Heavy Equipment Technician

First Period
Materials & Fastening Devices

Safety, Materials and Tools

Module 190101a
Objectives

1. Identify common metallic materials and

their applications.
2. Identify common non-metallic materials
and their applications.
3. Identify types of threaded fasteners
and their applications.
Objectives

4. Explain torque procedures and precautions

required when securing fastening devices.
5. Identify types of non-threaded fasteners
and their applications.
Objective One

Identify common metallic materials and

their applications.
Terms
Alloy
A material that is composed of two or more
chemical elements.
To alloy a steel, another metallic element is
added to the steel to improve corrosion
resistance, hardness or strength.

Ductility
Refers to the materials ability to stretch beyond
its elastic limits, without breaking or cracking.
Terms
Toughness
The amount of energy a material can absorb
before it breaks.

Malleability
The amount a material can be bent, dented, or
deformed without breaking.
Terms
Elasticity

Stretched
Bolts

Refers to the maximum stretch a material can

withstand, and return to it’s original shape.
Terms
Tensile Strength
The load in psi (MPa) that a material will
sustain before it fractures.

Hardness
The ability of a material to resist bending.

Work Hardening
Refers to the increased hardness and strength
of a metal as a result of deformation occurring
at low temperatures.
Terms

Oxidization
The chemical reaction that occurs when
oxygen combines with various elements and
compounds.

Annealing
Refers to a process of heating and slowly
cooling a metal in order to improve hardness
machinability, mechanical and electrical
properties, reduce brittleness, and facilitate
cold working.
Terms
Tempering
A heat and cooling treating process that
reduces hardness, brittleness thereby reducing
internal stress and increasing toughness.

Quench
Refers to cooling a metal suddenly from a
high temperature, by immersing in water, oil,
polymer solution or salt.
Metallic Materials
Classification:
Ferrous Metals
Metal alloys containing an iron base, and
is magnetic.

Non-ferrous Metals
Usually a natural element that do not have
an iron base composition.
Ferrous Metals
Steel
Is a composition of iron
and carbon, and is
commonly used in
nearly all body, frames,
and power trains. Steel Bars

Mild steel is heated and cooled slowly, and

becomes malleable in its annealed state.
• Toughens the steel, reduces brittleness,
and can be shaped or molded.
Ferrous Metals
Steel
When steel is heated
and quickly quenched,
it becomes hard and
brittle. Steel Truck Wheel
Mild steel contains 25% carbon and is very
malleable.
Medium steel contains up to 60% carbon.
Hard steel contains more than 60% carbon.
Ferrous Metals
Cast Iron
Contains 1.7% carbon
or higher.
It is porous, brittle, pours
and forms easier than
steel.

Commonly used for engine blocks, transmission

housing and flywheels.
• Usually course thread bolt holes are used.
Ferrous Metals
Wrought Iron

Forging Anvil

Contains approximately 30% carbon and slag.

• Tough, malleable, and relatively soft.
Ferrous Metals

Stainless Steel
Has a high chromium content and
varying degrees of carbon, nickel,
molybdenum, silicon, and copper.

Difficult to cut, drill, heat treat, is usually non-

magnetic and more expensive than steel.
Non-ferrous Metals
Aluminum
Usually non-magnetic,
light weight, and high
strength.

Melts at 660ºC, and has Aluminum Truck Wheel

excellent corrosion
resistant properties, high thermal conductivity,
and produces no sparks when struck.

Aluminum alloys will vary in strength, due to

the different elements used.
Non-ferrous Metals
Brass
Common alloy of copper
and zinc.

Has a melting point of

954ºC, tarnishes easily, is
durable and resists corrosion.

Used in bushings, shim stock,

and radiator cores.
Non-ferrous Metals
Copper

Has a melting point of 1100ºC, and is

tough, a good conductor of electricity
and heat.
Work hardens when heated, worked,
bent, or subjected to vibration.
Will break if bent two or three times,
back and forth.
Non-ferrous Metals

Lead
Properties:
Melting point of 327ºC.
Resist corrosion.
Very dense, absorbs
sound and vibration.
Blocks x-ray and gamma
radiation.
Non-ferrous Metals
Lead
Properties:
Solder (Tin
Lead’s natural lubricity & Lead)
makes it suitable as an
alloy in bearing application.
Toxic to the human body if ingested in
excessive amounts.
Causes nervousness and mental depression,
permanent nerve, brain and kidney damage.
Non-ferrous Metals
Nickel
Strong, good elasticity factor at high
temperatures.
Has a melting point of 1455ºC.

Pure nickel has excellent electrical and

magnetic properties.
Non-ferrous Metals
Silver
Pure silver has the highest thermal and
electrical conductivity factor, yet is the
cheapest of the precious metals.

Has a melting point of 961ºC. (silver solder)

Sometimes alloyed with copper or zinc for

greater flexibility.
Objective Two
Identify common non-metallic materials and
their applications.
Non-metallic Materials
Classification:

1. Natural

2. Synthesized
Non-metallic Materials
Natural Rubber
Soft and sticky when
hot.
Brittle when cold.
Susceptible to deterioration.
Swells when exposed to petroleum products.

Vulcanize: Rubber that is heated with sulphur,

so that it will not be affected by
temperature change.
Synthetic Rubber
Polymer is a generic term for all
synthetic and plastic materials, and
are processed from refined oil and
natural gas.
Neoprene
The most common oil-resistant
synthetic, and is found in gaskets,
seal rings, and o-rings.
Non-metallic Materials
Plastics and synthetic rubber may be from the
same or different family of polymers.

Headlight Assembly
Non-metallic Materials
Teflon

A very stable plastic polymer

that does not react with most
solvent and chemicals, and is
non-flammable.

Used in a variety of applications

such as packing, gaskets, rollers,
bearings and coatings, for work surfaces
where friction and corrosion are a factor.
Non-metallic Materials
Nylon
Radiator
A polymer that is compounded
Shroud
with reinforcements, fillers and
additives to enhance its
usefulness.

May be used as replacement

for metal such as radiator
shrouds, light wheels and vehicle body parts.
Non-metallic Materials
Fiberglass
A product comprised of
thin needle-shaped rods
of glass.

Used as insulation and

fireproofing, textiles and
plastics, filters, gaskets,
and seals.

Do not ingest or inhale, and wear

appropriate PPE..
Non-metallic Materials
Asbestos
A naturally occurring group of minerals, that
can only be identified under a microscope.
When asbestos becomes airborne, it can be
inhaled, and the particles will embed and
remain in the lungs.

Use a ventilation face mask and proper

technique when working with asbestos.
Non-metallic Materials
Silicone
A synthetic polymer
that is produced in
gels, fluids, rubbers
or elastomers.

Used in medicine,
food processing, oil,
lubricants and sealants.
Non-metallic Materials
Synthetic Fibre

Rayon, nylon, polyester, acrylic, and olefin are

the most common synthetic in use.
Cotton, wool, silk, leather and burlap are the
most common natural fibres in use.
Objective Three
Identify types of threaded fasteners and
their applications.
Threaded Fastening Devices
Bolts & Cap Screws
Functions:
Holds components together simply and
safely.

Allows components to be disassembled

for inspection.
Hold components together under extremes
of movement, pressure and temperature.
Threaded Fastening Devices
Bolts
Square head bolts
are found in certain
applications.

Hex head bolts are the

most common in use.

Bolts are usually

identified as being ¼” or
larger in diameter. Square Hex
Threaded Fastening Devices
Bolts
Carriage bolts are used
in areas where the head
may be worn or sheared
from the passing of
material.

Plow bolts are designed Plow

to hold the plowshare to Carriage
the mould board.
Threaded Fastening Devices
Cap Screw

Bolt

Nut

A cap screw used with a nut , is considered a bolt.

Threaded Fastening Devices
Cap Screw

Hex (Allen) 12-point Cap Screw

Socket Head

Hex socket head may be used in recessed

or sunken holes, or 12-point for difficult to
reach areas.
Threaded Fastening Devices
Major Diameter
Sizing
Minor
Diameter

Pitch
0.140”
Crest Pitch
Root Measured from
crest to crest.
0.140” ÷ 1” = 7 TPI
(Threads Per Inch)
Threaded Fastening Devices
Sizing

4.00”

Length Distance from under the bolt head to

the tip of the bolt.
Threaded Fastening Devices
Thread Standards UNC Unified
UNEF Unified National National Course
Extra Fine is not a
common fastener.

Bolts are either in

imperial or metric
sizes.

Thread type on a bolt UNF Unified

are referred to as a National Fine
Series (UNC, UNF, NPT.)
Threaded Fastening Devices
Thread Standards
National Pipe Thread
(NPT).
A tapered thread that
is greater in diameter
at the start, than it is
at the end.

Thread depth remains the same throughout

the length of the thread.
Threaded Fastening Devices
Thread Class
Threads are designated by class and fit.
Class 1 - Wing nut.
Class 2 - Nut & bolt.
Class 3 - Micrometer thread.
Class 4 - Interference fit thread.

Class 2 is the most commonly used.

Threaded Fastening Devices
Thread Class
Threads are also designated by type of thread.

A. External threads.

B. Internal threads.
Threaded Fastening Devices
Bolt Head Markings
Tensile Strength

Maximum stress the bolt

will sustain before it
fractures.
Grade
Lines
Add 2 to the number of
markings on the bolt to
identify the grade (tensile
strength).
Threaded Fastening Devices
Bolt Head Markings SAE Imperial Grade
Tensile Strength

No marks SAE Grade 1, Low Carbon

Steel, 65,000 psi.

3 marks SAE Grade 5, Medium

Carbon Steel, 120,000 psi.

6 marks SAE Grade 8, Medium

Carbon Alloy, 150,000 psi.
Threaded Fastening Devices
Bolt Head Markings ISO Metric Grading
Grade Specification Size Tensile Approx. Imperial
Marking Strength SAE Equivalent
Class 4.6 M5 400 MPa SAE
4.6 and Grade 1
57,000
larger psi
Class 4.8 Up to 420 MPa SAE
4.8
M16 60,000 Grade 1
psi
Class 5.8 M5 to 520 MPa SAE
5.8 M24 75,000 Grade 2
psi
Threaded Fastening Devices
Bolt Head Markings
Grade Specification Size Tensile Approx. Imperial
Marking Strength SAE Equivalent
Class 8.8 Up to 800 MPa SAE
8.8 M16 Grade 5
Over 830 MPa
M16 120,000
psi
Class 9.8 Up to 900 MPa 9% stronger
9.8
M16 130,000 than SAE
psi Grade 5
Threaded Fastening Devices
Bolt Head Markings
Grade Specification Size Tensile Approx.
Marking Strength Imperial SAE
Equivalent
10.9 Class 10.9 Up to 1040 SAE Grade
M36 MPa 8
150,000
psi
Different bolt manufactures design different
thread styles, like an inverted V thread, or
the root and crest may be rounded or flat.
Threaded Fastening Devices
Bolt Identification
Imperial
Diameter Length Series TPI Class Grade
1 ¼” x 4 UNC 7 A2 GR5

ISO Metric
Diameter Thread Pitch Length
M10 x 1.5 x 50
Threaded Fastening Devices
Nuts

Nylock insert or steel Self Locking Nuts are

a one time use only.
Threaded Fastening Devices
Lock Rings and Jam Nuts
Axle Spindle Axle Spindle
Inner (Thin) Wheel
Bearing Adjusting Dowel
Nut Adjusting
Nut

Wheel Bearing
Adjusting Nut Lock Lock Ring
Outer (Thick) Wheel Jam Nut
Bearing Adjusting Nut (Jam Nut)
Jam nuts are thinner and are used to keep the
main nut from working loose.
Threaded Fastening Devices
Washers
Flat washers protect the surface
and distributes pressure over a
greater area.

Helical spring washer grip the

surface and prevents the
fastener from becoming loose.

Internal and external washer

should not be used on soft
material.
Threaded Fastening Devices

Machine Screws
A threaded fastener that is smaller
than ¼” in diameter.
Head is normally recessed to
accept a screw driver tip, Allen
wrench or torx driver, or may have
a hex head.

May be used in a threaded

hole, or with a nut and washer.
Machine Screw Size and Drill Chart
Course Standard Thread (NC)
Sizes Threads Outside Diameter Tap Drill Decimal
per inch at Screw Sizes Equiv. of Drill
1 64 0.073 53 0.0595
2 56 0.086 50 0.0700
3 48 0.099 47 0.0785
4 40 0.112 43 0.0890
5 40 0.125 38 0.1015
6 32 0.138 36 0.1065
8 32 0.164 29 0.1360
10 24 0.190 25 0.1495
12 24 0.216 16 0.1770
Machine Screw Size and Drill Chart
Fine Standard Thread (NC)
Sizes Threads Outside Diameter Tap Drill Decimal
per inch at Screw Sizes Equiv. of Drill
0 80 0.060 3/64 0.0469
1 72 0.073 53 0.0595
2 64 0.086 50 0.0700
3 56 0.099 45 0.0820
4 48 0.112 42 0.0935
5 44 0.125 37 0.1040
6 40 0.138 33 0.1130
8 36 0.164 29 0.1360
10 32 0.190 21 0.1590
12 28 0.216 14 0.1820
Threaded Fastening Devices
Set Screws
Allen Setscrews
Are used to retain a hub,
collar, gear or sleeve in
position on a shaft.
Square Head
Hex set screws are
(Grub) Screw
sometimes doubled-up,
one on top of the other.

Square Head Set Screw may have a drilled

passage in the head, to allow the use of wire to
prevent the screw from coming loose.
Threaded Fastening Devices
Set Screws Point Styles

Set screws are sized the same as machine

screws, starting at 80 and progressing to
a bolt size greater than 1”.
Objective Four

Explain torque procedures and precautions

required when securing fastening devices.
Torque Wrenches
Insufficient torque leads to parts coming loose.

Over torquing leads to stretched or

broken fasteners, or deformation of
components, due to excessive or
uneven clamping.

A fastener that hasn’t been over torqued

resumes its original shape, when the
stretch from torquing is relieved.
• Providing its elastic limit has not
been exceeded.
Torque Wrenches
Bolt Clamp Load
Diameter & SAE Grade 2 SAE Grade 5 SAE Grade 8
Threads Clamp Dry Lub Clamp Dry Lub Clamp Dry Lub
per inch Load ft lb ft lb Load ft lb ft lb Load ft lb ft lb
(lb) (lb) (lb)
1/4 - 20 1310 5.5 4.2 2020 8 6.3 2850 12 9
NF 28 1500 6.3 4.7 2320 10 7.2 3250 14 10
5/16 – 18 2160 11 8 3340 17 13 4700 24 18
NF 24 2400 12 9 3700 19 14 5200 27 20
3/8 – 16 3200 20 15 4950 30 23 6980 45 35
NF 24 3620 23 17 5600 35 25 7900 50 35
7/16 – 14 4300 32 24 6780 50 35 9550 70 50
NF 20 4900 36 27 7570 55 40 10650 80 60
Torque Wrenches

Deflecting Beam Type

Torque Wrench

Types: Dial Type.

Indicating Click Type.
Digital Type.
Deflecting Beam Type.
Torque Procedures
3
Sequence Methods
1 5
9 3 1 5 7

4 2
8 6 2 4 10

Three Stages: 1. 1/3 of full torque.

2. 2/3 of full torque.
3. Full torque.
4. Recheck torque after all fastener are torqued.
Torque Procedures
Torque and Turn

+
Initial Torque
65 Lb-Ft Turn 120º

More accurate, and is generally used on cylinder

head, but not on applications using studs.
Objective Five
Identify types of non-threaded fasteners and
their applications.
Non-Threaded Fasteners
Keys
Maintains the position of
the unit on the driving
member, and transfers
torque.
Square Key Stock
A groove (keyway) is cut
into the gear or hub and
the shaft on which it
rides.
Woodruff
Keys
Non-Threaded Fasteners
Splines
Straight
Are externally machined Splines
grooves and lands on a
shaft, made to match
with an internal grooves
and lands, of an other
component.

Some components may be press fit and kept

in position by set screws, or may be free to
slide on the shaft.
Non-Threaded Fasteners
Splines
Helical splines act as drivers
for the component they mesh
with.

Allows a sliding helical gear

to be shifted into mesh with
another helical gear, without Helical Splines
clashing.

Offsets or counteracts axial or end thrust.

Non-Threaded Fasteners
Pins
Cotter Pins
Generally used to retain other
fasteners in place and are
made of mild steel, or brass for
special uses.

Cotter pin should be of the same diameter as

the hole it fits into, and long enough to bend
the ends over.
Use only once.
Non-Threaded Fasteners
Clevis &
Spring Pins
Spring Pin
Perform the same function as
a cotter pin, without bending
the ends.

Can be used repeatedly.

Spring Pin
Non-Threaded Fasteners
Tapered Pins, Split Pins and Roll Pins

Tapered pin fit precisely in a pre-drilled hole

and driven out from the small end.

May have threads on the small end or a flat

side to help keep it in position.
Non-Threaded Fasteners
Tapered Pins, Split Pins and Roll Pins
Split or spring pins are made Split Pin
of spring steel, to enable
them to fit tight in a hole.
Roll Pin
May be reused if removed
carefully.

Roll Pins are similar to split pins, but are multi-

layered.
Non-Threaded Fasteners
Tapered Pins, Split Pins and Roll Pins

A roll pin punch should be

used to install and remove
roll and split pins.

Ensure use of the proper

size roll pin punch to avoid
driving inside the pin, or
damaging component. Roll Pin Punches
Non-Threaded Fasteners
External Type
Locking Rings Retaining Ring
Snap rings are either of the
internal or external type.
Retaining rings are placed
within a groove on a shaft or
housing, to provide
component placement.

The component may be held firmly in position,

or allowed to rotate freely, or establish free
play. (end play)
Non-Threaded Fasteners
Locking Rings
Tru Arc uses a pin type snap ring pliers, for
removal and installation.

External
Internal External

“C” Clips are use for applications with no

pressure or speed against the C clip.
Non-Threaded Fasteners
Safety
A snap ring can slip off the installing pliers
before it is in position, and fly off with a great
deal of force.

Cover the snap ring with your hand or cloth,

when removing or installing.

Always wear proper PPE.

Non-Threaded Fasteners
Rivets
Generally used where screws or bolts would
be impractical.

Solid Rivets
Are installed cold, and are used to fasten
frames and crossmembers.
Non-Threaded Fasteners
Small Rivets

Are available in various

sizes and head design, Rivets
and may be made of
steel, brass or copper.

Brake linings are often

riveted to the shoe table, using hollow brass
rivets and a roll set.
Non-Threaded Fasteners
Tubular Rivets

Installer

May be a two piece design with the rivet end

mushrooming into the second head piece.
Non-Threaded Fasteners
Blind Rivets (pop rivets)

Are meant more for light

duty use.

Available in a variety of
materials, aluminum
and steel being the
most common.
Blind
Rivets
Non-Threaded Fasteners
Monobolts

Are a flush-break fastener that is easily

installed, and forms a strong vibration free join.
Available in diameters from 4.8 to 6.35 mm, in
aluminum, carbon steel or stainless steel.
Non-Threaded Fasteners
Huckbolts

Require both sides of the plates to be open,

are exceedingly strong, and do not allow
movement or flexing of components.
Non-Threaded Fasteners
Huckbolt Installation Procedure
The end results provides a secure clamping
force that leaves the fastener flush, after the
pintail is sheared.

Step 1.
Pintail
Pin is inserted through the
prepared hole.
Collar is placed over the Collar
pintail.
Non-Threaded Fasteners
Huckbolt Installation Procedure
Step 2.
Nose assembly is placed
over pintail.
Nose assembly
installation tool pulls on
pin and starts to drawing
sheets together.
Non-Threaded Fasteners
Huckbolt Installation Procedure

Step 3
Continued pulling on
pintail swages collar into
locking grooves.

Controlled volume swaging

lengthens collar and develops clamp.
Non-Threaded Fasteners
Huckbolt Installation Procedure
Step 4
As pull increases, pintail
breaks – Anvil pushes
off swaged collar.
Adhesives and Sealants
Safety
Read the Material Safety Data Sheet on
the product being used.
Read precaution labels on container.

Sealers and adhesives may be harmful to the

skin, eyes or respiratory system.
Effects due to prolonged exposure may
not appear until much later.
Adhesives and Sealants
Types and Uses

Are available in liquids, paste and spray.

Some products remain soft and pliable, some

hard and brittle, and others dry well, while
others remain tacky.

Products vary for temperature ranges,

pressure and types of liquids.
Adhesives and Sealants
Types and Uses

Gasket sealers are spread

thinly on paper-like gaskets,
to improve sealing qualities
on small surface irregularities.
Adhesives and Sealants
Types and Uses

Anaerobic sealers are used to seal close-fitting

components, and when exposed to air, will cure
and form a flexible rubberized seal.

An anaerobic sealers are not recommended

for use with gaskets.

Ensure adequate ventilation.

• Chemical vapors are emitted during
the curing process.
Adhesives and Sealants
Types and Uses

Thread locking material prevents

fasteners from working loose..
Three grades: Green - light
Blue - medium
Red - heavy

Fastener should be installed quickly, and

when cured, removal may require heat.
The End