Unit 3: Connective Devices

UNIT 3
Connective Devices

Unit Objectives:

At the completion of this unit each student will be able to:

- Identify the different types of fasteners used in our field
- Distinguish between the different types of seals and hoses used in
our industry.
- Identify the different types of bearings used in our field.

Unit References:

Threaded Inserts SESV0097*

Heli Coil Inserts SESV0156*
Identifying Fasteners (Pamphlet) SEEV0527
An Introduction to Seals and Gaskets SEBV0511
An Introduction to Bearings SEBV0507

* Print from Supplemental Material on Caterpillar Service Industry

CD ROM

Materials:

Various fasteners used in the shop

Various Seals, O-rings and sealants used in the shop
Various bearings used in the shop
NOTES
 Lesson 1: Fasteners
Lesson 1: Fasteners

Introduction:
Caterpillar uses many different types of fasteners on our machines
and engines, both metric and standard. Technicians will have to be
able to distinguish between sizes and types to be productive.
Objective:
After completing this lesson the student will be able to identify the
different types of fasteners used in our field.
References:
Threaded Inserts SESV0097*
Heli Coil Inserts SESV0156*
Identifying Fasteners (Pamphlet) SEEV0527

* Print from Supplemental Material on Caterpillar Service Industry

CD ROM

Materials:

Various fasteners used in the shop

Unit 3 3-1-2 Caterpillar Service Industry
Lesson 1

Fig. 3.1.1 and 3.1.2 Bolts, Nuts

Bolts, Nuts
Bolts are generally made of steel, stainless steel, or brass. A bolt is
made of a rod with threads on one end and a head on the other end.
The threads can have either deep grooves to make coarse threads or
fine grooves to make fine threads. The head on a standard bolt has
flat sides in an arrangement so that a wrench can be used to turn the
bolt. Bolt length is measured from the bottom of the head to the end
of the bolt. Bolt size is the outside diameter of the threads of the
bolt. The grip length is the section of the bolt between the bottom of
the head and where the threads start. The grip length has no threads.
Bolts can be made to have different strengths. The lowest strength
bolts are "grade 1." The bolt with the most strength is above "grade
8" and has seven radial marks (slashes) on the head of the bolt for
identification.
This fastener is used to hold components in a specific position.
These components must have a hole large enough to fit around the
bolt but smaller than the bolt head. The last component put on each
bolt must have inside (internal) threads that are the same as (match)
the bolt threads. This end fixture can be turned tight with a wrench
on the bolt head. Bolts get their ability to hold when they are turned
tight. This makes the bolt a little longer (stretch) and puts all of the
components between the head and the end fixture under compression.
The amount of torque to put on a bolt when it is tightened is found in
assembly manuals. Bolts with fine threads are used if a specific
torque is very important or the bolt is used for fine adjustment.
Unit 3 3-1-3 Caterpillar Service Industry
Lesson 1

Some bolts must have special characteristics for a specific

application. Some bolts must have corrosion resistance, extra high
tensile strength, special heads, or some other special characteristic.
Check assembly manuals for correct bolt selection. Make sure that
enough bolt threads are turned into the end fixture to hold all of the
components solidly when the bolt is tight. Check assembly manuals
to be sure that the bolt is tightened to the correct torque. Use the
correct tool to tighten or loosen bolts.

Fig. 3.1.3 and 3.1.4 Drilled End Bolt

Drilled End Bolt

The drilled end bolt has the same description as the standard bolt. In
addition to the standard bolt characteristics, the drilled end bolt has a
hole drilled radially through the bolt near the end. The hole is in the
section of the bolt with threads. The diameter of the hole must be
given in a description of this type of bolt.
This fastener is used when a bolt and nut are tightened to a low
torque and there is a danger that the nut can loosen during service.
The bolt is put through the components that are to be held. A
castellated or slotted hex nut is put on the end of the bolt. The nut is
tightened to the correct torque. If the hole in the bolt does not line
up with a set of slots in the nut, tighten the nut until they are in
alignment. The cotter pin is then put through the hole in the drilled
end bolt. This will hold the nut in the same position on the bolt until
the cotter pin is removed even if there is vibration present during
operation.
Unit 3 3-1-4 Caterpillar Service Industry
Lesson 1

Use the correct size drilled end bolt for the job to be done. Never
loosen a castellated or slotted nut to get alignment between the slots
and the drilled end hole. Always tighten the nut to get this alignment.
Use a cotter pin that is made for the size hole in the specific drilled
end bolt used.

Fig. 3.1.5 and 3.1.6 Drilled Head Bolt

Drilled Head Bolt

The drilled head bolt has the same description as the standard bolt.
In addition to the standard bolt characteristics, the drilled head bolt
has a hole drilled radially through the head of the bolt. The diameter
of this hole must be given in a description of this type of bolt.
This fastener is used to hold components and show that they need
special service. They can also be used when bolts must be held so
that they will not turn during operation of the machine. Lock wires
are used with drilled head bolts. The lock wire is put through the
drilled head hole. When the lock wire is in position through a series
of drilled head bolts, the lock wire can be fastened with a seal.
NOTE: Refer to "Identifying Fasteners" (Form SEEV0527) and
review the following:
- How to correctly identify metric and inch-type bolts.
- Grade markings for steel bolts and screws.
- General tightening torque for metric fasteners.
- General tightening torque for inch-type bolts, nuts, and
taper lock studs.
Unit 3 3-1-5 Caterpillar Service Industry
Lesson 1

Fig. 3.1.7 and 3.1.8 Plow Bolt

Plow Bolt
The plow bolt has a round head when seen from the top. The top of
the head has a flat or curved surface. The head also has a taper from
the top edge toward the section with the threads. At the bottom of
the taper is a section with flat sides that forms a square (square base).
The square base has sides that are generally the same length as the
diameter of the bolt. The grip length is measured from the top edge
of the bolt head to where the threads start. Bolt length is measured
from the top edge of the head to the other end of the bolt. Length of
the bolt head is measured from the top edge to the bottom of the
square base. The description of a plow bolt will tell the standard bolt
description plus the head diameter, size of the square base and length
and taper angle of the bolt head.
This fastener is used to keep a surface free of large bolt heads. An
example is the cutting edge of a motor grader. The earth must roll
smoothly over the fastened parts. The first component into which a
plow bolt is put must have a hole with a side taper and a square at
the bottom. This shape will fit that of the plow bolt head. The bolt
hole must not let the plow bolt turn since a wrench will not hold on
the top part of the bolt head. Caterpillar plow bolts and nuts are heat
treated for extra strength. Hardened washers are generally used with
plow bolts.
Use the correct size plow bolt for the job to be done. Make sure that
the head of the plow bolt fits the size and shape of the hole in the
component that is fastened. Use heat-treated nuts to hold the plow
bolt in position. Put the correct amount of torque on the plow bolt
nut.
Unit 3 3-1-6 Caterpillar Service Industry
Lesson 1

Fig. 3.1.9 and 3.1.10 Hex Socket Head Bolt

Hex Socket Head Bolt

The hex socket head bolt has the same grip and thread sections as a
standard bolt. The most common shapes for the bolt head are:
cylinder with flat top and bottom; flat top with a taper toward the
grip (countersink); and round top with flat bottom (dome). All bolt
heads have an axial hex shape hole made in the center of the heads.
Hex socket head bolts have heads of approximately the same
diameter of the washer face on a hex head bolt of the same size.
This fastener is used in applications where there is not enough space
to use wrenches on other types of bolts. The hex socket head bolt
can be used in a hole or any other application where small head size
is an advantage. The tip of the hex socket or Allen wrench will fit
into the hex hole in the bolt head. The wrench can then be used to
turn the hex socket head bolt.
Use the correct size hex socket head bolt for the job to be done.
Make sure that the hex wrench used fits tight into the hex hole in the
hex socket head bolt. Do not use a hex socket head bolt if the head
is cracked or broken.
Unit 3 3-1-7 Caterpillar Service Industry
Lesson 1

Fig. 3.1.11 and 3.1.12 12-Point Head Bolt

12-Point Head Bolt

The 12-point head bolt has the same grip and thread sections as a
standard bolt. The top part of the bolt head has 12 ridges that axially
run down the sides of thread. Between the ridges and the grip of the
bolt is a shoulder. Generally 12-point head bolts have the same bolt
and head diameters. Some very high strength bolts will have larger
heads.
This fastener is used when there is a need for a high strength bolt
with a small head. This bolt must be installed with a 12-point box
end wrench or 12-point socket. Make sure that the 12-point head
bolt is turned to the correct torque.

Fig. 3.1.13 and 3.1.14 Washer Head Bolt

Washer Head Bolt

The washer head bolt is a modification of the standard hex head bolt.
The bottom of the bolt head has a taper out to a flange surface. This
round flange surface is used as a washer on the bottom of the bolt
head. The head section of this bolt includes both the hex head and
the washer surface. The length of a washer head bolt is measured
from the washer surface to the end of the bolt. The bottom of the
washer surface can have small teeth to help the bolt head hold the
surface that it is tightened against.
Unit 3 3-1-8 Caterpillar Service Industry
Lesson 1

This bolt is used in applications similar to the standard hex head bolt.
The washer face on the bottom of the bolt head will let the bolt be
tightened smoothly. This washer face will also give distribution of
force over a larger area than with a standard hex head bolt. The
washer head bolt must be turned to the correct torque.

Fig. 3.1.15 and 3.1.16 Hex Nut

Hex Nut
The hex nut is generally made of steel, stainless steel, or brass. An
axial hole through the center of the nut has inside (internal) threads.
There are six equal flat surfaces on the sides of the hex nut. The size
of the hex nut is approximately the same as the head of the bolt that
it is used with. To find the thread pitch of a hex nut, a thread pitch
gauge is used. The top of the nut has a chamfer on the outside edges.
Some nuts have a small washer surface on the bottom of the nut.
The hex nut is the most common type of nut used on Caterpillar
equipment. The hex nut is used on the end of bolts or studs.
Components are held on a bolt or stud when the nut is turned tight
against them. The small washer surface of the nut must be against
the components held by the nut. Nuts must be tightened to the
correct torque. When the nut is turned tight, one or two bolt threads
must be outside the top nut surface for maximum strength.
Unit 3 3-1-9 Caterpillar Service Industry
Lesson 1

Fig. 3.1.17 and 3.1.18 Wing Nut

Wing Nut
The wing nut has a body with two radial attachments (wings) on
opposite sides. These wings are large enough to let the nut be turned
tight with fingers. The wings generally curve away from the
component held by the wing nut. A hole with threads is made
through the center of the wing nut body.
This fastener is generally used to hold component covers that are
removed regularly for operator service. Wing nuts can be used only
in applications where the amount of torque on the fasteners is not
important. The wing nut is only fastened hand tight. An advantage
of the wing nut is that it needs no tool to be removed. Clean threads
are important when a wing nut is used.
Unit 3 3-1-10 Caterpillar Service Industry
Lesson 1

Fig. 3.1.19 and 3.1.20 Acorn Nut

Acorn Nut
The acorn nut is very much like a hex nut with a cap on it. The top
of the nut has a round cap (dome) with no hole in it. There are six
flat sides near the bottom of the acorn nut. The bottom of the acorn
nut is flat or has a washer face. An axial hole with threads is made
through the bottom of the nut. This hole does not go through the top
of the acorn nut.
This fastener is used when the end of a bolt or stud must have a
cover. The acorn nut can only be turned until the end of the bolt hits
the bottom of the hole in the nut. For this reason, bolts and studs
must be short enough so that the acorn nut can be tightened against
the held components and not make contact with the end of the hole.
This nut can help stop injury caused to operators when a rough bolt
end is hit. Acorn nuts can also protect threads on the end of a bolt.
Unit 3 3-1-11 Caterpillar Service Industry
Lesson 1

Fig. 3.1.21 and 3.1.22 Jam Nut

Jam Nut
The jam nut is the same shape as the standard hex head nut. The
only difference is that the jam nut is approximately one half as high
as a standard hex head nut. The top of the jam nut has a chamfer on
the outside edges. Jam nuts may have a washer face on the bottom.
This fastener is used to hold (lock) other fasteners in position. The
jam nut can be put on a bolt, stud, or rod with outside threads. When
a fastener, or component with inside threads, is put into position the
jam nut can be turned tight (jammed) against it. This will make a
lock against inside and outside threads. A common application of the
jam nut is against the yoke on a control linkage.

Fig. 3.1.23 and 3.1.24 Castellated and Slotted Nut

Slotted Nut
The slotted nut has the same basic shape as the hex nut. On the top
of the nut are six radial slots cut around the diameter. These slots are
cut into the center of the flat side surfaces of the slotted nut. The
castellated nut is very similar to the slotted nut except that its outside
surface is round where the slots are.
These nuts are used with a drilled end bolt. A castellated or slotted
nut is tightened on a drilled end bolt until the torque is correct. If the
hole in the drilled end bolt is not in alignment with a set of slots on
the nut, the nut is tightened until there is alignment. A cotter pin is
then put through a set of slots in the nut and the hole in the drilled
end bolt. The free ends of the cotter pin are then bent back so that it
will not fall out.
Unit 3 3-1-12 Caterpillar Service Industry
Lesson 1

Fig. 3.1.25 and 3.1.26 Self-Locking Nut

Self -Locking Nut

The self-locking nut is generally like a hex nut with a round section
on top much like a castellated nut. There can be cuts on this round
section so that the top of the nut can be bent a little in toward the
center of the nut. A second type of self-locking nut can have an
elastic material with no threads made in the top of the nut. A third
type of self-locking nut will use an out-of-round hole to change the
shape of the bolt threads as the nut is tightened.
This type of nut will hold a bolt or stud so that it will not turn while
in service. When using a self-locking nut, it is not generally
necessary to use other locking fasteners. These nuts can be used in
an application where they must not get any tighter or looser. They
will stay in the position in which they are installed.
Unit 3 3-1-13 Caterpillar Service Industry
Lesson 1

Fig. 3.1.27 and 3.1.28 Lockwire

Lockwire
Lock wire is made from small diameter wire that can bend easily.
Generally two of these wires are bent around a third straight wire.
The total diameter of this arrangement must be small enough so that
it will go through the hole in a drilled head bolt. A metal seal can be
used to fasten lock wire so it will not loosen. The governor sealing
tool group contains all parts and tools needed to install lock wire.
The most common use of lock wire is to seal a component so it will
be adjusted or removed only by a Caterpillar dealer. Two or more
drilled head bolts are used to hold the component in position. The
lock wire is then put through the bolt heads and the ends are then
fastened with a metal seal. The lock wire must be removed to loosen
the drilled head bolt. Lock wire can also be used to hold drilled head
bolts so they will not become loose. In this application, the lock wire
is put through two or more holes and twisted so that if any of the
bolts start to loosen the wire will be pulled tighter.
Unit 3 3-1-14 Caterpillar Service Industry
Lesson 1

Fig. 3.1.29 and 3.1.30 Flat Washer

Flat Washer
The flat washer is a flat piece of metal cut in a round shape. The
center of the washer has a round hole. The variable characteristics of
flat washers are material, hardness, finish, quality, and size.
Materials for flat washers are generally steel, brass, or aluminum.
Washer thickness is the distance between the two flat sides. Washer
width is the outside diameter of the washer. The size of the bolt that
is used with a particular flat washer is the same as the description for
the hole size in that washer.
Flat washers are used for thrust load distribution over areas larger
than bolt heads or nuts. A flat washer will also limit damage to
component surfaces caused by bolt heads or nuts. The hole in a flat
washer will let a bolt be put through it. The flat washer can be used
between bolt heads or nuts and component surfaces. The correct type
and size flat washer must be used in all applications. Check
assembly manuals for the correct part number so that a flat washer is
not used in place of a hard washer.
Unit 3 3-1-15 Caterpillar Service Industry
Lesson 1

Fig. 3.1.31 and 3.1.32 Hard Washer (flat)

Hard Washer
Hard washers have the same description as other flat washers. Hard
washers are made of steel and are heat treated. This gives the
washers high strength and makes them difficult to bend. Hard
washers generally have a dark (almost black) color. When a flat
washer is used, be sure to check the part number in the assembly
manual so that the washer will have the correct hardness.
Hard washers are used in the same way as other flat washers. In
addition, they are used when the hole through which a bolt is put is
much larger than the bolt. The hard washer will not bend like a soft
washer when the correct torque is put on the bolt. A hard washer
must also be used when bolts and nuts are tightened to a high torque.
A soft washer can become thinner under load and release part of the
tension of the fasteners.

Fig. 3.1.33 and 3.1.34 Lock Washer (Split Spring)

Lock Washer
Split spring lock washers are made from rings of spring steel that
will fit around bolts. The top and bottom surfaces of the lock washer
are flat. The ring is cut through (split) at one location and one end is
bent up. The measurements for size descriptions of split spring lock
washers are made the same way as flat washers.
A split spring lock washer is used as a spacer between a bolt head or
nut and a fastened component. This type of washer has a uniform
surface on which to tighten a fastener. The bend in the lock washer
Unit 3 3-1-16 Caterpillar Service Industry
Lesson 1

will be made flat as the bolt or nut is tightened. The spring force of
the lock washer will put the fastener in a load condition. This load
will help to keep the fastener tight. Be sure to check assembly
manuals to tell when to use a split spring lock washer, a hard washer,
or no washer at all.

Fig. 3.1.35 and 3.1.36 Lock Washers (Internal and External Toothed)

Lock Washers
The toothed lock washer is a round steel washer. The hole in the
washer fits over the bolt, stud, or screw that is used with it. There are
notches cut around the outside diameter (external toothed), or around
the bolt hole (internal toothed), or around both (internal and external
toothed). Between the notches, the small teeth of the washer are
twisted.
This type of lock washer is generally used with electrical
connections. The twisted teeth on the lock washer work similarly to
the split ring washer. These teeth will both cut into the fastener and
hold the fastener under load condition. These washers can make a
good electrical connection when they are used with the screws on an
electric terminal.
Unit 3 3-1-17 Caterpillar Service Industry
Lesson 1

Fig. 3.1.37 and 3.1.38 Square Seat Conical Washer

Square Seat Conical Washer

The square seat conical washer is made from a round piece of steel
with a hole in the center. The square seat conical washer is not flat.
If the outside edge of the washer is put against a flat surface, the
center of the washer will be a small distance above the flat surface.
This distance is the height of the square seat conical washer. Size
description will include: outside diameter, hole diameter, thickness,
and height.
The square seat conical washer is used to put fastener force over a
large area. Soft or thin metals are damaged less by fasteners when
their area of force is increased. The conical shape also causes the
washer to give spring force as a bolt head moves against it. This
spring force helps to keep the bolt in tension so that it will stay tight.
When used, the outside edge of the square seat conical washer must
be against the component that is held.
Unit 3 3-1-18 Caterpillar Service Industry
Lesson 1

Fig. 3.1.39 and 3.1.40 Thread Forming Screw (Self Tapping)

Thread Forming Screws

Thread forming screws have head and thread sections. There is a
very short grip length on these fasteners. Thread forming screws are
made of hardened steel. The head can be any of the screw type
heads or it can have a hex head. The thread section will have a taper
at the tip. The length and threads of thread forming screws are
measured the same as other bolts and machine screws. There are two
types of thread forming screws: the thread rolling screw and the
thread cutting screw.
This fastener is used to hold metal parts that are not under high loads.
Screws can be used where a small fastener with threads is needed.
With thread forming screws, the screw hole needs no internal threads
before assembly. The diameter of this hole must be a little smaller
than the diameter of the screw. The internal threads are made as the
screw is turned into the hole. When used in a hole with threads, a
thread forming screw can make alignment easier.
Unit 3 3-1-19 Caterpillar Service Industry
Lesson 1

Fig. 3.1.41 and 3.1.42 Set Screw

Set Screw
Set screws are made of heat treated steel. These screws generally
have a square head, hex head, or no head at all. The set screws with
no head have a slot or hex socket on one end. The other end (point)
will have a shape to fit the application of the set screw. This shape
can be round, flat, a cup, or a cone. There are external threads
between the two ends of the set screw.
These fasteners are used to hold one component in a specific position
on a second component. One component will have a hole with
threads that will fit the set screw. The set screw will be turned into
this hole until the point is tight against the second component. This
second component can have a small hole or flat area to fit the point
of the set screw.

Fig. 3.1.43 and 3.1.44 Bar Key

Bar Key
The bar key can be made of a hard or soft metal. The sides of a bar
key are flat and the sides opposite each other are parallel. Check
assembly manuals and parts books to make sure that the right bar key
is used.
The bar key is used to hold a component in a specific position around
the diameter of a shaft. There is an axial groove (keyslot) on the
outside of a shaft. There is also a groove in the side of the hole in
the held component (keyway). The component is put on the shaft so
that the keyslot and keyway are in alignment. The bar key can then
be put into the keyslot and keyway. A soft-tipped hammer can be
used to put the bar key into position.
Unit 3 3-1-20 Caterpillar Service Industry
Lesson 1

Fig. 3.1.45 and 3.1.46 Woodruff Key

Woodruff Key
A woodruff key is made of the same materials as a bar key. The
woodruff key has a flat top and flat sides. The bottom and ends of
the key make a curve that is half of a circle. Description
measurements for a woodruff key are thickness and diameter of the
curve. Check to make sure that the correct size woodruff key is used
in all applications.
The woodruff key is used to hold a component in a specific position
around the diameter of a shaft. There is a key slot on the outside of
the shaft used with a woodruff key. The bottom of this key slot has a
curve the same as the curve of the woodruff key. The key way in the
component is the same as for a bar key. The woodruff key is put into
position on the shaft. The component is then pushed into position on
the shaft when the key slot and key way are in alignment.
Unit 3 3-1-21 Caterpillar Service Industry
Lesson 1

Fig. 3.1.47 and 3.1.48 Roll Pin

Roll Pin
The roll pin is a round steel pin. This pin is hollow down the center
of the pin. The roll pin is also open down one side. Since this is not
a solid pin, it can be made smaller radially. The roll pin has a radial
spring force. There is a chamfer on both ends of the roll pin.
The roll pin is used to hold components so they will not move in a
direction radial to the roll pin. The roll pin is held in one or more
holes. These holes must have a little smaller diameter than the roll
pin when it is not in compression. A soft-tipped hammer can be used
to put a roll pin into position in a hole. To remove a roll pin, use a
drift punch with a diameter just a little smaller than the outside
diameter of the roll pin.
Unit 3 3-1-22 Caterpillar Service Industry
Lesson 1

Fig. 3.1.49 and 3.1.50 Flat Metal Lock

Flat Metal Lock

The flat metal lock is generally made of a soft metal. Some locks are
hardened for special applications. These locks are flat pieces of
metal with one or more holes in them. The flat metal lock must have
a hole that is large enough for a bolt to go through. The outside edge
of a metal lock must be larger than the bolt head or nut. This outside
edge can have a special shape for a specific application. In a specific
application, check the assembly manual for the correct part number
of the flat metal lock used.
The flat metal lock is used to hold a bolt head or nut so that it will
not turn. This lock is put between the held component and the nut or
bolt head. When the fastener is tight, one outside edge of the lock is
bent up flat against a flat side of the fastener. An outside edge of the
lock can also be bent down flat over the edge of the component.
Bend metal locks with a cold chisel. Special sockets can be used to
loosen fasteners held by flat metal locks. Do not use a flat metal
lock more than one time.
Unit 3 3-1-23 Caterpillar Service Industry
Lesson 1

Fig. 3.1.51 and 3.1.52 Machine Screws

Machine Screws
The machine screw has a head and a section with threads. Generally,
the threads come all the way up to the head. A machine screw which
is less than 1/4 in. (6.1 mm) in diameter has a size number
description. Machine screws that are larger than this use their
diameter in their size description. Screw length is measured from the
bottom of the head to the end of the screw. The length of a
countersunk screw is measured from the top of the head to the end of
the screw.
This fastener is used to hold two or more components together.
Machine screws are used in applications where they are under little
load. The last component into which a machine screw is put must
have threads the same size as the screw. Flat washers and lock
washers can be used with machine screws.
Use the correct type and size of screwdriver to turn a machine screw.
A screwdriver can easily slide off many types of screws. Keep hands
away from areas where they will be hit if the screwdriver slides off
the screw.
Unit 3 3-1-24 Caterpillar Service Industry
Lesson 1

Fig. 3.1.53 and 3.1.54 Stud

Stud
A stud is a metal rod with threads on both ends. The grip length is
the part of the stud between the two sections with threads. The
threads on one end (stud end) will be more coarse than the threads on
the other end (nut end). The stud end can have a taper toward the
end of the stud. The nut end of a stud is the same as the thread
section of a bolt. Size description of a stud will include: diameter
and type of thread on each end; thread length of the stud end; thread
length of the nut end; grip length plus thread length of the nut end;
and any special characteristics of the stud.
Studs are used to fasten two or more components together. The stud
end of this fastener can be turned into a hole with threads in one
component. Be sure to use a stud end with a taper if the hole has a
taper. When the stud is held tight in the hole, a second component
with no threads can be put over the nut end of the stud. When all
components are in position, a nut can be put on the nut end of the
stud. Tighten this nut to the correct torque. A common application of
studs is in the top of an engine cylinder block. Some studs have no
taper and are held tight in a component because their diameter is a
little larger than the diameter of the threaded hole. This type of stud
is an "interference fit" stud. Use the correct tools to remove and
install all types of studs.
Make sure that the correct stud is used in each application. Some
studs have special characteristics like drilled holes, special material,
or added strength. When a stud is replaced, check the assembly
manual to make sure the correct stud is used.
Unit 3 3-1-25 Caterpillar Service Industry
Lesson 1

Fig. 3.1.55 and 3.1.56 Taper, Plug, and Bottom Taps

Taper, Plug, and Bottom Taps

The threaded portion of a tap looks like a bolt or machine screw with
four deep grooves cut along the length of the threads and equally
spaced around the diameter. Between each groove is a row of short
cutting threads. Above the threads is a short round shank with a
square drive lug on the top. The threaded tip of the tap is tapered
slightly so that when the tap starts in the hole, the first threads make
a shallow cut and gradually cut deeper until the full depth is reached.
Taps are used to cut threads in drilled holes or repair damaged
threads. When tapping a through hole, a taper tap may be used to
start and finish in one operation. When tapping a blind hole where
threads need not be to the bottom of the hole, a taper tap is used first
and is then followed by a plug tap. When tapping a blind hole where
threads must extend to the bottom, a taper tap is first used and then is
followed by a plug tap and finally a bottom tap. Any of these taps
may be used to repair damaged threads, but it is recommended to use
the tap with the most taper allowable for the application to prevent
breaking of damaged threads.
Unit 3 3-1-26 Caterpillar Service Industry
Lesson 1

NEVER user a tap to thread or repair damaged threads in a hardened

piece. NEVER apply excessive force if the tap binds. Either
condition may cause the tap to shatter causing possible injury. Never
use a tap with broken or damaged teeth. Keep the tap well lubricated
with cutting fluid or oil to minimize possibility of breakage. Wear
safety glasses if compressed air is used to clean the chips out of the
hole after tapping.

Fig. 3.1.57 and 3.1.58 Tap Wrench

Tap Wrench
Tap wrenches come in various sizes, but most common range from 6"
to 16" in length. The tap wrench looks like a piece of small diameter
bar stock with a small rectangular vice in the middle approximately
1/8 the length of the wrench. The center of the rectangular vise
contains two steel locking jaws with vee shaped slots for gripping the
head of the tap. One of these jaws is stationary and the other is
adjusted by rotating the movable, adjusting handle. Both ends of the
handles are knurled to provide a secure grip when tightening the
wrench.
Tap wrenches are used to provide a handle on all types of taps for
hand tapping and thread reconditioning.
Unit 3 3-1-27 Caterpillar Service Industry
Lesson 1

Fig. 3.1.59 and 3.1.60 Re-threading die

Re-threading Die
Re-threading dies are generally made from hexagonal tool steel bar
stock of various sizes, but all about 1/2" thick. The die has six rows
of cutting teeth arranged in a circular fashion with a large round hole
or flute between each row of teeth. The rectangular shape of the re-
threading die allows it to be used with a box end wrench or a ratchet
and socket. A threading die is round and must be used in a die
wrench.
Re-threading dies are used for repairing damaged external threads.
Although they can be sued for initially cutting threads, it is not
recommended because the rows of cutting teeth are not as strong as
on a threading die. Re-threading dies should NEVER be used on
hardened threads. This will cause damage to the die and will ruin it.
Hardened fasteners with damaged threads should be replaced. Be
sure to keep the die well lubricated with cutting fluid or oil to prevent
wear or damage. Make sure the die is started on the fastener straight
to prevent cross threading.
NEVER use the re-threading die on hardened threads or apply
excessive force if the die binds. Either condition may cause the die
to shatter and causing possible injury. Never use a die with damaged
or broken teeth.
Unit 3 3-1-28 Caterpillar Service Industry
Lesson 1

Fig. 3.1.61 and 3.1.62 Die Wrench

Die Wrench
The die wrench is similar in appearance to a tap wrench except the
center is circular instead of rectangular and both handles are
stationary. The most common die wrenches have either one or three
set screws in the circular part of the wrench that clamp the die into
the wrench. All threading dies in a set will have the same outer
diameters so that only one die wrench is needed.
Die wrenches are used to provide a handle for threading dies when
hand cutting threads.
Unit 3 3-1-29 Caterpillar Service Industry
Lesson 1

Fig. 3.1.63 and 3.1.64 Reamer

Reamer
A reamer is somewhat similar to a tap, except it is longer and does
not have rows of cutting teeth. The reamer has contoured grooves
between straight sharp cutting edges called flutes. Unlike the
gouging action of the threads of a tap, the flutes of a reamer have a
scraping action that removes small amounts of material to obtain an
accurate size and excellent surface finish. The most common
reamer has straight flutes with a very small taper on the end that
permits it to be started in the hole. The number of flutes range from
4 to 16 and are determined by reamer size. Many different types of
reamers are available, for example: spiral flute, taper, expansion,
etc.
Reamers are used to size and finish a hole when a high degree of
accuracy is required. Some of the more common applications in the
shop are re-sizing transmission bores on older machines and
re-sizing holes in special tool group fixtures in certain applications.
Tapered reamers may be used to chamfer holes to make assembly of
close fitting components easier.
Make sure that the drilled hole is not undersized before using the
reamer.
Unit 3 3-1-30 Caterpillar Service Industry
Lesson 1

Fig. 3.1.65 and 3.1.66 Threaded Insert

Threaded Insert
A threaded insert looks like a short length of small pipe with threads
covering both the inside and the outside. The outside of the insert
has four shallow grooves equally spaced around the diameter running
from top to bottom. In the top of each groove is a small steel pin
approximately 1/4 the length of the insert called a kee, which firmly
anchors the insert into the hole.
Threaded inserts are used to replace threads that have been damaged
beyond repair. These inserts can be used in any material that is soft
enough to be drilled and tapped. The only operations necessary to
install the insert is to drill, tap, and countersink the hole with the
proper size tooling and drive in the insert kees with the driving tool
furnished in the master kit. These inserts are excellent for saving
parts that are costly to replace.
Unit 3 3-1-31 Caterpillar Service Industry
Lesson 1

Fig. 3.1.67 and 3.1.68 Heli-Coil Insert

Heli-Coil Insert
A heli-coil insert is basically a threaded-shaped coil of metal that
serves the same purpose as a threaded insert. A threaded insert
resembles a small length of pipe with threads both inside and outside.
A heli-coil insert is more like a closely wound spring and is not solid
like a threaded insert. The top thread of the heli-coil is bent into the
center to provide a tang with which the heli-coil is threaded into the
hole.
Heli-coil inserts are for specific applications only. For general use,
threaded inserts are recommended because less tooling is required
and they are somewhat easier to install. On expensive items such as
cylinder heads, heli-coil are preferred because less metal has to be
removed in the drilling operation, thereby the part is weakened less.
If a heli-coil has been installed and the threads that hold it become
damaged, a threaded insert may be used since the heli-coil requires
larger holding threads.
Unit 3 3-1-32 Caterpillar Service Industry
Lesson 1

Fig. 3.1.69 and 3.1.70 Easy-Out Remover (Screw Extractor)

Easy-Out
The easy-out looks similar to a drill bit that is tapered on the end.
The top of the tool has a square drive lug so that it may be rotated
with a wrench. The tip of the tool has very large tapered spiral
threads that are sharpened to bite into the sides of the hole in the
broken fastener. The easy-out is made from small diameter tool bar
stock.
Easy-outs are only to remove broken studs, screws, and bolts. They
are not designed for any other type of use.
Tap the easy-out lightly to seat it. DO NOT strike it hard. This tool
is hardened and may shatter if abused. Safety glasses should be worn
during use in case the easy-out breaks.
Unit 3 3-1-33 Caterpillar Service Industry
Lesson 1

Fig. 3.1.71 and 3.1.72 Stud Remover

Stud Remover
The stud remover assembly consists of four parts: the collet, the
sleeve, the bolt, and the washer. The collet looks like a short length
of pipe approximately 2 1/2" long and 1" in diameter. One end of the
collet is bell shaped and has four slots cut in it that allows it to be
compressed tightly around the stud. This end also contains the
threads into which the stud is threaded. The other end of the collet is
not tapered and contains the threads into which the bolt is threaded.
The sleeve resembles a short piece of pipe with one end closed,
except for a small hole through which a bolt fits. The top of the
sleeve will have two flats or a hex so that the sleeve may be gripped
with a wrench.
Stud removers are used to remove and replace studs and are not
designed for any other purpose.
Unit 3 3-1-34 Caterpillar Service Industry
Lesson 1

Fig. 3.1.73 and 3.1.74 Clevis Pin

Clevis Pin
The clevis pin is a round metal pin. There is a head on one end of
the pin. The head is generally round with a flat top. The other end of
the pin has a radial hole drilled near the end. The top edge of the
opposite end of the clevis pin has a chamfer. There are no threads on
a clevis pin. The length of a clevis pin is measured from the bottom
of the head to the end of the pin. The diameter must be given in the
size description of a clevis pin.
This fastener is used to hold two components together. The clevis pin
will not hold components tight. It will let them move around the pin
like hinge. The held components have flanges with holes that are in
alignment. The clevis pin is put through these holes. The clevis pin
head will hold the components on one side. The drilled hole in the
pin is on the other side of the components. A cotter pin is put
through this hole.
Unit 3 3-1-35 Caterpillar Service Industry
Lesson 1

Fig. 3.1.75 and 3.1 76 Shear Pin

Shear Pin
The shear pin is a soft metal pin. It looks the same as a clevis pin
except that there is no drilled hole near the end of the pin. The size
description of a shear pin will be the pin diameter and length. The
length of a shear pin is measured from the bottom of the head to the
end of the pin. Some shear pins have no head and look like a short
length of rod. The length of this type of shear pin is measured from
end to end.
Shear pins are generally used to fasten some drive shafts to driven
shafts. These shafts must have fixtures with holes that can be put
into alignment. The shear pin is put through these holes. In this
application, the shear pin is used as a safety protection. If the driven
shaft gets a sudden very high torque it will cut through (shear) the
shear pin. This will cause a separation between the drive and driven
shafts. Never use a bolt for a shear pin.
Unit 3 3-1-36 Caterpillar Service Industry
Lesson 1

Fig. 3.1.77 and 3.1.78 Taper Pin

Taper Pin
The taper pin is a pin with one end a little larger than the other end.
This type of pin has no head. This gives the pin a small taper toward
the small end of the pin. Size description measurements generally
include length and diameter of the large end of the pin. The length is
measured from end to end on the taper pin.
This fastener is used to hold two components together. The taper pin
generally holds tighter than other types of pins. The taper shape can
be of assistance in the alignment of components for assembly. A
taper pin must be pushed tight into the pin hole, small end first. To
remove a taper pin, use a pin punch on the small end of the taper pin.
Taper pins can be used again may times and will still fit tight.

Fig. 3.1.79 and 3.1.80 Dowel Pin

Dowel Pin
The dowel pin is made from a section of metal rod. The diameter of
a dowel pin is the same at all locations along the length of the pin.
The sides of a dowel pin are smooth and both ends generally have a
chamfer. Measurements used for size description of a dowel pin are
diameter and length.
Dowel pins are used for assistance in the alignment of parts. These
pins are press-fitted into holes in a machine component. A second
component with a little larger hole can be put into alignment over
these pins. On the 3306 engine, dowel pins are press-fitted into the
cylinder head for assistance in the alignment of the valve cover. A
dowel pin is not generally removed from a component into which it
is press-fitted.
Unit 3 3-1-37 Caterpillar Service Industry
Lesson 1

Fig. 3.1.81 and 3.1.82 Cotter Pin

Cotter Pin
The cotter pin is made of soft metal, has two parallel legs (prongs),
and an eye on one end. The prongs can be the same or different
lengths. There can also be one or two eyes in a cotter pin. The size
description of a cotter pin will include: diameter (of the hole in
which the pin is used); length (from the bottom of the eye to the end
of the shortest prong); and prong end shape.
The cotter pin is used with drilled end bolts and clevis pins. The
cotter pin will either hold these fasteners in position or show that
they are already in position. The cotter pin is put through the hole in
a drilled end bolt or clevis pin. The cotter pin is pushed until the eye
is in contact with the hole. The prongs of the pin are then bent back
against the fastener. The prongs must be made straight to remove the
pin.
Unit 3 3-1-38 Caterpillar Service Industry
Lesson 1

Fig. 3.1.83 and 3.1.84 Rivet

Rivet
The rivet is made from a soft metal rod. There is a head at one end
of the rivet. The other end of the rivet (shank end) is straight. The
size description of a rivet will include: diameter of a shank, length of
a shank, and shape of head.
This fastener is used to hold two or more components together. The
rivet is put through holes in the components. The straight end of the
shank is then made into a shape similar to the head end. A riveting
machine, rivet set, or ball peen hammer can be used to give this
shape to the end of the shank. The rivet will then have two heads.
The components must be held tight between these two heads. An
assembly that is not tight can cause rivets to become broken.
Unit 3 3-1-39 Caterpillar Service Industry
Lesson 1

Fig. 3.1.85 and 3.1.86 Snap Ring

Snap Rings
Snap rings are made of spring steel. They are made in a circle shape
that is not closed at one location. Rings that fit into external groves
are external snap rings and those that fit into internal grooves are
internal snap rings. Some snap rings have a small hole on each side
of their opening. These small holes are made so that snap ring pliers
can be used to install or remove the snap rings.
These fasteners are used to hold, or limit movement of, pins or
shafts. An external snap ring will fit into a groove around a pin or
shaft. An internal snap ring will fit into a groove around the inside of
a hole. When snap rings are in position, a pin or shaft can no longer
slide out of a specific hole. Snap ring expansion or reduction will be
necessary to put a snap ring into position. Use the correct size and
type of snap ring in all applications.
Unit 3 3-1-40 Caterpillar Service Industry
Lesson 1

Fig. 3.1.87 and 3.1.88 Spring Clip

Spring Clip
The spring clip is made of spring steel. The spring steel wire is bent
into a shape with two legs (prongs). The prongs will have curves to
fit the outside diameter of a pin. One prong can be straight on some
spring clips. The bend between the two prongs will form an eye that
is used for easy removal of the spring clip. Size description will
include the diameter of the spring wire and the shape of the prongs.
This fastener is used to hold pins in position. The pin must have a
groove at the location where it is held by the spring clip. The spring
clip is pushed into position on the pin and fits into the groove. The
spring clip with the straight prong is used when the pin has a drilled
hole and the other prong holds on to the outside of the pin.
Unit 3 3-1-41 Caterpillar Service Industry
Lesson 1

Fig. 3.1.89 and 3.1.90 Cable and Tube Clip

Cable and Tube Clip

Cable and tube clips are made from flat metal strips that are bent to
the correct shape. These clips will have curves in a position to hold
one or more cables or tubes. There will be one or more holes in a
position on the clip so that it can be fastened with a bolt or screw in a
rigid position. Some clips will bend completely around a cable or
tube and will have a bolt hole.
This type of clip is used to hold cables and tubes in a specific
position to prevent damage to these components. Some clips hold
cables and tubes directly against a rigid surface. Some clips are put
around cables and tubes and fastened to a surface such that the cable
or tube does not touch that surface. A common application of this
clip is to prevent heat damage around engine components.
Unit 3 3-1-42 Caterpillar Service Industry
Lesson 1

Fig. 3.1.91 and 3.1.92 Plastic Strap (Wrap Ties)

Plastic Strap
The plastic strap, or wrap tie, is a flexible plastic strap with an eye on
one end. There is a metal lock inside the eye that will let the strap be
put through the eye in only one direction. Once the plastic strap is in
the desired position, the strap can not be pulled back out of the eye.
The size description for plastic straps is generally length and width.
The plastic strap can be cut easily with diagonal pliers.
The plastic strap is used to fasten around a number of wires or cables
to hold them as a tight group. The end of the plastic strap is put
through the eye and pulled until it is tight around the wires. There
will be an extra length of strap that will hang out of the eye. This
extra length of strap must be cut even with the top of the eye.
Unit 3 3-1-43 Caterpillar Service Industry
Lesson 1

Fig. 3.1.93 and 3.1.94 Spacers, Shims

Spacers and Shims

Spacers and shims are generally flat pieces of metal that have an
even thickness. The outside edges are generally either straight with
square corners or in the shape of a circle. Some shims have a hole of
a specific size at a specific location. Size descriptions will include:
thickness; length and width (outside diameter if round); and size and
location of any holes.
Spacers and shims are used to give specific distance between two
components that are fastened together. A number of spacers or shims
with different thickness can be used together to get the specific
distance needed between the two components. Before shims or
spacers are used, make sure that they are clean and not bent. Foreign
material on the surface of a shim can cause it to have a thickness that
is not even. When a number of shims are used, put the thin ones in
the middle with the thicker shims outside.
Unit 3 3-1-44 Caterpillar Service Industry
Lesson 1

Fig. 3.1.95 and 3.1.96 Turnbuckle

Turnbuckle
A turnbuckle has three component parts. There are two metal rods
with threads on one end. One rod has right hand threads and the
other has left hand threads. The other end of the rods have an eye or
hook. The rods are fitted into opposite ends of a center fixture. The
distance between the two eyes is increased or decreased when the
center fixture is turned. To change the direction of movement
between the eyes, the direction of rotation of the center fixture must
be changed.
This equipment is used to change and hold the distance between two
components. The eyes on the end of the rods can be fastened to two
components. When the center fixture on the turnbuckle is turned, the
distance between the two components is changed. The turnbuckle
will then hold any adjustment desired. Jam nuts can be used on the
rods against the center fixture to lock the turnbuckle at a specific
adjustment.