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McElroy TracStar 28 Operator's Manual

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TracStar
618i Fusion Machines
Manual: T18P1031563
Revision: B 9/24
Original Language: English
TracStar® 412i & 618i
28, 250, 412i &
®
Operator's
1
Manual

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Summary of Contents for McElroy TracStar 28

  • Page 1 TracStar 28, 250, 412i & ® 618i Fusion Machines Operator’s Manual: T18P1031563 Manual Revision: B 9/24 Original Language: English TracStar® 412i & 618i...
  • Page 2 Copyright 2024 McElroy Manufacturing, Inc. All rights reserved. P.O. Box 580550 Tulsa, Oklahoma 74158-0550, USA...

  • 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 Carriage Control Interface ................. 3 - 5 Indexer .
  • Page 6 Heater Removal ..................6 - 6 Upper Jaw Removal .
  • Page 7 Bleeding Air From Carriage Cylinders ............... . 10 - 5 Check Hydraulic Fluid .

  • 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 Do not start the engine near spilled fuel. Wipe up spills immediately. Environment Make sure the fuel tank cap is closed tightly and properly secured. Avoid repeated or prolonged fuel contact with skin or Electric motors and heaters are not explosion proof.

  • 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 Stand Clear Facer blades are sharp and can cut. Use care when Heater and facer pivot out rapidly and can cause AVVERTIMENTO AVVERTIMENTO operating the facer and when handling the unit. severe bodily injury if someone is standing too close. All personnel must stand clear of the back of the NOTICE: Never extend the facer blades beyond the inner or ¡ADVERTENCIA!

  • Page 16: Lifting Safety

    Lifting Safety Heater is Hot Follow all applicable federal, state, local, and industry specific regulations when lifting. 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! Safety warnings: heating pipe.

  • Page 17: Sound Information

    NOTICE: Failure to follow the pipe manufacturer’s fusion procedures or appropriate joining standard could result in a bad fusion joint. FusionStandard-4-18-24 Do Not Modify Machine Make no modifications to your equipment unless specifically recommended or requested by McElroy. TX05340-04-18 TracStar® 412i & 618i 2 - 7 Safety...

  • Page 18: General Information

    GENERAL INFORMATION Theory of Butt Fusion Nomenclature 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 19: Outboard Vehicle

    CD03245-5-28-24 Outboard Vehicle A - Literature Tube Stores the operator's manual, engine manual, and other important documents pertaining to the machine. B - Facer Hydraulic Quick Disconnects Connects the pressure and return tank lines to supply hydraulic fluid to the facer. C - Diesel Fuel Cap Diesel fuel tank cap.

  • Page 20: Carriage Assembly

    Carriage Assembly I - Hydraulic Jaw Clamps Hydraulic jaw clamps are hydraulically operated for The Pit Bull® 412i and 618i carriage assemblies consist of two clamping and unclamping the upper jaws. There are crossbars fixed jaws and two hydraulically operated movable jaws. connecting both clamping cylinder sets (fixed jaws and movable jaws) that are used for supporting the clamping The carriage assemblies can be removed from the vehicle in a...

  • Page 21: Hydraulic Clamping

    Manual Clamping CD03457-8-14-24 Hydraulic Clamping CD03449-8-9-24 TracStar® 412i & 618i 3 - 4 General Information...

  • Page 22: Carriage Control Interface

    Carriage Control Interface The carriage control interface consists of three panels: Center Panel, Left Control Panel and Right Control Panel. The carriage control interface on the DataLogger contains Center Panel controls needed to operate the carriage and turn the heater Displays carriage pressure and heater temperature.
  • Page 23 PH06530-8-23-24 A - Pressure Control Minus Button K - Pressure Control Slider Lowers slider position in 1% increments. Controls carriage pressure. The position of the slider is displayed as a percentage above the slider. B - Pressure Control Plus Button L - Heater On/Off Button Raises slider position in 1% increments.

  • Page 24: Stored Faults

    Active Faults and Warnings Stored Faults Active faults and warnings are indicated by a yellow warning To view stored faults, open the additional information window and tap FAULTS. icon at the bottom of the right control panel. PH06530-8-23-24 PH06513-8-1-24 Tap STORED FAULTS in the FAULTS AND WARNINGS To view active faults or warnings, open the additional information window and tap FAULTS.
  • Page 25 Machine Control Timeout As a safety measure, control from the carriage control interface will time out after three minutes of inactivity. To regain control, drag the touch slider to the right. The option to switch to the DataLogger interface is also present on this screen. PH06535-8-23-24 Hydraulic Lockout The carriage control interface is disabled during hydraulic lockout.

  • Page 26: Indexer

    Facer Latch Handle Indexer Brake Heater Latch Release Lever Facer Valve In-Ditch Guide Rod Storage Lock Bracket CD03173-5-16-24 CD03339-6-18-24 Indexer Facer The indexer assembly is attached to the 4-jaw carriage skid The facer is a rotating planer-block design. The blade holders and can be removed from the vehicle along with the 4-jaw each contain three blades and are chain driven (enclosed in carriage for off-vehicle fusion operation.

  • Page 27: Heater

    Lift Point Heater Handle Heater Retention Mechanism CD03182-5-16-24 CD03235-5-24-24 Heater Heater Bag Frame The heater is equipped with heater butt plates coated with an The heater bag frame protects and insulates the heater when anti-stick coating. the heater is not in use. The heater is hot and will burn clothing and skin.

  • Page 28: Diesel Engine

    Engine Side Carriage Side CD03351-6-24-24 CD03352-6-24-24 Diesel Engine D - Oil Filter Filters engine oil. Read and understand the engine owner's manual instructions E - Radiator Fill Cap before operating. The engine operator's manual is included Filler neck for enigine coolant. Refer to engine operator's with this machine and can be found inside the literature tube.

  • Page 29: Hydraulic System

    CD03350-6-24-24 Hydraulic System F - Hydraulic Fluid Cooler Cools hydraulic fluid. Components such as tracks, pipe lifts, carriage and facer are G - Diverter Valve operated by the hydraulic system. Redirects hydraulic fluid to tank when hydraulic system is A - Hydraulic Fluid Level Sight Gauge disengaged.

  • Page 30: Electrical Components

    CD03434-8-1-24 Electrical Components J - Carriage Fuse and Relay Block Contains several fuses and relays for carriage components. A - DataLogger Port Located on the back of the manifold bracket assembly. Connects the DataLogger to the carriage for operation, K - Heater Control Module (HCM) diagnostics and software updates.

  • Page 31: 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 for automated carriage carriage.

  • Page 32: 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 33: 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 34: 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 35: Stowing Indexer

    Stowing Indexer Return the indexer to the stowage position for lifting, 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 36: Operation - Butt Fusion

    OPERATION - BUTT FUSION Read Before Operating Starting from DataLogger The key switch must be turned to RUN at the vehicle console in order to start the engine from the DataLogger. From the DataLogger home screen, tap the carriage control icon to switch to the carriage control interface.

  • Page 37: Driving Vehicle

    Driving Vehicle Prepare Heater Before and while driving machine, ensure all jobsite Heater is not explosion proof. Operation of heater in PERICOLO AVVERTIMENTO personnel are visible to the machine operator an explosive atmosphere without necessary safety at all times. If all personnel are not visible, stop precautions will result in serious injury or death.

  • Page 38: 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. CD03472-8-23-24 Rotate the clamping cylinders out away from the upper jaws. CD03490-8-23-24 Rotate the clamp knobs out away from the upper jaws.

  • Page 39: 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 40: Positioning Facer

    Positioning 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 41: After Facing

    After Facing The facing pressure should be set as low as possible while still moving the carriage. Excessive pressure can damage the facer. Drag the carriage directional joystick to the right and allow the carriage to open completely. The Lock Open button can also Tap the Lock Close button in the carriage control interface to be used.

  • Page 42: Set Up Fusion Process

    Set Up Fusion Process Once the Hydraulics Start/Stop has been tapped, the Hydraulic Lockout screen will appear indicating hydraulic functions have been disengaged. In order to verify pipe alignment, the user must begin setting up the fusion process in the DataLogger interface. If access to the DataLogger interface is needed, tap the Return To DataLogger button.

  • Page 43: Job Summary

    To begin the fusion process, tap START on the main menu. On the Fusion Process screen, tap each item to enter a value for Fusion Type, Standard Specification, and Fusion Tapping START progresses the user to the Job Summary Guide Level. screen.
  • Page 44 Check Pipe Alignment On the Fusion Process screen, tap VERIFY ALIGNMENT to momentarily switch to the carriage control interface. In the carriage control interface, tap the carriage Lock Close button (A) to close the pipe ends together. Use the pressure control slider (B) or the -/+ buttons to adjust pressure as needed according to applicable standard.

  • Page 45: Weather Conditions

    The Setup Photos screen allows the user to take and annotate In the Pipe Settings screen, tap each item to set values for Pipe Size, Wall Thickness, Pipe Material and what pipe setup photos of the pipe to be fused. These can include will be fused in conjuction: Identical or Dissimilar.
  • Page 46 The Pressures screen requires the user to measure drag in order to display appropriate heat/soak and fusion operational pressures according to applicable standard. PH06461-4-17-24 PH06452-4-17-24 Pressures: Bead: Select to change value if desired Soak: and allowed by applicable standard Fuse: Measure Drag: Start the Measure Drag process.

  • Page 47: Check Heater Temperature

    Check Heater Temperature 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. NOTICE: Incorrect heating temperature can result in ОСТОРОЖНО...

  • Page 48: Level 3 Fusion Process

    Level 3 Fusion Process PH06047-5-23-24 PH06074-5-23-24 1. The alarm will sound to alert machine movement. 4. Heat/Soak cycle will start. IMPORTANT: Graphs shown on these screens are an example and may not reflect an actual graph of fusion performed to another standard. PH06049-5-23-24 PH06050-5-23-24 2.
  • Page 49 PH06052-5-23-24 PH06056-5-23-24 7. The carriage is opened, the indexer is moved right, and the 10. When the Fuse/Cool cycle is complete, the "Fusion heater is automatically removed. Process Complete" prompt will appear. Tap OK to accept completion and continue to the Fusion Notes screen. PH06053-5-23-24 PH06462-4-18-24 8.

  • Page 50: Level 2 Fusion Process

    Level 2 Fusion Process PH06061-5-23-24 PH06087-5-23-24 View fuse settings by tapping the drop down arrow and reset 4. Heat/Soak cycle will start. the timer by tapping RESET TIMER if needed. 1. Tap START BEADUP to begin bead-up. Tap CONFIRM START BEADUP to confirm start. IMPORTANT: Graphs shown on these screens are an example and may not reflect an actual graph of fusion performed to another standard.
  • Page 51 PH06081-5-23-24 PH06085-5-23-24 7. The carriage is opened, the indexer is moved right, and the 10. The "Fusion Process Complete" prompt will appear. Tap heater is automatically removed. OK to accept completion and continue to the Fusion Notes screen. PH06083-5-23-24 PH06462-4-18-24 8.

  • Page 52: Level 1 Fusion Process

    Level 1 Fusion Process PH06089-5-23-24 PH06091-5-23-24 View fuse settings by tapping the drop down arrow and reset 4. Heat/Soak cycle will start. Pressure will drop to drag the timer by tapping RESET TIMER if needed. pressure for Heat/Soak. 1. Waiting for carriage movement to start bead-up. The carriage control interface will open automatically.
  • Page 53 PH06093-5-23-24 PH06097-5-23-24 7. The carriage is closed at fusion pressure. Fuse/Cool cycle 10. The "Fusion Process Complete" prompt will appear. Tap is started. OK to accept completion and continue to the Fusion Notes screen. Allow Fuse/Cool cycle to run for the specified time. PH06095-5-23-24 PH06462-4-18-24 8.

  • Page 54: Joint Report

    Joint Report After Completed Fusion After a completed fusion, 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 55: 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 56: Outer Fixed Jaw Removal

    Outer Fixed Jaw Removal NOTICE: Retain all hardware for reinstallation of removed components. Certain fusion applications require more clearance than is Use a 3/8" hex key to remove the two bolts securing the outer available in a 4-jaw carriage configuration. When needed, fixed jaw to the skid and remove the jaw.

  • Page 57: 3-Jaw Carriage Removal

    3-Jaw Carriage 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. The 3-jaw carriage can be removed from the 4-jaw carriage NOTICE: Retain all hardware for reinstallation of removed skid for off-vehicle fusion operation.

  • Page 58: 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 59 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.

  • Page 60: 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 off-vehicle fusion clamps, extend the clamping cylinders or remove operation.

  • Page 61: 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 62: 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 63: Starting Engine With Detached Carriage

    Starting Engine with Detached Lift and maneuver the carriage around the pipe as depicted below. Carriage As a safeguard, the engine will not start if the carriage has been disconnected from the vehicle. If needed, this safeguard can be overridden by pressing the TracStar iSeries Carriage Disconnected Machine Start button.

  • Page 64: Lifting And Transport

    LIFTING AND TRANSPORT Stowing Indexer Lifting Safety Return the indexer to the stowage position for lifting, transport Follow all applicable federal, state, local and industry specific and when not in use. regulations when lifting. 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.
  • Page 65 Lifting Entire Machine CD03279-6-3-24 Lifting Vehicle CD03280-6-3-24 TracStar® 412i & 618i 7 - 2 Lifting and Transport...

  • Page 66: Lifting 4-Jaw Carriage

    Lifting 4-Jaw Carriage Lifting with indexer components pivoted out: Attach the 3-point lifting sling to each of the three 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 67: 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 68: Loading Machine For Transport

    Loading Machine for Transport Securing Machine for Transport Secure the machine for transport by tying it down to the trailer through the three tiedown points. There are two tiedown points on the movable jaw end of the track frame and one on the Before and while driving machine, ensure all jobsite fixed jaw end of the track frame.

  • Page 69: Cowlings

    COWLINGS Removing Side Cowlings Removing Dome Cowling Side cowlings are located on each side of the machine. Side cowlings must be removed before removing the dome cowling. Turn the engine off and ensure it is cool before removing the side cowlings. To remove the dome cowling, unscrew the two bolts holding the dome cowling in place.

  • Page 70: Removing Rear Cowling

    Removing Rear Cowling Removing Front Cowling Side cowlings must be removed before removing the rear The generator cowling must be removed before removing the cowling. front cowling. To remove the rear cowling, remove the two top bolts and To remove the front cowling, unscrew the four bolts holding the loosen the two bottom nuts holding the rear cowling in place.

  • Page 71: Removing Fuel Filter Guard Plate

    Once unbolted, remove the undercarriage access plate and place it in an area where it will not be damaged. CD03306-6-11-24 NOTICE: Reinstall the undercarriage access plate before reinstalling the carriage and indexer skid. Perform these steps in reverse to reinstall the undercarriage access plate.

  • Page 72: Labels And Markings

    Part Number - 8163288 DANGER HIGH VOLTAGE LABEL Part Number - 829201 BATTERY CHARGING CONNECTION LABEL Part Number - 8163292 LARGE MCELROY BRANDING LABEL Part Number - 8163120 SAFETY INSTRUCTIONS MANUAL LABEL Part Number - 816342 DIESEL FUEL ONLY LABEL...
  • Page 73 VOLTAGE LABEL Part Number - T1201702 SENSING MODULE INPUT LABEL Part Number - 08P0928983 CD03314-7-23-24 6x4" CAUTION: HOT SURFACE LABEL Part Number - MJQ00507 CD03315-7-23-24 CD03316-7-23-24 RESOURCE LIBRARY LABEL Part Number - DISRSRC24 EMERGENCY STOP LABEL Part Number - 08P0874736 CD03317-7-23-24 TracStar®...

  • Page 74: Maintenance

    MAINTENANCE Machine Maintenance Task Schedule Task Clean Machine Inspect Facer Blades Change Heater Butt Plates Replace Battery and Cables Check/Adjust Track Tension Bleed Air from Carriage Cylinders Adjust System Pressure Check Indexer Gas Springs Grease Check Hydraulic Fluid Check Machine Operation Inspect Heater Butt Plates Inspect Hydraulic Components and Hoses...

  • Page 75: Engine Maintenance Task Schedule

    Engine Maintenance Task Schedule Task Clean Engine Replace In-Line Fuel Filter Check Coolant Level¹ Check Engine Oil Level Check Fuel Lines and Clamp Bands Replace Air Cleaner Element Clean Fuel Filter Pot Check Fan Belt Tightness Change Engine Oil² Change Engine Oil Filter² Check Radiator Hoses and Clamp Bands Replace Engine Fuel Filter...

  • Page 76: 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 maintenance 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 77: Clean Heater Butt Plate Surfaces

    Clean Heater Butt Plate Surfaces Adjusting Track Tension The heater is hot and will burn clothing and skin. The grease in the track tension cylinder is pressurized. ATTENZIONE ATTENZIONE Keep the heater protected from personnel when If the grease valve is loosened too far, the valve and not in use and use care when handling heater and grease can be expelled at high pressure and cause ¡PRECAUCIÓN!

  • Page 78: Inspect Hydraulic Components

    Inspect Hydraulic Components Once the system pressure gauge reads 2,300 psi, retighten the jam nut and reinstall cowlings. Inspect hydraulic components, hoses and sleeves for any Bleeding Air From Carriage leaks or damage. Replace or repair any damaged or leaking hydraulic components, hoses or sleeves.

  • Page 79: Check Hydraulic Fluid

    Check Hydraulic Fluid To replace the hydraulic filter: Ensure the machine is off and all hydraulic fluid has been The hydraulic fluid level should be checked daily. drained. If hydraulic fluid is not visible in the sight gauge, fluid must be If changing oil based on the ISO Cleanliness guidelines, added by removing the hydraulic fill cap.

  • Page 80: Setting Engine Speed

    Setting Engine Speed To adust the flow, loosen the jam nut (A) and turn the adjustment screw (B) until the flow rate is 8 gpm (± 0.1). Remove the carriage side cowling to gain access to the throttle cable sheath and the hydraulic pump. Start the engine and move the throttle control lever to high speed.

  • Page 81: Battery Replacement And Charging

    Battery Replacement and Battery Charging Connection The battery can be charged through the remote battery Charging connector (E) on the front of the vehicle. Ensure the connector has the dust cover on when not in use. Disconnect battery power by turning the battery disconnect switch (A).

  • Page 82: Guided Firmware Update

    GUIDED FIRMWARE UPDATE Overview From the Settings screen, tap MACHINES. 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 83: Carriage Update Process

    Carriage Update Process Tap BEGIN to update the carriage firmware. 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. Turn the machine on without starting the engine by turning the key to RUN.

  • Page 84: Heater Control Module (Hcm) Update Process

    Heater Control Module (HCM) Wait for the two-minute timer on the DataLogger screen to finish. Update Process This timer allows time for the machine to save relevant status information for a successful boot. The DataLogger must be connected to wifi to download a firmware update file.
  • Page 85 Tap BEGIN to update the HCM firmware. PH06560-9-20-24 Step 3: Wait for the HCM firmware to update. A percentage to process completion is displayed under the loading animation. Do not power off the machine or disconnect the DataLogger during the update. PH06561-9-20-24 The update screen will indicate the HCM update was successful.

  • Page 86: 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 87: Editing Serial Numbers

    Editing Serial Numbers The next screen presents the option to edit the carriage controller serial number. If the controller serial number displayed is correct, tap CONTINUE to return to step two of The serial numbers of the carriage and carriage controller can the update process.

  • Page 88: Faults

    FAULTS Faults PH06492-5-10-24 1) Fault Description: Description of the active fault 2) Symptoms/Causes: Description of possible causes or symptoms of the active fault 3) Problem Location/Pinout: Description of the location or electrical pinout where the active fault is located 4) Machine Action: Description of the corrective information pertaining to the active fault 5) FMI (Failure Mode Indicator): Adds indication to type of fault received...

  • Page 89: 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 90: Specifications

    SPECIFICATIONS TracStar® 28, 250, 412i and 618i Specifications Specifications 14 - 1 TracStar® 412i & 618i...
  • Page 91 Model TracStar 28/250 TracStar 412i TracStar 618i Capabilities 2" IPS - 250mm 4" IPS - 12" DIPS 6" IPS - 18" OD (63mm - 250mm) (1 10mm - 340mm) (160mm - 450mm) Cylinder Force Type HF, LF HF, MF, LF...
  • Page 92 3-Jaw Carriage Length 30" (762 mm) 30.7" (779.8 mm) 31" (788 mm) 3-Jaw Carriage Width 30" 32.9" (836.6 mm) 37.7" (958 mm) (762 mm) 3-Jaw Carriage Height (Hydraulic 25.6" (652.5 mm) 28.7" (730 mm) Clamp Cylinders) 3-Jaw Carriage Height (Clamp Knobs) 23"...

  • Page 93: Notes

    NOTES Notes: TracStar® 412i & 618i 15 - 1 Notes...

This manual is also suitable for:

Tracstar 250Tracstar 412iTracstar 618i

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