and shear loads, corrosion, and vibration during engine operation. Helical portions of screws and bolts are called threads. When disassembling an engine, all parts, fasteners, and washers should be noted so they can be replaced in proper locations. Damaged fasteners should be replaced with new ones. Lightly rusted fasteners may be cleaned and examined for reuse. Alll threaded fasteners should be lubricated before installing, Bolts are threaded fasteners that hold parts together by squeezing them between the bolt head on one end and a nut on the other. A lock washer is often placed between the face of the nut and the part surface to prevent loosening caused by vibration. Nuts vary in shape and size, depending upon their intended function. Plain hexagon nuts are the most common. Other types are wing nuts, castle nuts, acorn nuts, jam nuts, and various self- locking nuts, Bolt terminology includes major diameter, head size, length, and thread pitch. Bolt grades are related to the minimum tensile strength of the bolt. Bolt heads are marked with symbols to identify grade. Thread types of significance for small gas engines are Unified National Coarse (UNC), Unified National Fine (UNF), and metric (M). Threads of a bolt or screw must be the same as the mating thread in the hole or nut. Threads are identified by a thread designation such as 1/2-13 UNC-2A for standard threads and M10 x 15 x 25 for metric threads. Screws hold parts together by passing through one part and threading into another. Machine screws and cap screws are commonly used on small engines. Set screws are heat treated, hardened-alloy steel used to secure pulleys, gears, and shafts. They have a variety of heads and points, Self-tapping screws are hardened steel and cut their own threads in a predrilled hole of proper size. Tightening bolts, nuts, and screws on engines should be done with a torque wrench toa specified tightness obtained from a torque chart. Section 1 Shop Equipment, Supplies, and Safety Threads can be repaired by chasing them with athreading tap for holes, or a threading die for bolts and screws. When tapping new threads, the proper size hole must first be drilled, as determined from a tap drill chart. Proper tapping and threading procedures must be applied to avoid breaking a tap in the hole. Flat washers are used to provide a bearing surface for bolt and screw heads and nuts. Various types of lock washers prevent loosening of bolts and screws. Cotter pins are used to secure castle nuts and dlevis pins. Dowel pins and straight pins are used for alignment of parts and should fit quite snugly. Grooved pins are driven into interference fit holes. The grooves are cut into the walls of the hole to secure the pin. Taper pins have a taper along their entire length. They are used to fasten pulleys and gears to shafts to prevent slipping around the shaft. Retaining rings are circular spring steel fasteners that fit into a groove around a shaft or ina hole. They require a special plier-like tool to install and remove. Keys are used on shafts that havea gear, pulley, or sleeve that fits and rotates with the shaft. The key rests in a keyseat and keyway. Many types of adhesives and sealants are used on engines and implements. Thread adhesives are used to prevent threaded fasteners from loosening due to vibration. Some liquid sealants are used to prevent leakage between the parts. It is important to use the correct sealant as specified by the manufacturer. Antiseize compounds are lubricants, that prevent parts from locking together. Gaskets seal between engine parts to prevent leakage of engine oil, coolant, compression, and vacuum, Gaskets are made of soft, pliable materials, that are die cut to fit the shapes of surfaces they seal. Selecting the correct material, shape, and thickness is important when replacing a gasket. Following the proper procedures when installing gaskets will prevent gasket failure. Review Questions a es Answer the following questions on a separate sheet of paper. 1. The helical portion of a screw or bolt, or the helix in a hole that it fastens into, is called a(n)Chapter 3 Fasteners, Sealants, and Gaskets 10. U1. 2, 13, 4. 15. 16. V7. 18, 19, 20. The unthreaded part of a bolt or screw is called the The helical portion of a bolt or screw is called the . A type of hardened screw that makes its own threads, usually found in sheet metal, is a(n) screw. . Name the four common head types for set screws . Name the six types of points found on set screws. The term bolt implies the use of a(n) Jam nuts are usually used with Answer the following about the thread notation given below: 3/8-16 UNC 1A, ‘The major diameter of the thread is How many threads per lineal inch are there? Is the thread coarse or fine? Is the thread internal or external? Is the thread a loose, average, or close fit? The proper thread notation for a 14 millimeter thread with a 15 millimeter pitch on a screw that is 40 millimeters long is nuts, moOOe> The process of cutting new threads in a hole is called For cutting threads in a through hole, the proper tap to use would be a(n) tap. ‘The cutting tool used to cut external threads is called a To provide a wider bearing surface for a bolt head or nut, a(n) or washer should be used. Ifa 1/8” rolled pin is to be used in a shaft, the correct drill size to use for drilling the hole for this pin should be diameter. What fasteners are used to lock castle nuts? steel. Retaining rings are made of. can be applied to the threads of nuts, bolts, or screws to prevent them from loosening during service. are used between engine parts to seal and prevent leakage of engine oil, coolant, compression, and vacuum When tightening bolts on an engine head use a(n) pattern unless a different pattern is specified by the manufacturer Suggested Activities 1. Make a collection of fasteners for a display board. Categorize and label each. 2. Explore the shop and identify as many different kinds of screws, bolts, nuts, and washers as you can, List them and the function of each kind. Identify UNC and UNF taps and dies. Identify the correct side to start a threading die. Identify taper, plug, and bottom taps. Chase threads on a damaged bolt. Chase threads on a nut, 7. Select the proper tap drill for a screw and drill a blind hole about 3/4” deep in a piece of mild steel. Tap threads to the bottom of the hole using the proper procedure and sequence of taps. If you have never tapped threads before, to avoid breakage, select a screw size 3/8” or more in diameter. 8. Make a display of keys and pins. 9. Display proper and improper installations of cotter pins. 10, Demonstrate proper installation of a gasket 11. Demonstrate the proper technique for tightening engine head bolts. Demonstrate the proper way to torque engine head bolts.72 Section 1 Shop Equipment, Supplies, and Safety This generator is a perfect example of how small gas engines are used today. (Honda)C HAPTER 8 Fasteners, Sealants, and Gaskets Name Date Class Learning Objectives After studying this chapter, you will be able to: * Identify fasteners used on small gas engines and implements. * Remove and install various fasteners correctly. * Repair or produce internal and external threads. * Properly select and install fasteners. * Remove, select, and install gaskets correctly. Instructions: After studying the chapter, complete the following questions and problems 1. List at least four of the various conditions to which fasteners are exposed during service. 2. A thread is an inclined ____ that. circles a bolt or hole. 2 3. Identify the bolt and screw heads illustrated below. 3. A. a a B. a @SG060 e— D.__ E. fe iow A B F 4. Cutting threads in a hole is a process called ___. 4, Copyightty The GoodheartNtiox Co ne Small Gas Engines Workbook 1710. nL 2, 1B. u. 16, 16. W 18 The unthreaded hole that a bolt or screw passes through should have a small amount of ___. The unthreaded portion of a bolt is called the A wider bearing surface can be provided for a bolt by adding a(n) under the head. Identify the nuts illustrated below. When axial clearance is required, such as with some bearings on shafts, a(n) nut and a cotter pin should be used. A(n) __nut can be used when a part is subjected to continuous vibration that might loosen the nut. Bolt grades relate to the minimum. strength of the bolt. When a bolt reaches its load bearing limit, it begins to and stretch, A. crack B. weaken C. bend D. None of the above. The markings on the heads of bolts are indicators of their. A bolt’s rated tensile strength is given in per square inch. ‘The largest diameter of a thread is called the diameter. The number of threads per inch on standard American threads is called the of the thread. A. pitch B. crest C. shank Dz tensile A thread with the greatest allowable manufacturing tolerance would be a Class fit. Small Gas Engines Workbook 10. u. 12, 13, 14, 15. 16. = ROO & > ‘Copyright ty The Goodhaart Wilcox Co, ine.Chapter 3 Fasteners, Sealants, and Gaskets Name 18. The fit that is found on most common fasteners is a 18. Class 19, A thread specified as a 3/8-24 UNF-2A x1 would be 19. a(n) thread with threads per inch and the fastener would be__long. 20. A thread designated as M-10 x 1.5 x 30 indicates it is 20. its diameter is__and the pitch is, 21. In order to tighten a right-hand screw or bolt ina 21. a threaded hole, it must be turned __ 22. If the threads in a hole are damaged, they can be recut. 22 by a process called__. 23. The tool used for cutting external threads isa thread. 23. 24. The correct drill size for tapping a new hole can be 24, found ina tap drill 25, The tool that holds a die for cutting external threads is 25, called a(n) 26. When cutting external threads with a die itisimportant 26. that the die be started on the correct side and that a good be used. 27, Using the tap drill chart in the appendix of this text, 27. determine the correct drill size for making a 3/8-16 UNC2B thread. 28. According to the tap drill chart in the appendix of this 28. text, the correct drill size for an M6 x 1 thread is a(n) drill. 29. Explain why a flat washer is used when tightening a bolt or screw against a relatively soft material. 30, The most commonly used lock washer is the 30. washer made of spring steel with beveled ends, 31 are used to retain parts in a fixed position or 31. maintain alignment. A. Pins B. Bolts C. Nails D. None of the above. Copght by The Goodneart-Wllzox Co, Ino. Small Gas Engines Workbook 1932. Identify the pins illustrated below. 32. AL = . D. — fa B E FE c F 33. Threaded fasteners can be protected from loosening 33. from vibration by applying a thread 34. Most sealants are resistant to. 34. ‘A. water and gasoline B. oiland salt C. grease D. Allof the above. 35. When threads are exposed to constantheating and cooling § 38. conditions, they can be kept from being cold welded together through the application of ___ compounds. 36, Gaskets are used between engine parts to preventleakage 36. of___. ‘A. engine oil and coolant B. vacuum C. compression D. Allof the above. 37, List the ten rules for properly installing gaskets. 20 Small Gas Engines Workbook Copyightby The Goodhear Wilox Co, In.Chapter 3 Fasteners, Sealants, and Gaskets Name Research and write complete answers to the following questions. 38. Why should head gasket bolts be tightened in a crisscross sequence? 39, Explain in some detail why there are so many different kinds of fasteners and fastener accessories. Describe the kinds of forces to which fasteners are often exposed, 40. Describe why it is so important to torque critical fasteners to specific tightness. What can occur if bolts are not torqued properly? Explain ductility, hardness, temper, and tensile and yield strength. ‘Copyright by The Goochear-Wiex Co, Inc. Small Gas Engines Workbook 2122 Small Gas Engines Workbook