WIXLIB

0180/10.02HELICOIL plus repairing of damaged threads

ContentsPageApplications for thread repair with HELICOIL plus3HELICOIL plus thread technology4Installation of HELICOIL plus thread inserts5Product range of HELICOIL plus repair kits and repair range kits6Repair kits with metric thread insertsRepair kits with metric thread inserts for special applications(oil drain, spark plug and Lambda probe threads)11 – 12Repair range kits with metric thread inserts13 – 14Repair kits with imperial thread inserts15 – 21Repair range kits with imperial thread inserts22 – 24Replacement installation and removal tools (metric)24 – 34HELICOIL plus design quidelines for thread technology35HELICOIL plus threads metric installation data36HELICOIL plus threads imperial installation data37HELICOIL plus TWINSERT thread inserts for metals27 – 1038 – 39

Repairing of damaged spark plug threadsIn the automotive industry the HELICOIL plus threadtechnology is widely used to provide high strengththreads.Thanks to efficient repair of damaged threads, valuablecomponents do not have to be replaced.Thread repair for aluminium enginesWith HELICOIL plus thread inserts, cost-intensivereplacements of threads in aluminium engines, such asemployed in motor sports, are no longer necessary.Preventive installation of HELICOIL plus ensuresminimum effort for thread repair during engine life.Thread repair in different industry sectorsCommon applications relying on threads are employedin the machine and plant construction, power plantengineering and shipbuilding. Scrap reclamation: Highvolume production parts with damaged threads can bereworked.Thread repair involves multiple standards.HELICOIL plus thread inserts comply with certificationsfor numerous industries, e. g. approved by: Technical Inspection Authority (TÜV) Germanischer Lloyd DET Norske VeritasIn the field of nuclear energy an individual inspection isbeing conducted.3

HELICOIL plus Thread Technology Thread inserts ensure heavy-duty connection capability, especially inlow-strength materials like aluminium and magnesium. For over fifty years,they have been used in practice and proven reliable. HELICOIL thread repair is used in metals as well as in many plastic andcomposite materials. Thread inserts are made from well-proven and tested quality stainless steel(A2) and are formed from rhomboidally profiled wire into a resilient spiral. HELICOIL plus thread inserts comply with multiple requirements and standards for general industry andaerospace industry such as DIN 8140, DIN 65536, EN 2944, LN 9039 and LN 9490. On request, we give youfurther standards the threads comply with. Scrap reclamation: High volume production parts with damaged threads can be reworked.HELICOIL plus – the solution for threads damaged by wear of overtorqueYour advantages Permanent high strength and wearresistant Corrosion and temperatureresistant Easy and quick mounting HELICOIL plus – the originalDamaged threadRepaired threadHow to install HELICOIL plus HELICOIL plus thread inserts are screwed in just like a common screw. The tool sleeve with leader catridge,that was required in the past, is no longer needed.All that is needed for screwing-in is an installation mandrel the size of a screw tap. The mandrel can be compared to a screw tap energised by a die wrench or other common tools from nutbodies with ratchet wrench. For particularly low-height thread repairs, the mandrel can be extended.The HELICOIL plus thread insert is screwed in until the nose meets the tang. Thus, the thread also works invertical installations. It guarantees safe repairing of threads. To determine the right depth of insertion, the last spiral wire has to be situated under the first flank of thethread. Since HELICOIL plus threads are installed without a leader cartridge, the depth of insertion can be visuallychecked. Thus, it is not necessary to use a depth control stop as it is for tools using leader cartridges.For easier identification in the fitted position, HELICOIL plus threads are green-coloured. After installation the tang is broken off at the notch (pre-set break-off point). The new HELICOIL plus technology allows repairing threads, that up until now could only be repaired usingspecial tools.4

Installation of HELICOIL plus thread insertsHELICOIL plus holdingthreadPlease only use thespecial HELICOIL plusscrew tap. For checkingthe holding thread, we cansend you plug limit gauge.Drilling the core holePlease take note of therecommended diametersfor drilling the core holeD1 HC from the table onpage 36/37. Please note,that information about thetwist drill B are only valuesfor orientation. For counterboring (burring) the corehole outer diameter of thecouterbore: DHC 0.1 mmHELICOIL plus installation without leader cartridge hole in centre verticalArrange manual tap:M 2 – M 16and M 18 – M 24 (onlynormal pitch)UNC 2-56 toUNC 1/2"-13UNF 4-48 toUNF 1/2"-20 UNC 5/8"-11HELICOIL plus installation with leader cartridgeBreak tangPlease remove the tangfrom the thread using thetang break-off tool. Thetang of threads M 14should be broken off withlong-nosed pliers by axialraising and lowering.1/4 Gang1/4 pitchRight hubHELICOIL plus threadinsert is to be installed atleast 1/4 thread below thework piece top surfaceand seated in a fully cutthread.1/4 Gang1/4 pitchException HELICOIL plusfor fine threads M 18 x 1.5UNC 9/16"-12 UNF 9/16"-18 G 1/8"-28 BSW 3/16"-24 BSF 1/4"-26Information aboutthe range ofHELICOIL pluslengths on page 35.5

Product range HELICOIL plus repair kits and repair range kitsRepair kits with HELICOIL plus metric thread inserts M 2 – M 16 x 1.5(available in three lengths per size, each 20 or 10 HELICOIL plus thread inserts) M 18 – M 36 x 1.5(with 10 HELICOIL plus thread inserts in one length) Oil drain threads M 12 x 1.5, M 14 x 1.5 and M 16 x 1.5(available in three lengths per size, each 10 HELICOIL plus thread inserts) Spark plug threads M 10 x 1, M 12 x 1.25 and M 14 x 1.25(available in three lengths per size, each 10 HELICOIL plus thread inserts) Lambda probe threads M 18 x 1.5(with 5 HELICOIL plus thread inserts in one length)Repair range kits of HELICOIL plus metric thread insertsSix different ranges: M 2.5 – M 6 M 4 – M 10 M 5 – M 12 M 6 – M 14 x 1.25 Range of spark plug threads M 10 x 1 – M 14 x 1.25 Range of oil drain threads M 12 x 1.5, M 14 x 1.5, M 16 x 1.5Repair kits of HELICOIL plus imperial thread inserts UNC 2-56 to UNC 1 1/2"-6 UNF 4-48 to UNF 1"-12 BSW 3/16"-24 to BSW 1 1/2"-6 BSF 1/4"-26 to BSF 1"-10 G 1/8"-28 to G 1"-11Repair range kits of HELICOIL plus respectively HELICOIL imperial threadinsertsFive different ranges: UNC (UNC 5-40 to UNC 12-24 and UNC 1/4"-20 to UNC 1/2"-13) UNF (UNF 4-48 to UNF 1/4"-28 and UNF 1/4"-28 to UNF 1/2"-20) BSW (BSW 1/4"-20 to BSW 1/2"-12)Repair kits HELICOIL plus TWINSERT from M 2.5 to M 16The HELICOIL plus TWINSERT uses two HELICOIL plus inserts, oneinstalled inside the other. Faults requiring the repair kit HELICOIL TWINSERTare thread bores which require correction, stripped and oversized oroff-centered threads which cannot be corrected using a larger bolt diameter.TWINSERT6

HELICOIL plus repair kits with metric thread insertsM 2 – M 16 x 1.5ISO metric threads, stainless steel A2Contents:HELICOIL plus thread inserts in three sizesTwist drill (up to M 12)HELICOIL hand tap HSSHELICOIL plus installation mandrelTang break-off tool (up to M 12)Thread sized (x P)M2M 2.5M3M 3.5M4M5M6M7M8M8x1M9M 10M 10 x 1PitchOrder no.Number ofRepairThread sizeOrder no.Number ofRefillRepair kitHELICOIL kitRefill packRefill packHELICOIL packInserts d (x P) x LP0.40.450.50.60.70.81.01.01.251.01.251.51.04185 102 00004185 125 00004185 103 00004185 135 00004185 104 00004185 105 00004185 106 00004185 107 00004185 108 00004185 108 30004185 109 00004185 110 00004185 110 300020 x M 2x2on request1.254185 110 9000 M2x24189 002 000220on request20 x M 2x3M2x34189 002 000320on request20 x M 2x4M2x44189 002 000420on request20 x M 2.5x 2.5M 2.5x 2.54189 025 002520on request20 x M 2.5x 3.75 on requestM 2.5x 3.754189 025 037520on request20 x M 2.5x5M 2.5x 5.04189 025 000520on request20 x M 3x3M3x34189 003 000320on request20 x M 3x 4.5M3x 4.54189 003 004520on request20 x M 3x6on requestM3x64189 003 000620on request20 x M 3.5x 3.5M 3.5x 3.54189 035 003520on request20 x M 3.5x 5.25 on requestM 3.5x 5.254189 035 005320on request20 x M 3.5x7M 3.5x74189 035 000720on request20 x M 4x4M4x44189 004 000420on requeston request20 x M 4x6M4x64189 004 00062020 x M 4x8on requestM4x84189 004 000820on request20 x M 5x5M5x54189 005 000520on request20 x M 5x 7.5M5x 7.54189 005 007520on request20 x M 5x 10on requestM5x 104189 005 001020on request20 x M 6x6M6x64189 006 000620on request20 x M 6x9M6x94189 006 000920on request20 x M 6x 12M6x 124189 006 001220on request10 x M 7x7M7x74189 007 000710on request10 x M 7x 10.5 on requestM7x 10.54189 007 010510on request10 x M 7x 14M7x 144189 007 001410on request10 x M 8x8M8x84189 008 000810on request10 x M 8x 12M8x 124189 008 001210on request10 x M 8x 16M8x 164189 008 001610on request10 x M 8 x 1x8M8 x1x84189 008 300810on request10 x M 8 x 1x 12M8 x1x 124189 008 301210on request10 x M 8 x 1x 16M8 x1x 164189 008 301610on request10 x M 9x9M9x94189 009 000910on request10 x M 9x 13.5 on requestM9x 13.54189 009 013510on request10 x M 9x 18M9x 184189 009 001810on request10 x M 10x 10M 10x 104189 010 001010on requeston requeston requeston request10 x M 10x 15M 10x 154189 010 001510on request10 x M 10x 20on requestM 10x 204189 010 002010on request10 x M 10 x 1x 10M 10 x 1x 104189 010 301010on request10 x M 10 x 1x 15M 10 x 1x 154189 010 301510on request10 x M 10 x 1x 20M 10 x 1on requeston request10 x M 10 x 1.25 x 10M 10 x 1.25Inserts10 x M 10 x 1.25 x 1510 x M 10 x 1.25 x 20on requestx 204189 010 302010M 10 x 1.25 x 104189 010 901010on requestM 10 x 1.25 x 154189 010 901510on requestM 10 x 1.25 x 204189 010 902010on request7

HELICOIL plus repair kits with metric thread insertsThread sized (x P)M 11M 12PitchOrder no.Number ofRepairThread sizeOrder no.Number ofRefillRepair kitHELICOIL kitRefill packRefill packHELICOIL packInserts d (x P) x LP1.51.754185 111 00004185 112 000010 x M 11x 1110 x M 1110 x M 11M 12 x 1.5M 141.251.52.04185 112 90004185 112 40004185 114 0000x 114189 011 001110on requestx 16.5 on requestM 11x 16.54189 011 016510on requestx 22M 11x 224189 011 002210on request10 x M 12x 12M 12x 124189 012 001210on request10 x M 12x 18M 12x 184189 012 001810on request10 x M 12x 24M 12x 244189 012 002410on requeston requestM 12 x 1.25 x 124189 012 901210on requestM 12 x 1.25 x 184189 012 901810on request10 x M 12 x 1.25 x 24M 12 x 1.25 x 244189 012 902410on request10 x M 12 x 1.5 x 12M 12 x 1.5x 124189 012 401210on requestM 12 x 1.5x 184189 012 401810on request10 x M 12 x 1.25 x 1810 x M 12 x 1.5 x 18on requeston request10 x M 12 x 1.5 x 24M 12 x 1.5x 244189 012 402410on request10 x M 14x 14M 14x 144189 014 001410on request10 x M 14x 2110 x M 14x 28on request10 x M 14 x 1.5 x 14M 14 x 1.5M 161.52.04185 114 40004185 116 000010 x M 14 x 1.5 x 21on request1.54185 116 40008x 214189 014 002110on requestx 284189 014 002810on requestM 14 x 1.5x 144189 014 401410on requestM 14 x 1.5x 214189 014 402110on requestM 14 x 1.5x 284189 014 402810on request10 x M 16x 16M 16x 164189 016 001610on request10 x M 16x 2410 x M 16x 3210 x M 16 x 1.5 x 2410 x M 16 x 1.5 x 32d Nominal thread diameter (mm)P Thread pitch (mm)L Length (mm)M 14M 1410 x M 14 x 1.5 x 28on request10 x M 16 x 1.5 x 16M 16 x 1.5 M 1110 x M 12 x 1.25 x 12M 12 x 1.25Insertson requestM 16x 244189 016 002410on requestM 16x 324189 016 003210on requestM 16 x 1.5x 164189 016 401610on requestM 16 x 1.5x 244189 016 402410on requestM 16 x 1.5x 324189 016 403210on request