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Crack Detection & Repair

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Minor Cracks in Horizontal
 WORD  PNG  TXT  JPG Surfaces
Cracks, chips and broken or
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1 Crack Detection & Repair Instruction Manual & Parts List Irontite Products Inc INSTALLATION
RECOMMENDATIONS.
Introduction The Irontite crack repair system is a cold repair process for repairing cracks in
2
castings by adding metal and moving the metal in the casting to close the crack. The basic crack Outdoor Rubber Tiles
repair process involves: 1. Detection of the crack - including determining the location of the crack. 2. INSTALLATION
Relieving the stress in the casting in the area of the crack. 3. Adding and moving metal in such a RECOMMENDATIONS Outdoor
manner as to close o the crack. 4. Re nishing the surface of the repaired casting. This cold crack Rubber Tiles Prior to
repair process does not in any way subject the casting to high temperatures of a welding process, nor does it alter the heat treated characteristics of the Installation: The Outdoor
casting. Cracks in metal castings are the result of stress or strain in some part of the casting. This stress or strain nds a weak point in that section of the Rubber Tiles and accessory
casting and causes the casting to separate at the weak point. Such stress or strain may develop from: or 1. The casting having been subjected to pressure or transition pieces intended for this installation
temperature changes before it was properly aged, 2. Having been subjected to excessive heat or cold, or 3. Subjected to too rapid a change in the have been shipped to you via a freight carrier
temperatures. Whatever may have caused the stress, and in turn the crack, the important job is to relieve the stress at the point of the crack, close o the
crack and resurface the casting. The rst step in the repair process is detecting the crack. Detection of the crack involves not only nding that a crack exists,
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but also determining its exact location and marking the entire crack for subsequent repair. The cracks may be detected: 1. By using a magnet and magnetic
powder for ferrous materials, 2. By the use of dye penetrant, or 3. By pressurizing the head or block with a pressure tester and applying a bubble solution.
Magnetic Crack Detection Electro Magnet Each Kit Contains: The Power-Pak Electro Magnet, 115V or 230V 1-Pound can of Magnetic Powder Powder Spray
Bulb Handy Tool Box Page 2 HAIR CLIPPER. Model No.
HC5150 HC5150 2. 3.
3 INSTRUCTIONS 1. Clean the surface of the casting to be checked. Remove all oil, grease or other dirt from the surface of the casting. Leave it dry. 2. Plug
All technical modi cations
the magnet input cord into a nearby convenient electric outlet. Make certain that the magnet cord is properly grounded and keep the unit away from water
reserved. 09/08. TSC 08.0634
or other liquids when in use. 3. Position the magnet on the surface of the casting and activate the magnet with the push-button switch. 4. Using the powder
HAIR CLIPPER 2. 3. 1. Model No.
spray bulb lled with magnetic powder, dust or drift the magnetic powder onto the surface of the casting between the two poles or legs of the magnet. The
HC5150 4. 10/UK/HC5150
magnet creates a magnetic eld in the casting, running from one pole to the other. If there is a crack in the casting between the two poles, it breaks the eld
Version 03/10 Part No. T22-
and draws an accumulation of magnetic powder, sharply outlining the crack. Since the magnetic powder reacts this way only between the poles of the
29458 REMINGTON is a Registered Trade
magnet, it is necessary to move the magnet around on the surface of the casting to check the area for other cracks and to show the full extent of any crack.
Mark of Spectrum Brands,
5. When the magnetic powder shows the existence and location of a crack, the crack should be completely marked so it can be easily identi ed later for the
repair. NOTE: This magnetic crack detection process can be used only on the types of castings subject to magnetic charges. It cannot be used on aluminum
castings. Page 3 More information

4 DYE PENETRANT CRACK DETECTION With dye penetrant crack detection, penetrant dye is used to show the existence and the location of the crack. This is
especially helpful for aluminum castings which do not react to magnetic detection. INSTRUCTIONS 1. Thoroughly clean the surface of the casting which is to Arctic Leash Instruction
be checked. It should be free of oil, grease and moisture. 2. Spray the surface of the casting with the penetrant - Kwik-Chek #1. Allow time for the penetrant Manual Alaskan Products
to dry - usually about 3 minutes (more time in colder weather). 3. Spray the same surface of the casting with the remover - Kwik-Chek #3. Immediately rinse
with water and wipe clean and dry. 4. Shake the Kwik-Chek #3 Developer until the agitators rattle and then spray the surface with a very light coating. 5. As Company LLC.
the thin coat of developer dries, cracks and porosity on the surface of the casting will show up in red lines or dots. Kwik-Chek Kit (Part No ) Includes: # 1 - Dye Retractable Cord Reel for
Penetrant # 2 - Remover # 3 - Developer CAUTION: THE PROPELLANT IN THE KWIK-CHEK CANS IS EXTREMELY FLAMMABLE. When storing or using the cans, Engine Block Heaters Arctic
keep them away from all ames and extremely hot areas. Review the Material Safety Data Sheets. Page 4 Leash Instruction Manual
Alaskan Products Company LLC.
5 PRESSURE TESTER CRACK DETECTION For castings that can be subjected to internal air pressure, such as water-cooled engine heads and blocks, the most INSTALLATION INSTRUCTIONS
comprehensive method of detecting the existence of cracks in castings is by using a pressure tester. With this method, the ports on the castings are closed This instruction manual is a reference guide
o and the casting is subjected to approximately pounds of air pressure. The surface of the casting is then sprayed with a bubble solution. Cracks in the for installing and operating
casting permit the air to escape and bubble up as the solution is sprayed on the casting. This is particularly suitable for detecting cracks in castings around
valve seats, where it is not practical to use the magnetic crack detection process. To operate a pressure tester, it is necessary to close o the port and heater
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outlets in order to allow the desired pressure to be set inside the head. Once the crack is detected, mark the crack for later repair. REFER TO THE PRESSURE
TESTER MANUFACTURER FOR CORRECT TEST PROCEDURES. Page 5

6 REPAIRING THE CRACK Tools for Repairing the Crack: Irontite Tapered Plugs Irontite Standard Drills Irontite Tapered Reamers Irontite Tapered Taps (see
Product Listings at the end of this Manual) GENERAL INSTRUCTIONS 1. The rst step is to stop or capture the crack - make certain the limit of the crack is
determined. 2. At the end of the crack, drill a hole suitable for the installation of an A-200 or A-235 plug. 3. Retest the area to see if the crack runs beyond the
hole. 4. Repeat this process until the crack does not run beyond the hole. Marked Crack Drill Holes for Plugs Capture the Crack Cut O Plugs Peen Plugs
NOTE: The particular technique or method used in repairing the crack varies depending on the location and accessibility of the crack, thickness of the metal,
etc. Experience will develop the most suitable technique for the operator to use. This manual will describe some of the most commonly used techniques
which will point the way for an operator to develop his best approach to repairing cracks. Whatever technique is used, one of the most important parts of
the repair process is the peening of the tops of the plugs after they have been installed and cut o down near the surface of the head or block. Page 6

7 TECHNIQUE ONE Installing tapered plugs along the line of the crack in areas of the casting that are subject to high pressure and temperatures. One of
the best examples of this type of crack is in the valve seat area of the head. In this instance, the plugs are installed at angles to the casting surface, not
perpendicular to the surface. In addition, they are installed in an overlapping fashion. 1. A plug hole is drilled, reamed and tapped and the plug is fully
torqued into place. 2. Cut o the excess part of the plug before the next hole is started. This permits locating the next plug so it will overlap the preceding
plug at the surface and below the surface. 3. Here, where the metal is thick, after drilling, the hole needs to be taper reamed before tapping. This helps give
the tapered tap a reasonable life. Drill & Tap for Plugs Capture the Crack (Plugs at each end) Continue to Fill in with Plugs Cut O and Peen the Plugs Remove
Excess Plug Material Re nish Surface like New 4. Cut o the installed plugs (with a small coping or other saw) and peen the tops of each plug NOTE: The
peening process is extremely important. It helps close the threads at the surface of the casting. When peening, always peen away from the center of the
plug. In the peening process, the position control of the air hammer is most important. It provides the necessary control over the direction of the ends of the
peening tools. Page 7

8 TECHNIQUE TWO Repairing cracks in readily accessible areas of a casting not subject to high pressure and high temperature, where the metal is relatively
thin. Here, the object is to close the crack with either a series of plugs down the line of the crack or alternate plugs on opposite sides of the crack,
supplemented with a thorough peening of the crack itself. 1. After the crack is carefully outlined, drill and tap holes along the line of the crack about 1/4 to
1/2 apart. NOTE: Where the material is less than 1/4 thick, it is not necessary to taper ream before taper tapping it. 2. Capture the crack at each end 3.
Torque the plugs in concurrently so that none of them will be loosened as other plugs are torqued in. 4. Cut the plugs o about 1/16 above the surface and
peen them, always peening from the center of the plug outwardly toward the thread in the plug. 5. Peen the crack itself, peening inwardly toward the center
of the crack. 1 Drill & Tap 2 Capture 3 Fill with 4 Cut O & 5 Resurface Crack Plugs Peen Plugs Alternately, the plug holes can be drilled and tapped in a lacing
fashion on opposite sides of the crack. Torque the plugs in concurrently and then cut them o . Peen the plugs and the crack in the same manner as above.
This process, in addition to closing the crack with additional metal and with peening the crack, develops a resistant elasticity in the metal which helps keep
the crack closed. THE IMPORTANCE OF PEENING IN CRACK REPAIR CANNOT BE OVEREMPHASIZED. Page 8

9 GENERAL INFORMATION The examples described in this manual are crack repair techniques intended only to illustrate various approaches to the
process of closing a crack in a casting. They can serve as guides in the process of repairing many di erent types of cracks in many di erent types of castings
- industrial as well as engine castings. The most important factors in closing the crack are the adding of metal by torquing in the tapered, threaded plugs and ENGINE COOLING SYSTEM
the moving of the metal through the peening process. NOTE: A tapered tap is cutting the full length of the tap, so if the metal is very thick, the hole must be
rst reamed with a tapered reamer if the tap is to have a reasonable life. Even when the hole is reamed with a tapered reamer, it is necessary to use the ENGINE COOLING SYSTEM 1988
proper amount of downward pressure with the tapered tap. For certain larger taps used in repairing and replacing the injector seat areas in heavy duty Toyota Celica 1987-88 TOYOTA
diesel engine heads, Irontite has developed lead screw nuts and arbors. To apply the lead screw principle, give just the right amount of downward pressure Engine Cooling Systems Celica
on the tap. NOTE: A good tapping uid should be used at all times with the tapered tap. Irontite recommends TAP-O tapping compound. TAP-o does not DESCRIPTION The basic liquid
contain oil or carbon tetrachloride. Irontite tapered plugs and tapered taps are designed so there will be a tight thread-to-thread t when the plugs are cooling system consists of a
torqued into position. When torqueing in the plug, as an added assurance of a leak-proof t, dip the plug in Irontite s Ceramic Seal just before torqueing it in. radiator, water pump, thermostat, cooling
This will help close any porosity that may be present in the threaded hole of the casting. Ceramic Seal is recommended because, being uid it will spread fan, pressure cap,
evenly on the threaded plug as it is torqued in. Page 9
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123 Industrial Loop Road

Paynesville, MN 56362 Phone:
1-800-864-1649 www.master-
123 Industrial Loop Road
Paynesville, MN 56362 Phone:
1-800-864-1649 www.master-
mfg.com INTRODUCTION The
purpose of this manual is to
assist you in the assembly, operation and
maintenance of your sprayer

10 IRONTITE CRACK REPAIR SEALANTS Irontite developed two types of professional grade cooling system sealants to supplement the crack repair process.
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In fact, these sealants can be used e ectively with or without a repair. IRONTITE CERAMIC SEAL As part of its overall crack repair process, Irontite
recommends Ceramic Seal. When properly applied, Ceramic Seal leaves a ne ceramic coating on the inside of the casting, closing porosity and the inside of
minor cracks. In conjunction with crack repair work, Ceramic Seal is applied to the casting after the repair process is complete to give the repair a nishing Solvent Cementing
touch and the added assurance the crack is sealed. INSTRUCTIONS 1. The head or block is remounted on the pressure tester and the water ports are sealed Instructions For Plastic Pipe &
so the casting can be pressurized. 2. After pressurizing the head or block and con rming the high quality of the Irontite repair job, secure the outlet and
return hoses on a circulator to opposite ends of the head or block. 3. Activate the circulator and circulate Irontite Ceramic Seal through the casting at the Fittings
temperature supplied by the circulator. 4. After circulating the Ceramic Seal for a period of minutes, close o both the outlet valve and the return valve. 5. Solvent Cementing Instructions
Depress the air pressure button, holding it down for a few seconds and then releasing it. This pressure forces the ceramic seal in the casting into any cracks For Plastic Pipe & Fittings
or porosity in the interior of the casting. 6. Turn the head over, open the circulator return valve and press the air pressure button for only a few seconds. Description Solvent cementing
This will force the remaining liquid Ceramic Seal back into the circulator tank. 7. Remove the casting and set it to one side allowing the Ceramic Seal in the is the process of fusing plastic
interior of the casting to cure. After a period of time, the Ceramic Seal will cure on the inside of the casting and will serve as an additional seal to the crack. pipe and ttings by the use of
The time required for the seal to set or cure will vary depending on temperature and humidity. IRONTITE ALL WEATHER SEAL This is a general purpose an adhesive containing a suitable active
sealant used in automobile cooling systems while there is anti-freeze or coolant in the system. Just shake it up, pour it in the radiator and drive on. All solvent
Weather Seal is widely used and e ectively takes care of many small leaks - quickly and easily. NOTE: When using Irontite Ceramic Seal, it is MANDATORY
that the cooling system be cleaned rst to make certain that any anti-freeze or coolant is ushed out and the system is clean. Ceramic Seal IS NOT
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COMPATIBLE WITH ANTI-FREEZE OR COOLANT. Combining them in the cooling system will clog the cooling system. Page 10

11 Page 11
Diesel Fuel Systems. Injection
12 Tools, Equipment and Supplies Kwik-Chek Dye Penetrant DESCRIPTION PART # Kwik-Chek Kit #1 Penetrant Dye #2 Dye Remover #3 Developer Bubble Nozzles
Solutions for Pressure Testing DESCRIPTION PART # Bubble Solution - 8oz Bubble Solution - 1/2 Gal Magnetic crack detection DESCRIPTION PART # Electro Diesel Fuel Systems Injection
Magnet Kit - 115V Electro Magnet Kit - 230V Mini-Magnet with Vial of Powder Magna Ray Permanent Magnet Spray Bulb Magnetic powder DESCRIPTION PART Nozzles Unit Terms Injection
# WHITE 1 lb. Can lb. Can lb. Can lb. Can GOLD 1 lb. Can lb. Can lb. Can lb. Can GREY 1 lb. Can lb. Can lb. Can lb. Can Page 12 nozzle Nozzle, nozzle holder,
valve, spring assembly Nozzle
13 Ductile Iron Threaded Plugs - Automotive DESCRIPTION Qty PART # A /Box A /Box A /Box A-235 1/2 100/Box B-1 50/Box C 25/Box C-1 25/Box D 25/Box assembly Valve, body, and spray
D-1 25/Box E 25/Box Ductile Iron Threadless Pins - Automotive DESCRIPTION Qty PART # TPD 100/Box TPC 100/Box TPA 100/Box TPB 50/Box Ductile Iron valve Ori ce Small hole Pintle Valve which the
Plugs - Diesel DESCRIPTION Qty PART # C-1 Special Each D-1 Special Each E-1 Solid Each E-1 Special Each G Solid Each G-3 Drilled Each G-4 Drilled Each GO end
Solid Each GO-3 Drilled Each GO-4 Drilled Each GO Short Each R Solid Each R-2 Drilled Each H Solid Each H-2 Drilled Each H-4 Drilled Each HO Solid Each HO-2
Drilled Each HO-4 Drilled Each Page 13
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14 Ductile Iron Plugs Diesel (cont) DESCRIPTION Qty PART # J Solid Each J-2 Drilled Each Diesel Ductile iron Plugs - Caterpillar DESCRIPTION PART # 3/4-12
Standard Caterpillar Plug /8-12 Standard Caterpillar Plug Standard Caterpillar Plug /4-12 Standard Caterpillar Plug Diesel Ductile iron Plugs - Caterpillar
DESCRIPTION PART # 3/4-12 Oversize Caterpillar Plug /8-12 Oversize Caterpillar Plug /8-12 Oversize Caterpillar Plug HSS TAPERED REAMERS DESCRIPTION
Plug Type PART # HSS Tapered Reamer A-200/A HSS Tapered Reamer B HSS Tapered Reamer B-1/ HSS Tapered Reamer C, C-1, C-1 Special HSS Tapered
Reamer D, D-1, D-1 Special HSS Tapered Reamer E, E-1, E-1 Special HSS Tapered Reamer G HSS Tapered Reamer H HSS Tapered Reamer HO HSS Tapered
Reamer J HSS TAPERED TAPS DESCRIPTION Plug Type PART # HSS Tapered Tap A HSS Tapered Tap A HSS Tapered Tap A-200 TN HSS Tapered Tap AL Page 14

15 HSS TAPERED TAPS (cont) HSS Tapered Tap A HSS Tapered Tap A-235 TN HSS Tapered Tap AL HSS Tapered Tap B HSS Tapered Tap AL - B HSS Tapered
Tap B-1/8 (CS) HSS Tapered Tap C, C-1, C-1 Special HSS Tapered Tap D, D-1, D-1 Special HSS Tapered Tap E, E-1, E-1 Special HSS Tapered Tap G HSS Tapered
Tap R w/pilot Hole HSS Tapered Tap GO HSS Tapered Tap H HSS Tapered Tap HO w/ Pilot Hole HSS Tapered Tap J & J-2 Drilled Jobber Length Drills
DESCRIPTION Plug Type PART # 6/64 HSS Drill A HSS Drill A-200 & TPA Pins /64 HSS Drill A /16 HSS Drill B /32 HSS Drill B-1/ /64 HSS Drill C, C-1, C-1 Special /32
HSS Drill D, D-1, D-1 Special /16 HSS Drill E, E-1, E-1 Special Extension Drills DESCRIPTION Plug Type PART # 11/16 HSS Extension Drill A /64 HSS Extension
Drill A Page 15

16 TAPPING COMPOUND AND NEVER-GALL DESCRIPTION Size PART # TAP-O Tapping Compound 8 oz TAP-O Tapping Compound 1/2 Gallon TAP-O Tapping
Compound 5 Gallon Never Gall Compound 1 Pound MicroFinish Tap & Lube 8 oz CRACK REPAIR KITS DESCRIPTION QTY PART # K-210 Crack Repair Kit
(Starter) Includes the following Items in a handy Tool Box: A-235 Iron Plugs (Automotive) /64 HSS Drill (A-235) HSS Tapered Reamer (A-200/235) HSS Tapered
Tap (A-235) Carbide File I/S (Oval) Coping Saw, New Style Coping Saw Blades, New Style Heat Tabs 255º 260º (100/Pkg) Devcon Adhesive Ceramic Seal (Pint)
TAP-O (8oz.) Plug Installation Tools R Plug Tool - Ratchet Tip Heat Tabs 255º - 260º 100/Pkg Heat Tabs 220º - 235º 100/Pkg Devcon Adhesive Tube Page 16

OWNER S MANUAL FORCE 10

17 Engine & Cooling System Additives CERAMIC SEAL Finish the crack repair job by circulating Ceramic Seal internally to seal any part of the crack that my
still be separated on the inside of the casting. Ceramic Seal DESCRIPTION Size PART # Ceramic Seal Pint Ceramic Seal Gallon Ceramic Seal 5 Gallon ALL MARINE COMPANY 23080
WEATHER SEAL Seals leaks and cracks in the cooling system Prevents anti-freeze leakage Fast-Acting; Non-Corrosive; Non-Clogging Recommended for use HAMILTON ROAD RICHMOND,
with any Anti-freeze or Coolant Lubricates Water Seals All Weather Seal DESCRIPTION Size PART # All Weather Seal Pint THORO FLUSH - THE PERFECT
CLEANER Protects and cleans the engine cooling systems Leaves them free from rust, sludge and grease Extends the life of the cooling system Thoro Flush Electric Water Heater OWNER S
DESCRIPTION Size PART # Thoro Flush Pint The 3-Pack (Trifecta) 1 Pint of Each Thoro Flush Ceramic Seal & All Weather Seal Page 17 MANUAL FORCE 10 MARINE
COMPANY 23080 HAMILTON
18 ROAD RICHMOND, BC CANADA
V6V 1C9 TEL: (604) 522-0233
FAX: (604) 522-9608 If your water Heater is
19 th Street SW, Suite D Cedar Rapids, Iowa USA +1 (319) FAX +1 (319)
Damaged or you have questions

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FASCINATION 700 HVLP CORROSION ENGINEERING

NITROUS TRANSFER PUMP Surface Engineering Solutions
TANNING PRO SYSTEM USER RESIN-BASED POLYMER
INSTRUCTIONS Rebuild, Repair and Protect
MANUAL CONCRETES AND GROUTS
NITROUS TRANSFER PUMP
FASCINATION 700 HVLP
Industrial Equipment
INSTRUCTIONS SAFETY TIPS AN ERGONARMOR COMPANY
Never directly inhale nitrous TANNING PRO SYSTEM USER Surface Engineering Solutions
TECHNICAL INFORMATION
oxide. When inhaled in large MANUAL Congratulations on Rebuild, Repair and Protect
SPECIFICATION FOR
quantities, nitrous oxide can choosing the Fascination 700 Industrial Equipment Whatever
INSTALLATION 07/11
cause respiratory ailments or in extreme HVLP Tanning Pro System! Your You Rebuild, Repair and
SUPERSEDES 04/00 PAGE 1 OF 6
cases, death by su ocation. system includes the following items: 1 Protect...... Find the Right
CORROSION ENGINEERING RESIN-BASED
Fascination 700 HVLP Tanning Pro Solution! Henkel's Solutions for all Surface
POLYMER CONCRETES AND GROUTS 1.
Engineering Needs
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CALIpER REbUILdING TUTORIAL 25-302 U.S. Patent # 6,298,828! Adhesive Recommendation for
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