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Summary of Contents for McElroy 28
- Page 1 Operator’s Manual 28 and 412 Rolling Hand Pump Fusion Machines Manual: 897701 Revision: B 02/19 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 If fusing other thermoplastic pipe materials, refer to the pipe manufacturer's fusion procedures or appropriate joining standard. The Rolling 28 HP fuses 2" IPS through 8" DIPS (63 mm - 200 mm). The Rolling 412 HP fuses 4" IPS through 12" DIPS...
- 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
Theory of Heat Fusion........2-1 Introduction to the 28 and 412 Hand Pump Fusion Machines ..2-2 Carriage Assembly . - Page 6 Lifting Safety ......... . 5-1 Lift the Machine - 28 Hand Pump ......5-1...
- Page 7 Specifications Fusion Machine Specifications: 28 Rolling Hand Pump ... . . 10-1 Fusion Machine Specifications: 412 Rolling Hand Pump ... . 10-2...
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Page 8: 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
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. FEEL any changes in the way the equipment operates. -
Page 10: Pipe Handling Safety
Safety Pipe Handling Safety Do not position yourself or any other personnel under supported or raised pipe. Pipe is heavy and could fall unexpectedly. 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 can generate tremendous force when that energy is released. -
Page 11: Electrical Safety
Safety Electrical Safety Always ensure power cords are properly grounded. It is important to remember that you are working in a wet environment with electrical devices. Proper ground connections help to minimize the chances of an electric shock. Frequently inspect electrical cords and unit for damage. Have damaged components replaced and service performed by a qualified electrician. -
Page 12: Have Tires Properly Serviced
Safety Have Tires Properly Serviced Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury or death. Have tires mounted by someone that is experienced, and has the proper equipment to perform the job safety. -
Page 13: Positioning Fusion Machine
Safety Positioning Fusion Machine Place fusion machine on as level ground as possible, and set the brake on the rear wheel. If it is necessary to operate machine on unlevel grade, chock the wheels and block the unit to make it as stable as possible. -
Page 14: Overview
Overview Theory of Heat Fusion The principle of heat fusion is to heat two pipe surfaces to a designated temperature, and then fuse them together by application of force. This develops pressure which causes flow of the melted materials, which causes mixing and thus fusion. When the thermoplastic material is heated, the molecular structure is transformed into an amorphous condition. -
Page 15: Introduction To The 28 And 412 Hand Pump Fusion Machines
If fusing other thermoplastic pipe materials, refer to the pipe manufacturer's suggested procedures or appropriate joining standard. The Rolling 28 HP fuses 2" IPS through 8" DIPS (63 mm - 200 mm). The Rolling 412 HP fuses 4" IPS through 12" DIPS (110mm - 340mm). -
Page 16: Oil Reservoir
Overview Oil Reservoir The hydraulic pump has a reservoir that stores the hydraulic fluid. The hydraulic fluid is filled through a plug on the top of the reservoir. Refer to the "Check Oil Level" section for instructions on checking and filling the hydraulic fluid. Refer to the "Hydraulic Fluids"... -
Page 17: Facer
Loosen the brush ground wire (B) and pull the wire loose. Repeat these steps on the wire on the opposite side. Store the brushes in a safe location until needed. A 1-1/8" hex shaft allows for manual operation in hazardous conditions. TX04102-6-28-10 2 - 4... -
Page 18: Heater
If the green indicator is not flashing then the controller may not be operating properly. If this occurs, disconnect power and have the heater repaired by a McElroy Authorized Service Center. The heater temperature is controlled by a microprocessor. It has a red indicator light on the handle at the bottom of the temperature scale. -
Page 19: Chassis
Pipe Lifts Pipe lifts are provided to assist in pipe handling. 28 Hand Pump: The pipe lifts can be secured using detent pins during machine transport or movement of pipe. 412 Hand Pump: Pump the pipe lift handle to raise the pipe. Turn the release valve to lower the pipe. -
Page 20: Clamp Knob
Overview Clamp Knobs Clamp knobs are equipped with a thrust bearing, which permits the operator to develop high clamping forces with minimal effort. TX03099-4-12-10 2 - 7... -
Page 21: Butt Fusion Procedure
Butt Fusion Procedure Read Before Operating Before operating this machine, please read this manual thoroughly, and keep a copy with the machine for future reference. The fusion procedures in this manual are for use with polyethylene pipe. If fusing other thermoplastic pipe materials, refer to the pipe manufacturer's suggested procedures or appropriate joining standard. -
Page 22: Set Up Pipe Supports
Butt Fusion Procedure Set up Pipe Supports Set up pipe stands or pipe rollers and adjust height so the pipe is in line with the jaws. TX02955-4-15-09 Install Clamping Inserts Select and install appropriate clamping inserts for the pipe that is being fused. -
Page 23: Determine Fusion Pressure
Open the upper jaws and insert pipe in each pair of jaws with applicable inserts installed. Let the ends of the pipe protrude past the face of the jaws 0.75" for 28 and 1.25" for 412. TX02983-4-27-09 3 - 3... -
Page 24: Face The Pipe
Butt Fusion Procedure Face the Pipe Pivot facer into place Turn on the facer. Move the carriage control valve to the close carriage position. Pump the handle to move the carriage to the left against the facer. If the facer begins to stall, reduce the amount of pressure applied to the handle. -
Page 25: Remove Facer
Butt Fusion Procedure Remove Facer Move the carriage control valve to the open carriage position and open the carriage. Release the trigger lock, and pivot the facer out. Remove chips from pipe ends. Do not touch faced pipe ends. Inspect both pipe ends for complete face off. If the face off is incomplete, return to Loading Pipe into Machine. -
Page 26: Position Carriage For Heater Insertion
Butt Fusion Procedure Position Carriage for Heater Insertion Move carriage to the right to open a gap large enough to insert the heater. TX00374-9-15-94 Check Heater Temperature NOTICE: Incorrect heating temperature can result in questionable fusion joints. Check heater plates periodically with a pyrometer and make necessary adjustments. -
Page 27: Insert Heater
Butt Fusion Procedure Insert Heater Heater is not explosion proof. Operation of heater in an explosive atmosphere without necessary safety precautions will result in serious injury or death. ¡PELIGRO! 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. -
Page 28: Fuse The Pipe
Butt Fusion Procedure Fuse the Pipe NOTICE: Failure to follow pipe manufacturer's fusion procedures may result in a bad joint. After following the pipe manufacturer's suggested heating procedure: Shift carriage control valve to the open position. Move the carriage to the right just enough to engage the stripper bar. Quickly remove the heater. -
Page 29: Open Fixed Jaws
Butt Fusion Procedure Open Fixed Jaws Open the fixed jaws. TX00381-9-16-94 Position Machine for Next Joint Move the fusion machine into position for the next fusion joint. TX02985-5-4-09 Install Next Piece of Pipe Move the carriage control valve to the open position and actuate the pump lever to open the carriage completely. -
Page 30: Special Operations - In Ditch
Open carriage completely. 28 Hand Pump: Attach lifting straps to the inner fixed jaw and the outer movable jaw, then lift the carriage assembly. 412 Hand Pump: Attach lifting sling to the two fixed jaw braces and the manifold bracket, then lift the carriage assembly. -
Page 31: Outrigger
Special Operations - In Ditch Outrigger The outrigger is an arm that is retractable and adds support to the carriage assembly when opening the jaws and pivoting the facer away from the carriage. To extend or retract the outrigger, press the locking button near the base of the outrigger and push or pull the arm until the button snaps to the locked position. -
Page 32: Remove 3-Jaw Assembly From The Carriage
Special Operations - In Ditch Remove 3-Jaw Assembly from the Carriage Remove braces from inner fixed jaw. Remove the four bolts holding carriage assembly to the chassis with the wrench provided. Attach lifting strap to the lift point above the carriage control valve as shown and lift the carriage assembly. -
Page 33: Manual Facer Operation
4-Jaw 28 Hand Pump: Open carriage leaving 3 inches guide rod exposed near the guide rod support plate. -
Page 34: Clamp Carriage Assembly To Pipe
Special Operations - In Ditch Clamp Carriage Assembly to Pipe Position carriage assembly on side of the pipe. Lift pipe and slide carriage assembly under pipe. Rotate carriage assembly around to a normal upright position. Attach the top jaws and loosely clamp around pipe. TX00879-2-19-96 Make Fusion Joint Refer to the "Butt Fusion Procedure"... -
Page 35: Remove Carriage Assembly From Ditch
Special Operations - In Ditch Remove Carriage Assembly from Ditch Loosen clamp knobs and remove top jaws. Rotate carriage assembly from under the pipe. IMPORTANT: Always rotate unit with valve system facing up to protect against damage. Attach straps according to section "Lower 3-Jaw or 4-Jaw Carriage into Ditch". -
Page 36: Special Operations - Lifting Fusion Machine
Do not shock or impact load the lifting device. Inspect all lifting pins for damage. TX04594-4-18-13 Lifting the Machine - 28 Hand Pump Lifting requires a hoist or lifting equipment of proper lifting capacity to lift the machine. Use proper overhead rigging and equipment of adequate load rating to lift the fusion unit. - Page 37 Special Operations - Lifting Fusion Machine Lifting the Machine - 412 Hand Pump Lifting requires a hoist or lifting equipment of proper lifting capacity to lift the machine. Using proper overhead rigging and equipment of adequate load rating to lift the fusion unit. To lift the machine, attach the lifting sling to the 4 lifting points on the sides of the vehicle.
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Page 38: 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 39: Check Gauge
Maintenance Check Gauge Gauge should be checked daily. The gauge should read zero when the unit is not under pressure. Damaged gauges should be replaced. TX02974-4-15-09 Clean Jaws and Inserts To prevent slippage and insure proper alignment, the jaws and inserts must be clean. -
Page 40: Fasteners Must Be Tight
Maintenance Fasteners Must Be Tight Check all nuts, bolts, and snap rings to make certain they are secure and in place. TX00437-9-13-94 Facer The facer should be lubricated annually. TX00438-9-15-94 Facer Blades Blades bolt directly to the blade holder and should be inspected for damage and sharpness. -
Page 41: Clean Heater Surfaces
IMPORTANT: Do not over tighten the bolts. The surface of the butt fusion heater plates are coated with an antistick coating. TX04103-6-28-10 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. -
Page 42: Heater Indicator Light
If the green indicator is not flashing then the controller may not be operating properly. If this occurs, disconnect power and have the heater repaired by an McElroy Authorized Service Center. The heater has a red indicator light on the handle at the bottom of the temperature scale. -
Page 43: Fusion Machine Checklist
Carriage Control Valve operates smoothly Brake functions properly Tire pressure is correct HEATER Cord and plug are in good condition Heater surface is clean and in good condition Thermometer is in good working order Surface temperature checked with pyrometer TX04105-6-28-10 7 - 1... -
Page 44: Determining Fusion Pressure
DRAG = as measured in PSI (for this example use 30 PSI) 4.71 3.24 1.66 Recommended IFP = 75 PSI 11.78 6.01 3.14 Using a Model 28 High Force Fusion Unit 11.78 6.01 3.14 6.01 3.14 O.D. 8.625 t = ------------- = --------------- = 0.784 824/T630 29.44... - Page 45 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).
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Page 46: Specifications
Specifications Fusion Machine Specifications: 28 Rolling Hand Pump 49.5" 1257mm 65.5" 38" 1664mm 965mm 23.5" 591mm 43.75" 28.25" 1111mm 718mm 28 Rolling HP Machine Weight: 475 lbs. (215.4Kg) 4 Jaw Carriage Weight: 229 lbs. (103.9Kg) 3 Jaw Carriage Weight 150 lbs. (68Kg) Facer: 39 lbs. -
Page 47: Fusion Machine Specifications: 412 Rolling Hand Pump
54 lbs. (24.5 kg) Heater: 24 lbs. (10.9 kg) Specifications: Designed for 4" IPS to 12" DIPS pipe (110mm to 340mm) Maximum Pressure: 1400 psi max. Fluid Capacity: 1 pint Designed for connecting the McElroy Datalogger® unit . TX04106-02-11-19 10 - 1... - Page 49 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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