Related Manuals for McElroy TracStar 500 Series 3
Summary of Contents for McElroy TracStar 500 Series 3
- Page 1 Operator’s Manual Fusion Machine Original Language: English Manual: T5019210 Revision: Rev C 11/18...
- 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 Always return the manual to the literature compartment. TX04535-10-24-12 McElroy University For more than 30 years, McElroy has been the only pipe fusion machine manufacturer to continuously offer advanced training. Course offerings are meant to enhance your efficiency, productivity and safety in the proper use of McElroy machines.
- Page 4 McElroy or has become damaged McElroy reserves the right to make any changes in or due to misuse, negligence or casualty, or has not been improvements on its products without incurring any operated or maintained according to McElroy’s printed...
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Page 5: Table Of Contents
Hydraulic Clamping ........2-6 COPYRIGHT © 2018, 2016, 2014, 2012, 2011, 2010 McELROY MANUFACTURING, INC. Tulsa, Oklahoma, USA All rights reserved All product names or trademarks are property of their respective owners. - Page 6 Table of Contents Operation Read Before Opening ........3-1 Check Hydraulic Fluid Level .
- Page 7 Table of Contents Special Operations - Lifting the Machine Lifting Safety ......... . 5-1 Required Equipment .
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Page 8: Fusion Equipment Safety
Follow all applicable federal, state, local, and industry specific regulations. McElroy Manufacturing, Inc. cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this manual and on the machine are therefore not all inclusive. -
Page 9: General Safety
Fusion Equipment Safety General Safety Safety is important. Report anything unusual that you notice during set up or operation. LISTEN for thumps, bumps, rattles, squeals, air leaks, or unusual sounds. SMELL odors like burning insulation, hot metal, burning rubber, hot oil, or natural gas. -
Page 10: Units With Engines
Fusion Equipment Safety Units With Engines Combustion engines can cause explosions when operated in an explosive atmosphere. Do not operate gas or diesel powered machines in an ¡PELIGRO! explosive atmosphere. When operating in an explosive atmosphere, keep engine and chassis in a safe area by using hydraulic extension hoses. Help prevent fires by keeping machine clean of accumulated trash, debris and facer shavings. -
Page 11: Battery
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. -
Page 12: Units With Hydraulics
Fusion Equipment Safety Units With Hydraulics It is important to remember that a sudden hydraulic oil leak can cause serious injury, or even be fatal if the pressure is high enough. Escaping fluid under pressure can penetrate the skin causing serious injury. Keep hands and body away from pinholes which eject fluid under pressure. -
Page 13: Facer Blades Are Sharp
Fusion Equipment Safety 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. -
Page 14: Heater Is Hot
Fusion Equipment Safety 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. -
Page 15: Overview
Overview Theory of Heat Fusion The principle of heat fusion is to heat two surfaces to a designated temperature, and then fuse them together by application of force. This pressure causes flow of the melted materials, which causes mixing and thus fusion. When the polyethylene material is heated, the molecular structure is transformed from a crystalline state into an amorphous condition. -
Page 16: Tracstar ® 500 Series 3 Console
Overview TracStar ® 500 series 3 Console ENGINE OIL COOLANT PRESSURE TEMPERATURE 150 180 210 VOLT FUEL °F METER GAUGE FUEL VOLTS °C HEADLIGHTS HIGH WORK (Power for FUSION VEHICLE LIGHT heater) LIGHT LIGHT VEHICLE FUSION LIGHT LIGHT 150 180 210 °F FUEL VOLTS... -
Page 17: Pipe Lift Controls
Overview 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. -
Page 18: Inlet Fans
TX04990-04-27-16 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-ditch operation and features a lifting point for lifting the facer in and out of the ditch. -
Page 19: Heater
Overview Heater The heater is equipped with butt fusion heater plates, coated with an antistick coating. This heater is not explosion proof. Operation of heater in an explosive atmosphere without necessary safety precautions will result in serious ¡PELIGRO! injury or death. The heater cord plugs into a military type receptacle on the heater arm and electrical box. -
Page 20: Diesel Engine
Overview Diesel Engine Read the operating and maintenance instructions for the engine before operating. There is a key ignition on the console that shows the preheat, start, run and off positions. TX01465-2-10-98 Hydraulic Fluid Reservoir The hydraulic fluid reservoir is located under the front hood of the machine. -
Page 21: Operation
Operation Read Before Operating Before operating this machine, please read this manual thoroughly and keep a copy available for future reference. Return manual to the protective storage box when not in use. This manual is to be considered part of your machine. TX00401-9-15-94 Check Hydraulic Fluid Level Check fluid level in sight gauge on reservoir and add fluid if... -
Page 22: Moving Machine Into Position
Operation Moving Machine Into Position Make sure all personnel are safely clear of the machine before moving. Move both track control levers forward to go in a straight line. Release the levers to stop. Moving just the right track forward turns the machine to the left. Moving just the left track forward turns the machine to the right. -
Page 23: Install Clamping Inserts
Operation Install Clamping Inserts Select and install appropriate clamping inserts for the pipe that is being fused. TX00368-9-15-94 Set up Pipe Supports Set up pipe stands and adjust height so the pipe is in line with the jaws. X00367-9-15-94 Loading Pipe into Machine Clean the inside and outside of pipe ends that are to be fused. -
Page 24: Positioning Pipe In Machine
Operation Positioning Pipe into Machine Swing the facer into place. Move the carriage toward the fixed jaw, while watching the gap at each end of the facer guide rod brackets. When the pipe is in contact with the facer, this gap indicates the amount of material that will be trimmed from the pipe end. -
Page 25: Begin Facing
Operation Begin Facing Turn facer on by opening valve on top of the facer. Move the selector valve on the hydraulic manifold block to the top (facing pressure) position. The facing pressure should be set as low as possible while still facing pipe. -
Page 26: Check Alignment
Operation Check Alignment Move carriage to the left at facing pressure, until pipe ends contact. Look across the top surface of pipe ends to check alignment. If there is a noticeable step across the joint, adjustments must be made. Hydraulically operated equipment is operated under pressure. -
Page 27: Set Fusion Pressure
Operation Set Fusion Pressure With the selector valve in the down position, the fusion pressure can be set. The theoretical fusion pressure can be calculated using the enclosed fusion pressure calculator. Always add drag pressure to the theoretical fusion pressure. Gauge (Fusion) Pressure = Theoretical Fusion Pressure + Drag Pressure TX03024-10-19-10... -
Page 28: Check Heater Temperature
Operation Check Heater Temperature NOTICE: Incorrect heating temperature can result in questionable fusion joints. Check heater plates periodically with a pyrometer and make necessary adjustments. Check heater surface temperature. Refer to the pipe manufacturer's recommendations or appropriate joining standard for proper heater temperature. TX04536-10-24-12 Inserting Heater Heater is not explosion proof. -
Page 29: Heat Pipe
Operation Heat Pipe Shift the selector valve (A) to the center position, and set the heating pressure (if required). If heating pressure is not required, set the pressure reducing valve (B) at its lowest setting, or the drag pressure, whichever is higher. Shift the selector valve (A) to the fusion position and move the carriage control valve (C) to the left to bring pipe ends in contact with the heater. -
Page 30: Opening Movable Jaws
Operation Opening Movable Jaws After the joint has cooled for the pipe manufacturer's recommended time, shift the carriage control to the neutral position. Unclamp the clamp cylinders, and open carriage far enough to open the jaw nearest the facer. Open the movable jaws. TX04486-10-24-12 Opening Fixed Jaws Open the fixed jaws. -
Page 31: Install Next Piece Of Pipe
Operation Install Next Piece of Pipe Insert a new piece of pipe in movable jaws and repeat all previous procedures. TX00384-10-12-95 3 - 11... -
Page 32: Special Operations - In Ditch
Special Operations - In Ditch Overview The carriage may be removed and hoisted into a ditch. The 4 jaw carriage can be used with heater and facer attached to the indexer or if needed, a more compact 3 jaw carriage. Using the 3 jaw carriage requires lifting equipment to hoist the heater and facer from overhead and will require an optional 3 jaw in-ditch kit containing heater and facer stands, stripper bars for heater, and... -
Page 33: Removing 4 Jaw Carriage
Special Operations - In Ditch Remove 4 Jaw Carriage Remove the carriage pin at the front of the machine. Slide the carriage as far 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. -
Page 34: Removing Heater And Facer
Special Operations - 3 Jaw Removing Heater and Facer To Remove the Facer: Remove the two bolts that attach the facer splice plate to the facer. Rotate the facer pivot arm away from the facer. Disconnect the facer hydraulic hoses. Attach a lifting sling to the lift point on the facer and lift the facer from the carriage. - Page 35 Special Operations - 3 Jaw Removing Heater and Facer (continued) Remove the bracket for in-ditch operations from the facer stand. Attach the in-ditch 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.
- Page 36 Special Operations - 3 Jaw Removing Heater and Facer (continued) To Remove the Heater for In-Ditch Operation: Heater may be hot and could cause injuries from burns. Allow heater to cool before attempting to remove 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.
- Page 37 Special Operations - 3 Jaw Removing Heater and Facer (continued) Install the heater handle and stripper bar for in-ditch operation: Remove 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.
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Page 38: Removing 3 Jaw Skid
Special Operations - 3 Jaw Removing 3 Jaw Skid If the carriage is going to be used for fusing to a tee or for close quarters fusion, you can use the 3 Jaw carriage. Remove the outer fixed jaw braces. Remove the pin that connects the cylinder tie bar on the inner clamp cylinder. -
Page 39: Lift 3-Jaw Carriage From Machine
Special Operations - In Ditch Lift 3-Jaw Carriage from Machine Connect the hydraulic hoses to each other to keep dirt out of the 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. -
Page 40: Attach Upper Jaws
Special Operations - In Ditch Attach Upper Jaws Attach the top jaws and clamp around pipe. TX01484-2-26-98 Attach Hydraulic Hoses and Cables For the 4 Jaw carriage, there are 2 sets of hydraulic hoses for connections to the carriage and facer. Connect the extension hoses for the carriage, facer, indexer, and hydraulic clamping. -
Page 41: Make Fusion Joint
Special Operations - In Ditch Make Fusion Joint Refer to the "Butt Fusion Procedure" for operating instructions. After facing operation, remove the facer from ditch. TX00450-9-16-94 Remove Upper Jaws Unclamp jaws, pull ball lock pins and remove the top jaws. TX04495-10-24-12 Remove Hydraulic Hoses and Cables Disconnect hydraulic hoses and electrical cables to the carriage... -
Page 42: Remove Carriage From Ditch
Special Operations - In Ditch Remove Carriage From Ditch Attach sling to lifting points. Rotate carriage assembly from under pipe. Lift carriage assembly from ditch. TX04497-10-24-12 4 - 11... -
Page 43: Special Operations - Lifting The Machine
Special Operations - Lifting the Machine Lifting Safety Follow all applicable federal, state, local, and industry specific regulations when lifting. Safety warnings: Do not exceed rated load or lift loads greater than the rated load rating of the lifting device. Do not operate a damaged or malfunctioning device. -
Page 44: Attach Slings
Special Operations - Lifting the Machine Attach Slings Ensure the lifting points are in good repair before lifting the machine. Attach 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. -
Page 45: Maintenance
Maintenance Preventative Maintenance To insure optimum performance, the machine must be kept clean and well maintained. With reasonable care, this machine will give years of service. Therefore, it is important that a regular schedule of preventative maintenance be kept. Store machine inside, out of the weather, whenever possible. TX00428-8-10-95 Washing the Machine The machine should be cleaned, as needed with a soap and... -
Page 46: Grease
Maintenance Grease Keep moving parts well lubricated daily with high temperature grease. Indexer carriage bearings Facer pivot bushings Heater pivot bushings TX04522-10-24-12 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. -
Page 47: Engine Oil System
Maintenance Engine Oil System Read the engine maintenance instructions for scheduled maintenance intervals. Use appropriate oil for the ambient temperature. The oil filter is located behind 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. -
Page 48: Facer Blades
Maintenance 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 Clean Jaws and Inserts To prevent slippage and insure proper alignment, the jaws and inserts must be clean. -
Page 49: Bleeding Air From Hydraulic System
Maintenance Bleeding Air From Hydraulic System The two carriage cylinders have air bleed screws and must be bled if the system ever runs low on oil or leaks air on inlet side of pump. Air in the system is indicated when carriage movement becomes jerky and erratic. -
Page 50: Clean Heater Surfaces
Maintenance 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. -
Page 51: Engine Maintenance
Maintenance Engine Maintenance Refer to the operation and maintenance manual for the engine. TX01500-3-5-98 Checking Track Tension Park the machine on a flat solid surface. Use the spreader bar or hydraulic jacks for raising machine off the ground. Place adequate supports under the bottom frame after lifting. Measure the deflection between the bottom center roller and the inside surface of the rubber track. -
Page 52: Checking Oil Level In Gearbox
Maintenance Check Oil Level in Gearbox Check the oil level in the gearbox every 100 hours of operation. To check the oil level, stop the machine with the gear motor plugs aligned horizontally. Remove the plugs and check that the oil level is up to the plug holes. -
Page 53: Adjusting Heater Temperature
Maintenance Adjusting Heater Temperature Turn knob to desired temperature. Measure the heater surface temperature with a pyrometer. Any variance must be corrected to the pyrometer reading. Loosen setscrew in the knob. Turn knob to point to the same temperature as the pyrometer. Tighten setscrew in the knob. Turn knob to desired temperature. -
Page 54: Maintenance Checklist
Maintenance Checklist TracStar ® 500 series 3 TRACSTAR INSPECTION CHECKLIST Repairs Made Date Repaired 1. For engine maintenance & service, Review engine manual 2. Machine is clean 3. Inserts and inserts keeper pins are with machine 4. All nuts & bolts are tight 5. -
Page 55: Determining Fusion Pressure
Determining Fusion Pressure Variable Definitions O.D. = Outside Diameter of Pipe (inch) = Wall Thickness of Pipe (inch) = 3.14 = Standard Dimensional Ratio of Pipe (unitless) = Interfacial Pressure of Pipe (PSI) TEPA = Total Effective Piston Area of Carriage Cylinders (inch²) Formulas O.D. - Page 56 Hydraulic Fluids Hydraulic Fluids The use of proper hydraulic fluid is mandatory to achieve maximum performance and machine life. Use a clean, high quality, anti-wear hydraulic fluid with a viscosity index (VI) of 135 minimum. It should have a maximum viscosity of 500 cSt (2000 SSU) at startup (ambient temperature) and a minimum viscosity of 13 cSt (65 SSU) at the maximum fluid temperature (generally 80°F above ambient).
- Page 57 Specifications Fusion Machine Dimensions Length, Pipe Lift up: 94.5" (2,400mm) Track Width: 50.5" (1,283mm) 94.5" Overall Width: 67.5" (1,715mm) 2400mm Centerline Height, Carriage: 32.5" (826mm) Overall Height: 53" (1,346 mm) Fusion Machine Weights Total Vehicle Weight (fluids full): 3123 lbs (1,417kg) Carriage, 4 Jaws: 750 lbs (340kg) Carriage, 3 Jaws: 365 lbs (166kg)
- Page 59 About this manual . . . McElroy Manufacturing continually strives to give customers the best quality products available. This manual is printed with materials made for durable applications and harsh environments. This manual is waterproof, tear resistant, grease resistant, abrasion resistant and the bonding quality of the printing ensures a readable, durable product.