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McElroy MegaMc PolyHorse Operator's Manual

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Operator's
Manual
®
MegaMc
®
PolyHorse
Manual: 4839401 Revision: Rev D 3/19
Original Language: English

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Summary of Contents for McElroy MegaMc PolyHorse

  • Page 1 Operator’s Manual ® MegaMc ® PolyHorse Manual: 4839401 Revision: Rev D 3/19 Original Language: English...
  • Page 2 Cancer and Reproductive Harm - www.P65warnings.ca.gov 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 The productivity tool consists of a series of pipe racks and powered pipe stands that hold enough pipe for a day’s worth of fusion work. With the pipe stored in a single location and ready for use, the MegaMc PolyHorse allows heavy machinery to work in other places on the jobsite.
  • 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...

  • Page 5: Table Of Contents

    Overview MegaMc PolyHorse........2-1 MegaMc PolyHorse Tracked Pipe Stand..... . 2-2 MegaMc PolyHorse Roller Pipe Stand .
  • Page 6 Hydraulic Fluids ........9-1 Specifications MegaMc PolyHorse........10-1...

  • Page 7: 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 8: General Safety

    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 9: Hazard Zone

    Do not enter in the hazard zone while pipe is on the rack or when handling pipe. Use the hazard cones to block off the hazard zone of the MegaMc PolyHorse. SETUP A HAZARD ZONE OPERATOR OPERATOR...

  • Page 10: Use Stanchions

    Equipment Safety Use Stanchions Use stanchions at all times. Do not stack pipe. Failure to do so will result in death or serious injury from falling pipe. ¡PELIGRO! TX04286-6-27-11 Cutting Pipe Bands Do not stand in the hazard zone while cutting pipe bands.

  • Page 11: Axial Pipe Movement

    Adjust the racks height to make them level to each other. NOTICE: Do not use the MegaMc PolyHorse in icy conditions. Ice on the racks can cause the pipe to slide uncontrolled on the racks.

  • Page 12: Lifting Safety

    Safety warnings: Read and understand this operator’s manual before using the lifting device. Do not exceed rated load or lift loads other than the McElroy MegaMc PolyHorse with the lifting device. Do not operate a damaged or malfunctioning lifting device or one missing parts.

  • Page 13: Units With Hydraulics

    Equipment Safety Units With Hydraulics For hydraulically operated equipment, 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.

  • Page 14: Overview

    Rear Rack – two rear racks that support and store the pipe until it moves into the front rack. Extension Hoses – hydraulic hoses that connect the tracked and roller pipe stands. Control Pendant - controls all the functions of the MegaMc PolyHorse and has extension cable to reach the operator location.

  • Page 15: Megamc Polyhorse Tracked Pipe Stand

    Overview MegaMc PolyHorse Tracked Pipe Stand Parts of the Tracked Pipe Stand Base Frame – supports the machine and rests on the ground. Trolley – moves transversely and supports the boom. Wheels – support trolley and allows transverse movement. Boom – moves vertically and supports the tracks.

  • Page 16: Megamc Polyhorse Roller Pipe Stand

    Overview MegaMc PolyHorse Roller Pipe Stand Parts of the Roller Pipe Stand Base Frame – supports the machine and rests on the ground. Trolley – moves transversely and supports the boom. Wheels – support trolley and allows transverse movement. Boom – moves vertically and supports the rollers.

  • Page 17: Megamc Polyhorse Pipe Rack

    Overview MegaMc PolyHorse Pipe Rack Parts of the Pipe Rack Dispenser Arm – releases a single stick of pipe into the pipe stand. Dispenser – dispenses pipe into the pipe stand. Front Pipe Racks – stores and supports the pipe to be dispensed into the pipe stands and includes the dispenser.

  • Page 18: Pendant Controls

    Overview Pendant Controls OFF - Turns the HPU off. ON - Turns the HPU on. PIPE LEFT* - Moves the pipe toward the fusion machine. PIPE RIGHT* - Moves the pipe away from the fusion machine. PIPE RELOAD - Places a stick of pipe into the dispenser.

  • Page 19: Setup

    OPERATOR SETUP B Setup of the MegaMc PolyHorse must be done on ground that is as level and stable as possible. Place the PolyHorse on as level and stable ground as possible. Operating on unlevel ground could cause the pipe to move uncontrolled causing serious injury or death.

  • Page 20: Handling Megamc Polyhorse Components

    Setup Handling MegaMc PolyHorse Components Handling of the components can be done using overhead lifting equipment or forked lifting equipment. Stand clear of loads being lifted. Loads can swing or fall causing serious injury or death. Attach to lifting equipment...
  • Page 21 Setup Handling MegaMc PolyHorse Components (continued) Forked Lifting Equipment When forking the tracked pipe stand, the boom must be raised slightly so it is clear of the forks path. The pipe stands should only be forked from the side as shown. When using forked lifting equipment, the forks of the equipment must be 6 feet or longer.

  • Page 22: Position Megamc Polyhorse Pipe Stands

    Setup Position MegaMc PolyHorse Pipe Stands Proper spacing of the pipe stands and racks is important. The racks must be spaced far enough apart to provide stability but close enough that the pipe is supported by both stands when inserted into the fusion machine. The spacing is dependent on pipe length and the model of the fusion machine.
  • Page 23 Setup Position MegaMc PolyHorse Pipe Stands (cont'd) The pipe stands must be set with their base frames centered on and square with the same line as where the fused pipe string will be. It is the base frame that must be centered and not the center of the V of the rollers and tracks.

  • Page 24: Connect Pipe Racks To Pipe Stands

    Setup Connect Pipe Racks to Pipe Stands The front racks with the dispenser bolted to them connect to the pipe stands. Move the rack into position using overhead lifting equipment or forked lifting equipment. Lower the rack into the two large holes in the pipe stand.

  • Page 25: Connect Hydraulic Hoses And Operator Pendant

    Setup Connect Hydraulic Hoses and Operator Pendant Connect the extension hoses between the pipe stands. The extension hose bundle is stored under the toolbox. The connections are below the HPU on the tracked pipe stand and below the outrigger pad storage on the roller pipe stand.

  • Page 26: Attach Lowering Arm Assembly

    Setup Attach Lowering Arm Assembly Lifting Eyes The lowering arm assemblies are removed when stacking the pipe stands for transport or storage. There are two identical lowering arm assemblies, one on each pipe stand. Use lifting equipment to lower the assembly onto the pipe stand using the lifting eyes at the top of the assembly.

  • Page 27: Set And Position Dispenser Mechanism

    Setup Set and Position Dispenser Mechanism Dispenser Arm The dispenser mechanisms are adjustable for three different ranges of pipe sizes. The location of the adjustment pin determines the range. Adjustments must be made without pipe on the racks. To change the range, turn off the machine. Firmly grip the end of the dispenser arm, pull the adjustment pin out, Adjustment Pin rock the arm to the desired range and reinsert the pin...

  • Page 28: Place Hazard Cones

    Do not enter in the hazard zone while pipe is on the rack or when handling pipe. Use the hazard cones to ¡PELIGRO! block off the hazard zone of the MegaMc PolyHorse. TX04300-6-27-11 3 - 10...

  • Page 29: Position Fusion Machine

    Setup Position Fusion Machine The fusion machine should have its movable jaws toward the tracked pipe stand. Place the fusion machine so that its inner fixed jaw is the length of the pipe minus 2 feet (610mm) from the rollers of the roller pipe stand. This is to keep the pipe on the rollers when the pipe is fed into the fusion machine.

  • Page 30: Load Pipe On Racks

    Setup Load Pipe on Racks Before loading pipe onto the racks of the machine, ensure the dispenser arms are both set to the correct pipe size. Set the dispenser arms to the dump position for loading by using the dump switch on the pendant. Load the pipe onto the racks from the stanchion end of the racks using proper lifting equipment.

  • Page 31: 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 Periodically check the hydraulic fluid level in reservoir.

  • Page 32: Dispense Pipe

    Use the hazard cones to block off the hazard zone of the MegaMc PolyHorse. Start with pipe in the racks and no stick of pipe on the pipe stands (A). The operator stands at the fusion machine and operates the pendant.

  • Page 33: Insert Pipe

    Operation Insert Pipe Actuate the Pipe switch to left to move the pipe towards the fusion machine. As the pipe moves to the jaws, ensure that the pipe will clear the jaws of the fusion machine. If necessary, stop the pipe and make adjustments to the booms and trolleys to align the pipe to the jaws.

  • Page 34: Position Pipe For Next Joint

    Operation Position Pipe for Next Joint Once the fusion joint is complete, unclamp the pipe and open the jaw clamps on the fusion machine. Lower the roller pipe stand. Raise the tracked pipe stand. Raise the pipe lifts on the fusion machine to allow the pipe to be pulled through to position for the next fusion joint.

  • Page 35: Special Operation - Rotating Pipe

    Special Operation - Rotating Pipe Rotating Pipe The MegaMc PolyHorse can rotate the pipe stick to match ovality, match print lines, or orient a bow. The pipe will need to be in the pipe stands before it is inserted into the fusion machine.

  • Page 36: Disassembly

    Disassembly Position for Disassembly Fork Pocket Center Marks Before disconnecting the unit from power, the components need to be properly positioned. Turn on the HPU and use the pendant to center both trolleys aligning the center marks of the trolley and the base frame. Lower both booms on the pipe stands and then raise the tracked pipe stand boom enough that it clears the fork pocket's path.

  • Page 37: Detach Pipe Racks

    Disassembly Detach Pipe Racks Rear Rack Pin Lift the rear rack at the jack leg end and retract the legs to the shortest position using the crank handle. Pull the drop leg pin to retract the drop legs. Pull the rear rack pin connecting the rear rack to the front rack.

  • Page 38: Store Components

    Disassembly Store Components Disconnect the pendant cable at the control box and pendant. The cable, lifting sling, and pendant can be stored in the toolbox, but the pendant should be stored on top to prevent damage. Coil the cable and store in the toolbox (A) on the roller pipe stand.

  • Page 39: Storage And Transport

    Storage and Transport Remove Lowering Arm Assemblies Lifting Eyes The lowering arm assemblies are removed when stacking the pipe stands for transport or storage. There are two lowering arm assemblies, one on each pipe stand. Disconnect the two hydraulic hose quick disconnects from the lowering arm assembly hydraulic cylinder.

  • Page 40: Stacking Stands

    TX04324-7-25-11 Transport All of the components of the MegaMc PolyHorse will fit on a trailer, leaving enough room for the fusion machine and generator. The pipe stands are stacked on top of each other. The pipe racks should be placed on the trailer with the legs alternating each other.

  • Page 41: 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 preventive maintenance be kept. Store machine inside, out of the weather, whenever possible. Service intervals are approximate for average service and may need to be done more frequently in severe service conditions or can be done less frequently if used minimally.

  • Page 42: Change Hydraulic Filter And Fluid

    Maintenance Change Hydraulic Filter and Fluid The hydraulic filter and breather should be replaced every year. The hydraulic fluid should be replaced every two years. Hydraulic fluid drain plug is located in the rear of the hydraulic reservoir. Unscrew the breather to add hydraulic fluid. Fill the reservoir from a clean container.

  • Page 43: Adjust Track Tension

    TX04328-7-25-11 Adjust Flow Controls To change the speed of the MegaMc PolyHorse, adjust the flow controls located in the valve stack on the hydraulic manifold. Use a ¾” open end wrench to loosen the lock nut. Use a ¼” hex key to adjust the flow control.

  • Page 44: Lifting Slings

    Maintenance Lifting Slings Before each lift of the machine, inspect the lifting sling for damage. Do not use a damaged sling. In addition, a thorough yearly inspection should be done by a qualified person per ASME Standard B30.9. In severe service it should be inspected more frequently than yearly.

  • Page 45: Troubleshooting

    Maintenance Troubleshooting Problem Action May need to increase the counterbalance valve setting. Proper counterbalance valve setting is 1-1/4 turns clockwise from fully counter clockwise position. May need to replace counterbalance valve. • If counterbalance valve requires replacement: Load Lowers Remove pipe from pipe stand. Lower pipe stand completely.
  • Page 46 Maintenance Troubleshooting Problem Action Hold or repeatedly actuate the switch to either the dump or the reload position until the Dispensers out of lagging dispenser arm catches up with the other. synchronization Air in the extension hoses can cause erratic movement and out of synchronization movement of the dispenser mechanism and lowering arms.
  • Page 47 Troubleshooting Manually Operate Solenoid Valves During maintenance or troubleshooting it may be necessary operate manually the MegaMc PolyHorse using the solenoid valves. Using the legend on the top of the electrical box, determine which valves control the operation you are wanting to operate.

  • Page 48: Hydraulic Fluids

    Hydraulic Fluids Hydraulic Fluids The use of proper hydraulic oil is mandatory to achieve maximum performance and machine life. Use a clean, high quality, anti-wear hydraulic oil 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 oil temperature (generally 80°F above ambient).

  • Page 49: Specifications

    Specifications MegaMc PolyHorse Dimensions: Tracked or Roller Pipe Stand with Trolley Centered, Transfer Ramps on, and Lowering Arm Assembly attached: 91" Length: 130" (3302 mm) (2311 mm) Width: 91" (2311 mm) Height: 65" (1651 mm) Rear Rack (each) Length: 173" (4394 mm) Width: 30"...
  • Page 50 Specifications MegaMc PolyHorse Mega PolyHorse Pipe Rack Capacity Number of Pipe Sticks "Single "Double Pipe OD (mm) Pipe OD (inches) Truckload Racks" Racks" 1200 Notes: 1. An additional pipe can be loaded directly into the pipe stands. 2. Pipe counts are theoretical and egged or bowed pipe may cause actual loading to be one less.
  • Page 51 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.

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