McElroy TracStar 500 Series 3, Operator'S Manual

Page 1: ...Manual T5019210 Revision Rev C 11 18 Fusion Machine Operator s Manual Original Language English ...

Page 2: ...This product and other products could be protected by patents or have patents pending All the latest patent information is available at patent mcelroy com ...

Page 3: ...achine manufacturer to continuously offer advanced training Course offerings are meant to enhance your efficiency productivity and safety in the proper use of McElroy machines McElroy University classes are structured so that the skills learned and the machines used in each class closely match the machines found on pipelining jobsites We offer training at our facility or yours Our uniquely qualifi...

Page 4: ...h Fulton Street Tulsa Oklahoma 74158 0550 PHONE 918 836 8611 FAX 918 831 9285 EMAIL fusion McElroy com Note Certain repairs warranty work and inquiries may be directed at McElroy s discretion to an authorized service center or distributor TX02486 11 4 13 DISCLAIMER OF LIABILITY McElroy accepts no responsibility of liability for fusion joints Operation and maintenance of the product is the responsi...

Page 5: ...Theory of Heat Fusion 2 1 TracStar 500 series 3 Console 2 2 Auto Throttle 2 2 Alternate Drive Controls 2 2 Pipe Lift Controls 2 3 Carriage Assembly 2 3 Indexer Controls 2 3 Inlet Fans 2 4 Facer 2 4 Hydraulic Manifold Block 2 4 Heater 2 5 Diesel Engine 2 6 Hydraulic Fluid Reservoir 2 6 Filter 2 6 Hydraulic Clamping 2 6 COPYRIGHT 2018 2016 2014 2012 2011 2010 McELROY MANUFACTURING INC Tulsa Oklahoma...

Page 6: ...ertion 3 7 Check Heater Temperature 3 8 Inserting Heater 3 8 Heat Pipe 3 9 Fusing the Pipe 3 9 Opening Movable Jaws 3 10 Opening Fixed Jaws 3 10 Raise Pipe 3 10 Position Pipe for Next Joint 3 10 Install Next Piece of Pipe 3 11 Special Operations In Ditch Overview 4 1 Remove Hydraulic Hoses and Cables 4 1 Removing 4 Jaw Carriage 4 2 Removing Heater and Facer 4 3 Removing 3 Jaw Skid 4 7 Lift 3 Jaw C...

Page 7: ...ean Jaws and Inserts 6 4 Bleeding Air From Hydraulic System 6 5 Installing Butt Fusion Heater Plates 6 5 Clean Heater Surfaces 6 6 Fasteners Must Be Tight 6 6 Engine Maintenance 6 7 Checking Track Tension 6 7 Adjusting Track Tension 6 7 Checking Oil Level in Gearbox 6 8 Changing Oil in Gearbox 6 8 Adjusting Heater Temperature 6 9 Heater Indicator Light 6 9 Maintenance Checklist TracStar 500 series...

Page 8: ...ractices IMPORTANT can help you do a better job or make your job easier in some way PELIGRO Read and Understand Do not operate this equipment until you have carefully read and understand all the sections of this manual and all other equipment manuals that will be used with it Your safety and the safety of others depends upon care and judgment in the operation of this equipment Follow all applicabl...

Page 9: ... and other applicable personal protective equipment Remove jewelry and rings and do not wear loose fitting clothing or long hair that could catch on controls or moving machinery WR00053 12 2 92 Fuel Handling Gasoline and diesel fuel are extremely flammable and their vapors will explode if ignited Do not fill the fuel tank while the engine is hot or running as spilled fuel could ignite Refuel in a ...

Page 10: ...before entering the explosive atmosphere for fusion WR00034 11 30 92 TX04467 03 24 14 PELIGRO Carbon Monoxide Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide can cause severe nausea fainting and death Avoid inhaling exhaust fumes and never run the engine in a closed or confined area TX00954 5 14 96 WR00093 5 14 96 Units With Engines Combustion engines can cause explosions wh...

Page 11: ...2 1 4 Fusion Equipment Safety Battery Do not expose the battery to flames or electrical sparks Hydrogen gas generated by battery action is explosive Blindness or serious injury can result from an exploding battery Do not allow battery fluid to contact your skin eyes fabrics or painted surfaces Sulfuric acid can cause burns After touching a batter or battery cap do not touch or rub your eyes Eye Co...

Page 12: ... in serious injury or death Pipe that is bent can store a great amount of energy Do not bend and force the pipe into the machine A bent pipe with stored energy could cause serious injury or death when that energy is released It is recommended that the pipe is always be held securely by either being clamped securely in the fusion machine jaws or attached to the lifting device Keep persons that are ...

Page 13: ...y or death TX01902 3 30 11 CD00402B 12 30 97 Facer Blades Are Sharp Facer blades are sharp and can cut Never attempt to remove shavings while the facer is running or is in the facing position between the jaws Use care when operating the facer and when handling the unit NOTICE Disconnect power from the facer and remove the facer blades before attempting any maintenance or adjustment NOTICE Never ex...

Page 14: ...6 TX04469 10 24 12 Heater Is Hot The heater is hot and will burn clothing and skin Keep the heater in its insulated heater shroud when not in use and use care when heating the pipe NOTICE Use only a clean non synthetic cloth to clean the heater plates TX04244 10 12 10 WR00030 2 10 93 Do Not Attempt to Tow Fusion Machine NOTICE The machine is not designed for towing Attempting to tow the machine ca...

Page 15: ...result The principal operations include Clamping The pipe pieces held axially to allow all subsequent operations to take place Facing The pipe ends must be faced to establish clean parallel mating surfaces perpendicular to the centerline of the pipes Aligning The pipe ends must be aligned with each other to minimize mismatch or high low of the pipe walls Heating A melt pattern that penetrates into...

Page 16: ... 0 0 25 kPa PSI 75 50 100 350 700 40 C F 250 100 150 180 210 8 10 12 14 16 18 80 120 QUARTZ 0 0 0 1 1 1 10 HOURS VEHICLE LIGHT THROTTLE FUSION LIGHT FORWARD BACKWARD T5017103 HIGH Power for heater LOW No power for heater AUTO Cycles engine throttle on demand HEADLIGHTS FUEL GAUGE ENGINE OIL PRESSURE COOLANT TEMPERATURE PREHEAT PLUG OFF RUN START IGNITION PREHEAT PLUG LIGHT WORK LIGHT VOLT METER FO...

Page 17: ... 12 PH04739 10 24 12 Pipe Lift Controls The pipe lift controls are located on the operator side of the machine to the right of the alternate drive controls Moving the right lever up and down moves the rear pipe lift up and down Moving the left lever up and down moves the forward pipe lift up and down TX02003 4 24 02 PH04730 10 1 12 Indexer Controls The indexer controls are located on the movable j...

Page 18: ...ttom valve adjusts fusion pressure to a maximum of 2300 psi which is the set system pressure G DataLogger port TX04541 10 24 12 PH04731 10 1 12 CD00138H 1 12 11 Facer The facer is a McElroy rotating planer block design The blade holders each contain three cutter blades The block rotates on ball bearings and is chain driven enclosed in lubricant by a hydraulic motor The facer is removable for in di...

Page 19: ...exer mounted pivot arm for in ditch operation The heater has a lifting point on the top of the heater and a stripper bar is available for in ditch operation The optional extension kit as well as the optional heater stand is needed for in ditch heater operation GFCI Operation and Testing 1 Press RESET button The GREEN power LED should be ON 2 Press TEST button GREEN LED should turn OFF RED LED shou...

Page 20: ...have knobs that can adjust the stroke of the cylinder for Hi Lo adjustment TX04476 10 24 12 PH04790 10 24 12 PH04027 3 2 10 Hydraulic Fluid Reservoir The hydraulic fluid reservoir is located under the front hood of the machine The fluid level sight gauge is located on the front of the reservoir Proper fluid level is indicated on the sight gauge TX01467 05 05 14 PH01251 1 29 98 Filter This machine ...

Page 21: ...essary Refer to the Hydraulic Fluids section of this manual for hydraulic fluid recommendations TX01450 05 05 14 PH01251 2 2 98 Diesel Engine Read the operating and maintenance instructions for the engine before operating The key ignition has four positions Preheat off run and start NOTICE Switch the engine to slow speed before starting For cold weather starting turn switch to preheat for no longe...

Page 22: ... PH04729 10 1 12 Prepare Heater Install butt fusion heater plates NOTICE Non coated heaters should never be used without butt fusion heater plates installed Refer to the Maintenance section of this manual for installation procedure Heater is not explosion proof Operation of heater in an explosive atmosphere without necessary safety precautions will result in serious injury or death If operating in...

Page 23: ...riate clamping inserts for the pipe that is being fused TX00368 9 15 94 PH02283 4 2 02 3 3 Operation Loading Pipe into Machine Clean the inside and outside of pipe ends that are to be fused Open the upper jaws and insert pipe in each pair of jaws with applicable inserts installed Let the pipe ends protrude more than 1 past the face of the jaws TX01094 8 20 96 PH04734 10 1 12 ...

Page 24: ...e movable jaws To unclamp the jaws With your free hand hold the tie bar between two cylinders Rotate the valve knob up to unclamp Pull the tie bar towards operator until the cylinders come to rest To clamp the jaws Push the cylinder tie bar toward the jaws until cylinders are vertical Rotate the valve knob down to clamp Hi Lo adjustment Unclamp the jaw slightly and return the clamping control to t...

Page 25: ... position between the jaws Use care when operating the facer and when handling the unit Activate the carriage control valve and move the carriage to the left to begin facing Continue to face the pipe until the rest buttons on the jaws bottom out on the facer rest buttons TX04261 3 30 11 3 5 Operation PH04735 10 2 12 PH04736 10 2 12 After Facing Turn facer motor off Move carriage all the way to the...

Page 26: ...heck alignment If there is a noticeable step across the joint adjustments must be made Hydraulically operated equipment is operated under pressure Anything caught in the machine will be crushed Keep fingers feet arms legs and head out of the machine while operated Ensure there is no unacceptable gap between the pipe ends If there is an unacceptable gap return to Loading Pipe into Machine If pipe i...

Page 27: ...auge Fusion Pressure Theoretical Fusion Pressure Drag Pressure TX03024 10 19 10 PH04004 8 25 09 Check for Slippage Bring the two sections of pipe together under fusion pressure to make sure they don t slip in the jaws If slippage occurs return to Loading Pipe into Machine TX00971 12 7 10 PH04737 10 8 12 3 7 Operation Position Carriage for Heater Insertion Move the carriage to open a gap large enou...

Page 28: ...s not explosion proof This unit is not explosion proof Operation of heater in an explosive atmosphere without necessary safety precautions will result in serious injury or death If operating in an explosive atmosphere heater should be brought up to temperature in a safe environment then unplugged before entering the explosive atmosphere for fusion Use a clean non synthetic cloth to clean the butt ...

Page 29: ...ted heating and soaking procedure or joining standard TX04264 3 30 11 PH04804 10 24 12 PH04731 10 24 12 C B A Fusing the Pipe NOTICE Failure to follow the pipe manufacturer s heating time pressure and cooling time may result in a bad joint After following the heating procedure verify carriage control valve is in neutral and move selector valve down to fusion position Move the carriage to the right...

Page 30: ...ble jaws TX04486 10 24 12 PH04806 10 24 10 2 Opening Fixed Jaws Open the fixed jaws TX00381 9 16 94 PH04807 10 24 12 Position Pipe for Next Joint Move the fusion machine to end of pipe or pull the pipe through the jaws until the end of the pipe is protruding more than 1 past the jaw face of the fixed jaw TX01091 8 20 96 3 10 Operation Raise Pipe Raise the joined pipe using the hydraulic pipe lift ...

Page 31: ...3 11 Operation Install Next Piece of Pipe Insert a new piece of pipe in movable jaws and repeat all previous procedures TX00384 10 12 95 PH04809 10 24 12 ...

Page 32: ...t containing heater and facer stands stripper bars for heater and guide rod bracket for facer An optional hose and cable extension kit is required for both 3 jaw and 4 jaw in ditch operation NOTICE Turn ignition key to off position before doing anything else TX04487 10 24 12 PH04790 10 24 12 Remove Hydraulic Hoses and Cables Disconnect the hydraulic hoses electrical cables and heater power cable f...

Page 33: ... forward as possible Attach lifting device to the four lifting points on the carriage Lift the carriage from the vehicle The outer fixed jaw of the carriage can be removed if needed on the 4 jaw skid This will allow fusing tees or ells with heater and facer attached to the indexer TX04489 10 24 12 PH04762 10 8 12 PH014767 10 24 12 ...

Page 34: ...ulic hoses Attach a lifting sling to the lift point on the facer and lift the facer from the carriage In order to use the facer in an in ditch operation the bracket that rests on the carriage guide rods must be exchanged with an in ditch facer bracket that in stored on the facer stand Remove the two bolts that hold the bracket in place PH04763 10 8 12 PH04752 10 8 12 PH04777 10 8 12 PH04757 10 8 1...

Page 35: ...ch facer bracket to the facer with the two bolts The bracket that is not being used can be stored on the optional facer stand until it is needed Place the facer in the facer stand Remove detent pin from facer latch handle and store in open hole near the roller housing PH04759 10 8 12 PH04760 10 8 12 PH04761 10 8 12 PH04811 10 8 12 PH04812 10 8 12 ...

Page 36: ...ove heater Disconnect the heater power cable on the top of the heater Remove the two bolts that attach the heater splice plates to the heater Rotate the heater pivot arm away from the heater Attach a lifting sling to the lift point on the top of the heater Lift the heater away from the carriage and place it into the heater stand PH04763 10 8 12 PH04752 10 8 12 PH04752 10 8 12 PH04757 10 8 12 PH047...

Page 37: ...move the two bolts of the handle from heater shroud Remove the handle Install the handle on the end of the heater using fasteners supplied with the 3 Jaw in ditch kit Attach the heater stripper bar from the 3 Jaw in ditch kit to the heater using the three supplied bolts TX04490 10 24 12 PH04797 10 8 12 PH04798 10 8 12 PH04799 10 8 12 ...

Page 38: ...he tie bar away from the inner clamp cylinder Disconnect the two hydraulic hoses that connect the inner clamp cylinder to the outer clamp cylinder Remove the four bolts that attach the 3 Jaw skid to the 4 jaw skid Disconnect the hydraulic hoses and electrical cables on the underside of the carriage The 3 Jaw skid can now be lifted out of the 4 Jaw skid leaving the outer fixed jaw behind TX04542 10...

Page 39: ...connectors The three jaw unit should be used only when space is not available for the entire carriage such as fusing onto a tee or an ell Attach lifting sling to the lifting eyes on the carriage Lift carriage assembly and lower into ditch TX04492 10 24 12 PH04748 10 8 12 Removing Top Jaws If the carriage needs to be hoisted and slid underneath the pipe the top jaws need to be removed Unclamp all j...

Page 40: ...ectrical connection on the component For the 3 Jaw carriage there are 2 sets of hydraulic hoses for connections to the carriage and facer Connect the extension hoses for the carriage facer and hydraulic clamping The extension hoses are connected between the hydraulic connection on the machine and the hydraulic connection on the component There is also 1 electrical cable for the heater Connect the ...

Page 41: ... TX00450 9 16 94 Remove Upper Jaws Unclamp jaws pull ball lock pins and remove the top jaws TX04495 10 24 12 PH04787 10 8 12 PH02284 4 17 02 Remove Hydraulic Hoses and Cables Disconnect hydraulic hoses and electrical cables to the carriage and remove hoses from ditch TX04496 10 24 12 PH01299 3 4 98 Special Operations In Ditch 4 10 ...

Page 42: ...From Ditch Attach sling to lifting points Rotate carriage assembly from under pipe Lift carriage assembly from ditch TX04497 10 24 12 PH014767 10 24 12 PH04748 10 24 12 CD01038 10 8 12 Special Operations In Ditch 4 11 ...

Page 43: ...d the operator s manual before using the device 8 Stay clear of the suspended load 9 Lift loads only as high as necessary 10 Do not alter or modify the lifting device 11 Employ generally accepted safe lifting practices 12 Do not shock or impact load the lifting device 13 Inspect all lifting pins for damage TX04268 02 27 14 SAFE1st 12 14 92 WR00014 3 8 93 Required Equipment Proper overhead rigging ...

Page 44: ...the sling to the lift points on the machine The steel tube goes to the outside of the machine as shown at A the shorter cable with white sleeve goes to the rear of the machine as shown at B and the longer cable with the yellow sleeve goes to the front of the machine as shown at C TX04498 10 24 12 PH04791 10 24 12 PH04792 10 24 12 A B C ...

Page 45: ...hydraulic fluid is not visible in the sight gauge fluid must be added If level drops below this point fill reservoir to the HIGH level on the sight gauge Never allow dirt or other foreign matter to enter the tank Refer to the Hydraulic Fluids section of this manual for hydraulic fluid recommendations TX01913 05 05 14 Preventative Maintenance To insure optimum performance the machine must be kept c...

Page 46: ...now be started TX01505 3 12 98 PH01309 3 12 98 Grease Keep moving parts well lubricated daily with high temperature grease Indexer carriage bearings Facer pivot bushings Heater pivot bushings TX04522 10 24 12 CD00183 10 22 12 Adjusting System Pressure Remove the side engine cover to gain access to the hydraulic pump Start the engine and select high speed The system pressure should be at 2300 psi T...

Page 47: ... the engine access panel The oil drain plug is located on the bottom of the oil pan and has a drain hose to drain the oil away from the tracks When the drain hose is not being used it should be stowed above the cross member away from the exhaust The oil filler cap and dip stick are located on top of the engine PH01311 3 12 98 PH04768 10 8 12 PH04802 10 8 12 PH01313 3 12 98 TX04524 10 24 12 ...

Page 48: ...of any dirt or residual material using a stiff bristled brush PH00927 8 20 96 TX00433 9 15 94 Facer Blades Blades bolt directly to the blade holder and should be inspected for damage and sharpness Dull or chipped blades must be replaced NOTICE Never extend the blade beyond the inner or outer circumference of the facer TX02475 3 29 05 PH04741 10 8 12 ...

Page 49: ...ntil no air is indicated and quickly tighten the plug Repeat this operation on the opposite cylinder Tilt the machine so the opposite end is higher than the fixed jaw end Move the carriage to the end opposite the fixed jaw and repeat the above procedure on the this end of the cylinders TX00877 2 16 96 PH01296 3 4 98 Installing Butt Fusion Heater Plates Butt fusion heater plates are installed with ...

Page 50: ...2 2 25 98 Clean Heater Surfaces The heater faces must be kept clean and free of any plastic build up or contamination Before each fusion joint the heater surfaces must be wiped with a clean non synthetic cloth NOTICE Do not use an abrasive pad or steel wool Use a non synthetic cloth that won t damage surfaces PH04738 10 24 12 TX04526 10 24 12 ...

Page 51: ...justing Track Tension The grease in the hydraulics of the track is pressurized If the grease valve is loosened too much grease can be expelled at high pressure and cause serious injury Injury could also result if the grease nipple is loosened Never loosen the grease nipple Remove screws and cover to access the adjustment system To tighten the track connect a grease gun to the nipple and add grease...

Page 52: ...03299 9 18 06 TX01474 2 25 98 Changing Oil in Gearbox Replace the oil after the first 200 hours of operation Subsequent oil changes should be scheduled at least once a year or every 1000 hours To replace the oil stop the gearbox with the gear motor plugs aligned vertically Remove both plugs and drain out all oil Move machine until the plug holes align horizontally Fill the gearbox through one of t...

Page 53: ...o stabilize at the new temperature 5 to 10 minutes after adjusting The thermometer on the heater body indicates internal temperature and should be used as a reference only TX02009 3 13 02 PH04810 10 24 12 Heater Indicator Light The heater has a red indicator light to the right of the heater temperature knob When the heater is turned on and preheating the red light glows steadily until the set temp...

Page 54: ...es are in good condition 15 Engine starts and runs properly 16 Facer works properly 17 Heater in good condition no nicks or gouges 18 Surface temperature check with a pyrometer 19 All indicators work properly 20 Three position throttle control works properly 21 No damage to lift points and tie downs 22 Low oil voltage high water temperature alarm works 23 Primary pump pressure 2300 psi 24 Hydrauli...

Page 55: ...measured in PSI for this example use 30 PSI Recommended IFP 75 PSI Using a Model 28 High Force Fusion Unit O D 8 625 t 0 784 SDR 11 TEPA 4 71 From Table O D t t IFP GAUGE PRESSURE DRAG TEPA 8 625 784 784 3 14 75 GAUGE PRESSURE 30 PSI 338 PSI 4 71 TX02893 04 18 16 Fusion High Force Medium Low Force Model A160 A180 A250 0 90 28 4 71 3 24 1 66 250 4 71 3 24 1 66 412 11 78 6 01 3 14 618 11 78 6 01 3 1...

Page 56: ... the pressure setting age of the pump wind etc Mobil Univis N46 hydraulic fluid is installed at our factory The advantage of this fluid is a wider temperature range however this fluid should not be used for continuous operation below 24 F NOTE The Mobil DTE 10 Excel series replaced the DTE 10M Series The Exxon Univis N series are now Mobil Univis N TX03082 2 26 14 NOTE This chart is based on pump ...

Page 57: ...tand 21 lbs 10kg Specifications Maximum Pipe Diameter 20 500mm Minimum Pipe Diameter 6 180mm Effective Piston Area 6 01 sq in 38 7 sq cm Maximum Force 13 823 lbs 6 270kg Travel Speed Low Speed 1 18 mph High Speed 2 08 mph Power Pack 23 5 hp 17 5kW 1001 cc 3 cylinder Liquid Cooled Diesel Engine 11 gal 42 liters Fuel Capacity Operational Fuel Capacity Auto Throttle 11 hours 2 300 PSI 158 bar Operati...

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Page 59: ...This manual is waterproof tear resistant grease resistant abrasion resistant and the bonding quality of the printing ensures a readable durable product The material does not contain any cellulose based materials and does not contribute to the harvesting of our forests or ozone depleting constituents This manual can be safely disposed of in a landfill and will not leach into ground water TX001660 8...

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