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Summary of Contents for McElroy Pit Bull 412
- Page 1 Rolling 412 & 618 Fusion Machines Operator’s Manual: 18P1051548 Manual Revision: - 12/24 Original Language: English Rolling 412 & 618...
- Page 2 Copyright 2024 McElroy Manufacturing, Inc. All rights reserved. P.O. Box 580550 Tulsa, Oklahoma 74158-0550, USA...
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Page 3: Important Safety Information
WARNUNG publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by McElroy is used, you must satisfy yourself that it is safe for you VORSICHT OSTRZEŻENIE... -
Page 4: Table Of Contents
McElroy University ........ - Page 5 Gas-Powered Units ..................3 - 3 Electric Units .
- Page 6 SPECIAL OPERATIONS Overview ....................6 - 1 4-Jaw Carriage Removal .
- Page 7 Clean Jaws and Inserts ..................9 - 6 Clean Thrust Bearings .
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Page 8: Literature Information
Read and understand the basic precautions listed in the safety For more than 30 years, McElroy has been the only pipe section before operating or performing maintenance and fusion machine manufacturer to continuously offer advanced repair on this machine. -
Page 9: Patent Information
Replacement Parts This product and other products could be protected by patents Refer to the McElroy parts finder at www.mcelroy.com to or have patents pending. All the latest patent information is locate parts for purchase. Reference the model number on the available at patent.mcelroy.com... -
Page 10: Limited Warranty
5 years after shipment, with the exception of purchased items (such as electronic devices, McElroy reserves the right to make any changes in or pumps, switches, etc.), in which case that manufacturer’s improvements on its products without incurring any liability warranty applies. -
Page 11: Safety
If a safety message is attached to a part that is replaced, install a safety message on the replacement part. New safety Wear a hard hat, safety shoes, safety glasses, and other messages can be ordered from McElroy using the part number applicable personal protective equipment. listed. -
Page 12: Do Not Operate In A Hazardous Environment
Do Not Operate in a Hazardous Make sure the fuel tank cap is closed tightly and properly secured. Environment Avoid repeated or prolonged fuel contact with skin or breathing of fuel vapor. Electric motors and heaters are not explosion proof. PERICOLO Operation of these components in an explosive atmosphere will result in serious injury or death. -
Page 13: Carbon Monoxide
Carbon Monoxide Never push, roll, dump or drop pipe lengths, bundles or coils off the delivery truck, off handling equipment, or into a trench. Always use appropriate equipment to lift, move, and lower the pipe. Engine exhaust gases contain poisonous carbon PERICOLO monoxide. -
Page 14: Battery
Battery NOTICE: Disconnect the machine from the power source before attempting any maintenance or adjustment. Do not expose the battery to flames or electrical AVVERTIMENTO sparks. Hydrogen gas generated by the battery is explosive. Serious injury can result from an ¡ADVERTENCIA! exploding battery. -
Page 15: Facer Blades Are Sharp
Facer Blades Are Sharp Do Not Tow Fusion Machine at Speeds Greater Than 5 MPH Facer blades are sharp and can cut. Use care when AVVERTIMENTO operating the facer and when handling the unit. The vehicle is not designed for over-the-road towing. AVVERTIMENTO Towing speeds greater than five miles per hour can NOTICE: Never extend the facer blades beyond the inner or... -
Page 16: Keep Machine Away From Edge Of Ditch
Keep Machine Away From Edge Personal Lifting Safety of Ditch The machine components are heavy. Using one ATTENZIONE person to lift some machine components may result Heavy equipment too close to a ditch can cause the in an injury. Use two people to lift those machine AVVERTIMENTO walls of the ditch to cave-in. -
Page 17: Positioning And Setting Fusion Machine
FusionStandard-11-1-24 Do Not Modify Machine Make no modifications to your equipment unless specifically recommended or requested by McElroy. WR00076-11-1-24 Sound Information The operator position Equivalent Sound Pressure Level for a gas-powered unit is 90 dB(A) max at full engine RPM. This is measured from the operator location at the carriage of the machine. -
Page 18: General Information
GENERAL INFORMATION Theory of Butt Fusion DataLogger® Integration The principle of heat fusion is to heat two pipe surfaces to The DataLogger 7 can be integrated into the operation of a designated temperature, and then fuse them together by this machine as an optional accessory to determine fusion application of force. -
Page 19: Nomenclature
CD03518-10-16-24 Nomenclature G - Carriage Bulkhead Contains the carriage hydraulic quick disconnects. Vehicle The carriage assembly is mounted on a four-wheel vehicle for mobility around a job site and along a pipeline. NOTICE: The vehicle is not designed for over-the-road towing. -
Page 20: Gas-Powered Units
CD03523-10-16-24 Gas-Powered Units F - Literature Compartment Stores the operator's manual, engine service manual and other important documents pertaining to the machine. G - GFCI Box Combustion engines can cause explosions and other PERICOLO unmanaged behavior when operated in an explosive Supplies power to the heater. -
Page 21: Electric Units
CD03527-10-17-24 Electric Units E - Heater Power Connector Connects heater power to the carriage. F - Literature Compartment Always ensure equipment is properly grounded. It Stores the operator's manual and other important documents AVVERTIMENTO is important to remember that you are working in pertaining to the machine. -
Page 22: Carriage Assembly
Carriage Assembly K - Fixed Jaw Braces Two jaw braces are installed between the outer fixed jaw The Pit Bull® 412 and 618 carriage assemblies consist of two and the inner fixed jaw and are removed for outer fixed jaw fixed jaws and two hydraulically operated movable jaws. - Page 23 Manual Clamping CD03522-10-16-24 Hydraulic Clamping CD03521-10-16-24 Rolling 412 & 618 3 - 6 General Information...
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Page 24: Indexer Assembly
CD03542-10-31-24 CD03543-10-31-24 Indexer Assembly Facer The indexer assembly allows facer and heater movement The facer is a rotating planer-block design. The blade holders along a guide rod for fusion operation. each contain three blades and are chain driven (enclosed in lubricant) by a hydraulic motor. -
Page 25: Heater
CD03544-10-31-24 CD03545-10-31-24 Heater E - Heater Control Module Used to turn the heater on and off and control heater The heater is equipped with heater butt plates coated with an temperature. See Heater Control Module (HCM) for more anti-stick coating. information. -
Page 26: Heater Control Module (Hcm)
CD03541-10-31-24 Heater Control Module (HCM) E - Heater On/Off Switch Turns heater on and off. The heater control module is mounted to the back of the F - HCM Programming Port indexer assembly and allows heater temperature adjustment. Connects the DataLogger to the heater control module for firmware updates. -
Page 27: Gas Engine
CD03538-10-30-24 Gas Engine C - Engine Oil Fill Filler neck for engine oil. Refer to engine operator's manual for Read and understand the engine service manual before checking oil and oil recommendations. operating. The engine service manual is included with this NOTICE: Only use API, SF, SG or SH 10W30 engine oil. -
Page 28: Hydraulic System
CD03535-10-22-24 Hydraulic System Components such as the pipe lift, carriage and facer are operated by the hydraulic system. A - Hydraulic Fluid Reservoir Retains hydraulic fluid. B - Filter Restriction Gauge Displays hydraulic filter restriction and is used to indicate hydraulic filter replacement. -
Page 29: Indexer Operation
INDEXER OPERATION Overview If the machine is equipped with hydraulic jaw clamps, remove the crossbar quick pin and raise the crossbar to allow clearance for the heater and facer to be pivoted out of the The indexer is mechanically operated to allow for automatic carriage. -
Page 30: Positioning Indexer
Pivoting Heater Out: To disengage the brake, pivot the heater or facer in slightly. IMPORTANT: Pivot the component intended for use when releasing the indexer brake. Heater and facer pivot out rapidly and can cause Once the brake is disengaged, the indexer will move freely AVVERTIMENTO severe bodily injury if someone is standing too close. -
Page 31: Disengaging Heater Latch
Disengaging Heater Latch Heater in "Out" Position The heater can be manually disengaged from all three latch points if needed. To disengage the heater from latch points 1 and 2: 1) Pivot the heater in past latch point 2 without engaging latch point 3. -
Page 32: Automatic Heater Removal During Fusion Operation
To disengage the heater from latch point 3: NOTICE: The following latch release method is intended as a last resort and should not be implemented as a If the heater is fully pivoted between the fixed jaws, refer to regular practice. "Unstowing Indexer."... -
Page 33: Stowing Indexer
Stowing Indexer Return the indexer to the stowage position for transport and when not in use. To secure the indexer in the stowage position, position the heater and facer between the fixed jaws and pivot the heater, heater bag frame and facer in between the fixed jaws. NOTICE: If the machine is equipped with hydraulic jaw clamps, extend the clamping cylinders or remove the crossbar quick pin and raise the crossbar to... -
Page 34: Operation - Butt Fusion
OPERATION - BUTT FUSION Read Before Operating Starting Instructions Read and understand the engine service manual before operating a gas-powered unit. NOTICE: Ensure the facer valve is open, the heater is off and the carriage is set to neutral at the carriage manifold before starting the machine. -
Page 35: Prepare Heater
Prepare Heater Starting an Electric Unit Connect the machine to a proper power source using the electrical unit's power cable. NOTICE: Always connect units to the proper power source as Heater is not explosion proof. Operation of heater in PERICOLO listed on the unit or in the operator's manual. -
Page 36: Open Jaws
Open Jaws Jaw Clamp Knobs: Loosen the clamp knobs to open the upper jaws. NOTICE: Use the speed wrench to loosen clamp knobs. Do not use power tools to tighten or loosen clamp knobs. CD03582-11-5-24 Rotate the clamping cylinders out away from the upper jaws. CD03577-11-5-24 Rotate the clamp knobs out away from the upper jaws. -
Page 37: Jaw Inserts
Jaw Inserts Close Jaws If required, install the appropriate size jaw inserts for the pipe Once pipe is in position, close the upper jaws around the that is being fused. Inserts are held in place by detent pins. pipe. Jaw Clamp Knobs: Rotate the clamp knobs over the upper jaw clamp pads. -
Page 38: Position Facer
Position Facer Turn the hydraulic jaw clamp control knobs downward to clamp hydraulic jaw clamps. Once pipe has been loaded into the carriage, the facer can be moved into position for facing. The facer can be moved left and right along the indexer guide rod and pivoted into and out of the carriage. -
Page 39: After Facing Pipe
The facing pressure should be set as low as possible while Turn the facer off by closing the facer valve. still moving the carriage. Excessive pressure can damage the facer. Shift the carriage directional valve (C) to CLOSE on the carriage manifold to begin facing. -
Page 40: Check Pipe Alignment
Check Pipe Alignment On the carriage manifold, shift the carriage directional valve (C) to CLOSE at facing pressure until the pipe ends make contact. CD03581-11-5-24 Hydraulic Jaw Clamps: To correct HI/LO misalignment on a carriage with hydraulic jaw clamps, open the carriage enough that the pipe ends are not touching. -
Page 41: Determine Drag Pressure
Determine Drag Pressure The theoretical fusion pressure can be determined using the fusion pressure calculator included with this machine. Use the carriage manifold to determine the drag pressure. Use the carriage directional valve (A) to move the carriage at facing pressure so that the faced pipe ends are approximately 2"... -
Page 42: Check For Slippage
Check for Slippage Check Heater Temperature Check for slippage by shifting the carriage directional valve (A) to CLOSE at fusing pressure. The heater is hot and will burn clothing and skin. ATTENZIONE Keep the heater protected from personnel when not in use and use care when handling heater and ¡PRECAUCIÓN! heating pipe. -
Page 43: Heat Pipe
Heat Pipe The indexer is designed to automatically disengage the heater latch and remove the heater from the fusion zone during the open/close cycle of the fusion process. The heating pressure was obtained during drag pressure measurement. NOTICE: Open the carriage wide enough to allow heater removal. -
Page 44: After Completed Fusion Joint
After Completed Fusion Joint After a completed fusion joint, loosen the clamp knobs or unclamp the hydraulic jaw clamps and open the upper jaws. NOTICE: Verify the indexer is positioned between the fixed jaws as to not interfere with opening the upper jaws. -
Page 45: Special Operations
SPECIAL OPERATIONS Overview 4-Jaw Carriage Removal The carriage can be removed from the vehicle for in-ditch tie- The 4-jaw carriage and skid can be removed from the vehicle ins and fusing tees or fittings that require more working space for off-vehicle fusion operation. than is possible while the carriage is mounted on the vehicle. -
Page 46: Outer Fixed Jaw Removal
Outer Fixed Jaw Removal Use a 3/8" hex key to remove the eight bolts securing the two fixed jaw braces to the inner fixed jaw as shown. Certain fusion applications require more clearance than is NOTICE: Retain all hardware for reinstallation of removed available in a 4-jaw carriage configuration. -
Page 47: 3-Jaw Carriage Removal
3-Jaw Carriage Removal Use a 3/8" hex key to remove the sixteen bolts securing the two fixed jaw braces. Remove the fixed jaw braces from between the inner fixed jaw and the outer fixed jaw as shown. The 3-jaw carriage can be removed from the 4-jaw carriage skid for off-vehicle fusion operation. -
Page 48: Facer Removal
To remove the facer from the pivot arm: Use a 3/8" hex key to remove the four bolts holding the 3-jaw carriage assembly to the skid. Pivot the facer into the carriage and turn off the machine. NOTICE: Retain all hardware for reinstallation of removed Attach a lifting sling of adequate load rating to the handle on components. - Page 49 Slowly lift the facer using an overhead lifting device. Attach the hydraulic extension hoses from the in-ditch kit to the facer motor and connect the other ends to the vehicle. NOTICE: If the machine is equipped with hydraulic jaw clamps, extend the clamping cylinders or remove the crossbar quick pin and raise the crossbar to allow clearance for the facer to be lifted out of the carriage.
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Page 50: Heater Removal
Heater Removal Carefully remove the slack from the lifting sling to support the heater before it is unbolted. The heater can be removed from its indexer pivot arm and NOTICE: If the machine is equipped with hydraulic jaw manually lowered into the carriage for 3-jaw fusion operation. clamps, extend the clamping cylinders or remove the crossbar quick pin and raise the crossbar to Keep the heater clean by utilizing the optional heater/facer... -
Page 51: Upper Jaw Removal
Upper Jaw Removal To set up heater for top loading: The upper jaws can be removed from the carriage to allow more room for positioning the carriage around pipe in an Ensure heater power is off before connecting or in-ditch situation. AVVERTIMENTO disconnecting heater power cables. -
Page 52: Positioning 4-Jaw Carriage For In-Ditch Operation
Positioning 4-Jaw Carriage for The carriage must be positioned upright as shown below. In-Ditch Operation The removed 4-jaw carriage can be used for in-ditch fusion with the heater and facer attached to the indexer. Positioning the 4-jaw carriage for in-ditch fusion requires it to be lifted. - Page 53 Lift and maneuver the carriage around the pipe as depicted below. CD03635-11-11-24 Once the 3-jaw carriage is positioned around the pipe, reinstall the upper jaws and loosely clamp the jaws around the pipe. The carriage must be positioned upright as shown below. CD03636-11-11-24 Once the 3-jaw carriage has been positioned around the pipe as depicted above, connect all in-ditch kit extension hoses...
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Page 54: Lifting And Transport
LIFTING AND TRANSPORT Lifting Safety The correct configuration for lifting the entire machine is shown on the next page. The back two legs of the sling should run through the outer fixed jaw and the front two legs should run Follow all applicable federal, state, local and industry specific through the inner fixed jaw. - Page 55 Lifting Entire Machine CD03715-12-10-24 Lifting Vehicle CD03714-12-10-24 Rolling 412 & 618 7 - 2 Lifting and Transport...
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Page 56: Lifting 4-Jaw Carriage
Lifting 4-Jaw Carriage Lifting with indexer components pivoted out: Attach the 4-point lifting sling to each of the four lift points In order to remove the 4-jaw carriage from the vehicle, the shown below. carriage must be lifted using an overhead lifting device. Maneuvering and positioning the 4-jaw carriage after it has been removed from the vehicle also requires it to be lifted. -
Page 57: Lifting 3-Jaw Carriage
Lifting 3-Jaw Carriage In order to remove the 3-jaw carriage from the 4-jaw carriage skid, the carriage must be lifted using an overhead lifting device. Maneuvering and positioning the 3-jaw carriage also requires it to be lifted. Refer to "Special Operations" for 3-jaw carriage removal. -
Page 58: Stowing Indexer
Stowing Indexer Loading Machine for Transport Return the indexer to the stowage position for transport and when not in use. To secure the indexer in the stowage position, position the A raised machine could fall and result in serious AVVERTIMENTO heater and facer between the fixed jaws and pivot the heater, injury or death if a lifting device fails. - Page 59 This page intentionally left blank. Rolling 412 & 618 7 - 6 Lifting and Transport...
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Page 60: Labels And Markings
UNLEADED FUEL ONLY LABEL Part Number - T804301 (Gas Only) YELLOW LIFT POINT LABEL Part Number - MJQ00379 CD03652-11-13-24 McELROY LABEL Part Number - 8163121 TOWING SPEED LABEL Part Number - 8163220 YELLOW LIFT POINT LABEL Part Number - MJQ00379... - Page 61 DANGER HIGH VOLTAGE LABEL Part Number - 829201 207 MINIMUM INPUT VOLTAGE LABEL Part Number - 816326 (Electric Only) VOLTMETER LABEL Part Number - 816328 (Electric Only) CD03651-11-13-24 CARRIAGE OPEN/CLOSE LABEL Part Number - 8163218 CD03655-11-13-24 RESOURCE LIBRARY LABEL Part Number - DISRSRC24 SELECTOR VALVE LABEL Part Number - 8163211 FACING, HEATING, FUSING PRESSURE...
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Page 62: Maintenance
MAINTENANCE Machine Maintenance Task Schedule Task Clean Machine Inspect Facer Blades Change Heater Butt Plates Replace Battery and Cables Check Tire Pressure Bleed Air from Carriage Cylinders Adjust System Pressure Check Indexer Gas Springs Check Carriage Pressure Gauge Replace Drive Belts Grease Check Hydraulic Fluid Check Machine Operation... -
Page 63: Engine Maintenance Task Schedule
Engine Maintenance Task Schedule Task Clean Engine Check Engine Oil Level Check Air Cleaner Element Service/Replace Low- Profile Precleaner Replace Air Cleaner Element Change Engine Oil* Remove Cooling Shrouds and Clean Cooling Areas Check Oil Cooler Fins (If Equipped) and Clean if Necessary Change Engine Oil Filter* Replace Fuel Filter... -
Page 64: Engine Maintenance Tasks
Engine Maintenance Tasks Inspect Facer Blades All engine maintenance tasks are in the engine's operation Blades bolt directly to the blade holder and should be and service manual. Perform the appropriate engine inspected for damage and sharpness. maintenance task based on the correct interval in the Dull or chipped blades must be replaced. -
Page 65: Clean Heater Butt Plate Surfaces
Clean Heater Butt Plate Surfaces Adjusting System Pressure The heater is hot and will burn clothing and skin. Do not touch belts and rotating parts while the ATTENZIONE ATTENZIONE Keep the heater protected from personnel when engine is running. Failure to do so could result in not in use and use care when handling heater and injury. -
Page 66: Bleeding Air From Carriage Cylinders
Bleeding Air From Carriage Check Hydraulic Fluid Cylinders The hydraulic fluid level should be checked daily. NOTICE: Ensure machine is on level ground. 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 If hydraulic fluid is not visible in the sight glass, fluid must be side of pump. -
Page 67: Check Fasteners Are Tight
Clean Thrust Bearings To replace the hydraulic filter: Ensure the machine is off and all hydraulic fluid has been The thrust bearings located in the clamp knobs must turn freely. drained. Wash the clamp knob bearing assembly with a solvent, and If changing oil based on the ISO Cleanliness guidelines, then lubricate with 30W or lighter oil. -
Page 68: Drive Belt Replacement
Drive Belt Replacement Replacing drive belts on a gas-powered unit: The two drive belts (A) tensioned between the engine and hydraulic pump are: V-Belt 3VX-425. The two drive belts (B) tensioned between the hydraulic pump and generator are: Do not touch belts and rotating parts while the V-Belt 3VX-335. - Page 69 Remove both engine drive belts. Once the generator drive belts have been replaced, shift the generator back torwards it's original position to apply tension. CD03694-11-26-24 Loosen the three bolts securing the generator to the vehicle CD03695-11-26-24 Tighten the three generator bolts to secure the generator in frame.
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Page 70: Battery Replacement
Replacing drive belts on a gas-powered unit: Once the drive belts have been replaced, shift the electric motor back torwards it's original position to apply tension. The three drive belts (A) tensioned between the electric motor and hydraulic pump are: V-Belt 3VX-315. CD03701-11-26-24 Tighten the four electric motor bolts to secure the electric motor CD03699-11-26-24... -
Page 71: Guided Firmware Update
GUIDED FIRMWARE UPDATE Overview In the Manage Machines screen, tap EDIT on the machine intended for an update. The guided firmware update process allows users to update components which are controlled by firmware for operation. The guided process, presented on the DataLogger 7, can be used as a step-by-step guide for updating machine components as new releases become available. -
Page 72: Heater Control Module (Hcm) Update Process
Heater Control Module (HCM) Tap BEGIN to update the HCM firmware. Update Process The DataLogger must be connected to wifi to download a firmware update file. An internet connection is recommended while performing an update but can be performed offline if the update file has been downloaded onto the DataLogger. -
Page 73: Offline Updating Procedure
Offline Updating Procedure Port Connection Issues An internet connection is recommended while performing an The DataLogger will detect if the wrong port has been update but may not always be available. An update can be connected to for an update process. performed offline if the update file has been downloaded onto The DataLogger will also detect if it is not connected to any the DataLogger. -
Page 74: Overview
FAULTS Overview Faults are indentified using the indicator light on the heater control module (HCM). The indicator light emits red and green illuminations to provide visual status alerts for the heater and HCM. The indicator light glows red to indicate the heater is preheating to setpoint and glows green to indicate the heater is unpowered to regulate temperature at setpoint. -
Page 75: Determining Fusion Pressure
DETERMINING FUSION PRESSURE Variable Descriptions Descriptions of variables: - Outside Diameter of Pipe (in) - Wall Thickness of Pipe (in) ∏ Pipe - 3.14 - Standard Dimensional Ratio of Pipe (unitless) - Interfacial Pressure of Pipe (psi) TEPA - Total Effective Piston Area of Carriage (in²) Formulas Use the formulas below to obtain variables. -
Page 76: Hydraulic Fluids
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 77: Specifications
SPECIFICATIONS Generator Sizing Form Complete this form and provide a copy to your generator supplier. This information will enable your generator supplier to correctly size a generator for your application. Motor: 5.0 Horsepower Motor Code Letter: H (from motor nameplate) Motor Voltage: 240 VAC Motor Phases: 3 Delta Motor Frequency:... -
Page 78: Rolling 412 And 618 Specifications
Rolling 412 and 618 Specifications Specifications 14 - 2 Rolling 412 & 618... - Page 79 Model Rolling 412 Rolling 618 Capabilities 4" IPS - 12" DIPS 6" IPS - 18" OD (1 10mm - 340mm) (160mm - 450mm) Cylinder Force Type HF, MF, LF HF, MF, LF High Force TEPA: 1 1.78 in² TEPA: 1 1.78 in² Total Effective Piston Area (75.9 cm²) (75.9 cm²)
- Page 80 Shipping Length (Min.) 61" (1,549 mm) 61" (1,549 mm) Shipping Width (Min.) 91" 91" (2,31 1 mm) (2,31 1 mm) Shipping Height (Min.) 64" 64" (1,626 mm) (1,626 mm) Engine Horse Power 19 HP (14 kW) 19 HP (14 kW) Engine Fuel Tank Capacity 5 gallons (19 liters) 5 gallons (19 liters)
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Page 81: Notes
NOTES Notes: Rolling 412 & 618 15 - 1 Notes...
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