McElroy PolyHorse User manual

PolyHorse®
Pipe Rack System
Operator’s
Manual
Original Language: English
Manual: 1877501 Revision: G 11/18

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
Cancer and Reproductive Harm -
www.P65warnings.ca.gov
8163361

Thank you for purchasing this McElroy
product.
The Polyhorse®is a pipe rack system designed to
stage multiple sticks of plastic pipe at the proper
height for feeding directly into a McElroy fusion
machine. By doing this, the time consuming task
of pipe loading into the fusion machine is greatly
reduced increasing overall productivity.
Before operating this machine, please read this
manual thoroughly, and keep a copy with the
machine for future reference. This manual is to be
considered part of your machine. A replacement
manual can be obtained online at:
www.mcelroy.com
Always return the manual to the literature
compartment.
TX02678-12-6-06
PH03439-12-6-06
Introduction
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. McElroy University
classes are structured so that the skills learned and the
machines used in each class closely match the machines
found on pipelining jobsites. We offer training at
our facility or yours. Our uniquely qualified McElroy
University course instructors offer years of industry
experience.
Tuition for each course includes lunches, course materials
and a certificate of completion. Online registration,
as well as up-to-date course offerings and dates, is
available at www.mcelroy.com/university
This manual is intended as a guide only and does not
take the place of proper training by qualified instructors.
The information in this manual is not all inclusive and
can not encompass all possible situations that can be
encountered during various operations.
MU2-03-13-14
TX04659-03-24-14

Warranty
LIMITED WARRANTY
McElroy Manufacturing, Inc. (McElroy) warrants all
products manufactured, sold and repaired by it to be
free from defects in materials and workmanship, its
obligation under this warranty being limited to repairing
or replacing at its factory and new products, within 5
years after shipment, with the exception of purchased
items (such as electronic devices, pumps, switches, etc.),
in which case that manufacturer’s warranty applies.
Warranty applies when returned freight is prepaid and
which, upon examination, shall disclose to have been
defective. This warranty does not apply to any product
or component which has been repaired or altered by
anyone other than McElroy or has become damaged
due to misuse, negligence or casualty, or has not been
operated or maintained according to McElroy’s printed
instructions and warnings. This warranty is expressly in
lieu of all other warranties expressed or implied. The
remedies of the Buyer are the exclusive and sole remedies
available and Buyer shall not be entitled to receive any
incidental or consequential damages. Buyer waives
the benefit of any rule that disclaimer of warranty shall
be construed against McElroy and agrees that such
disclaimers herein shall be construed liberally in favor of
McElroy.
RETURN OF GOODS
Buyer agrees not to return goods for any reason except
upon the written consent of McElroy obtained in advance
of such return, which consent, if given, shall specify the
terms and conditions and charges upon which any such
return may be made. Materials returned to McElroy, for
warranty work, repair, etc., must have a Return Material
Authorization (RMA) number, and be so noted on the
package at time of shipment. For assistance, inquiry shall
be directed to:
McElroy Manufacturing, Inc.
P.O. Box 580550
833 North Fulton Street Tulsa, Oklahoma 74158-0550
PHONE: [phone], FAX: [phone].
EMAIL: [e-mail]
Note: Certain repairs, warranty work, and inquiries may
be directed, at McElroy’s discretion, to an authorized
service center or distributor.
TX02486-11-4-13
DISCLAIMER OF LIABILITY
McElroy accepts no responsibility of liability for fusion
joints. Operation and maintenance of the product is the
responsibility of others. We recommend qualified joining
procedures be followed when using McElroy fusion
equipment.
McElroy makes no other warranty of any kind whatever,
express or implied; and all implied warranties of
merchantability and fitness for a particular purpose which
exceed the aforestated obligation are hereby disclaimed
by McElroy.
PRODUCT IMPROVEMENT
McElroy reserves the right to make any changes in or
improvements on its products without incurring any
liability or obligation to update or change previously sold
machines and/or the accessories thereto.
INFORMATION DISCLOSED
No information of knowledge heretofore or hereafter
disclosed to McElroy in the performance of or in
connection with the terms hereof, shall be deemed to be
confidential or proprietary, unless otherwise expressly
agreed to in writing by McElroy and any such information
or knowledge shall be free from restrictions, other than a
claim for patent infringement, is part of the consideration
hereof.
PROPRIETARY RIGHTS
All proprietary rights pertaining to the equipment or
the components of the equipment to be delivered by
McElroy hereunder, and all patent rights therein, arising
prior to, or in the course of, or as a result of the design
or fabrication of the said product, are exclusively the
property of McElroy.
LAW APPLICABLE
All sales shall be governed by the Uniform Commercial
Code of Oklahoma, U.S.A.
Register your product online to activate your warranty:
www.McElroy.com/fusion
(Copy information listed on the machine nameplate here
for your records).
Model No.
Serial No.
Date Received
Distributor

Table of Contents
Equipment Safety
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Read and Understand . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . 1-2
Crush Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Use Stanchions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Tipping Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Crush Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Cutting Pipe Bands . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Overview
PolyHorse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
PolyHorse Power Assist (Optional) . . . . . . . . . . . . . . . . 2-4
Initial Setup
Truss Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Truss Assembly Positioning . . . . . . . . . . . . . . . . . . . . . 3-2
Adjusting Front Height . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Adjusting Rear Height . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Adjusting Roller Assembly Drop Foot Height . . . . . . . . . 3-3
Stanchions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Additional Truss Assemblies . . . . . . . . . . . . . . . . . . . . 3-4
Additional Roller Assemblies . . . . . . . . . . . . . . . . . . . . 3-5
Fusion Machine Setup
Positioning Fusion Machine. . . . . . . . . . . . . . . . . . . . . 4-1
Power Assist Setup
Connect Power Assist to Machine (Optional). . . . . . . . . 5-1
Pipe Handling
Loading Pipe onto the PolyHorse . . . . . . . . . . . . . . . . . 6-1
Cutting Pipe Bands . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Loading Pipe into Rollers . . . . . . . . . . . . . . . . . . . . . . 6-4
Pipe Pulling Procedure . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Power Assist Pipe Pulling Procedure (Optional) . . . . . . . 6-5
Pipe Staging
Max Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Pipe Staging Options. . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Assembly Parts
PolyHorse Assembly Parts Numbers . . . . . . . . . . . . . . . 8-1
Specifications
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
COPYRIGHT © 2018, 2017, 2014, 2009
McElroy Manufacturing, Inc.
Tulsa, Oklahoma, USA
All rights reserved
All product names or trademarks are property of their respective owners. All information,
illustrations and specifications in this manual are based on the latest information available at the
time of publication. The right is reserved to make changes at any time without notice.
TX02679-10-13-09

Equipment Safety
1 - 1
Safety Alerts
This hazard alert sign appears in this manual.
When you see this sign, carefully read what it says.
YOUR SAFETY IS AT STAKE.
You will see the hazard alert sign with these words:
DANGER, WARNING, and CAUTION.
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
Indicates a hazardous situation which,
if not avoided, may result in minor or
moderate injury.
In this manual you should look for two other words:
NOTICE and IMPORTANT.
NOTICE: can keep you from doing something that might
damage the machine or someone's property. It may also
be used to alert against unsafe practices.
IMPORTANT: can help you do a better job or make
your job easier in some way.
TX00030-12-1-92
¡PELIGRO!
¡PELIGRO!
WR00051-11-30-92
Read and Understand
Do not operate this equipment until you have carefully read, and
understand all the sections of this manual, and all other equipment
manuals that will be used with it.
Your safety and the safety of others depends upon care and
judgment in the operation of this equipment.
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.
You must satisfy yourself that a procedure, tool, work method, or
operating technique is safe for you and others. You should also
ensure that the machine will not be damaged or made unsafe by
the method of operation or maintenance you choose.
TX02946-4-15-09
WR00052-12-1-92

Equipment Safety
1 - 2
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.
SEE problems with wiring and cables, hydraulic connections, or other
equipment.
REPORT anything you see, feel, smell, or hear that is different from
what you expect, or that you think may be unsafe.
TX00114-4-22-93
SAFE1ST-12-22-92
Wear Safety Equipment
Wear a hard hat, safety shoes, safety glasses, and other
applicable personal protective equipment.
Remove jewelry and rings, and do not wear loose fitting clothing
or long hair that could catch on controls or moving machinery.
TX000324793
WR00053-12-2-92
Crush Hazard
Pipe can move and crush operator. Do not
stand within bounds of racks while pipe is
stacked or handling pipe. Failure to do so
may result in serious injury or death.
TX02680-05-30-14
CD00726-12-6-06
¡PELIGRO!
CD00735-12-6-06

Use Stanchions
Use stanchions while pipe is on racks. Do not
stack pipe above stanchion height. Failure to do
so may result in serious injury or death.
TX02681-05-30-14
CD00727-11-28-06
Tipping Hazard
Never use pipe racks without drop foot
properly in place. Failure to do so may cause
racks to tip and injury may occur.
TX02682-12-6-06
Crush Hazard
Moving parts may crush. Keep hands and
feet away from moving parts. Failure to do so
could result in injury.
TX03031-10-13-09
CD00729-11-29-06CD00783-10-13-09 CD00728-11-28-06
¡PELIGRO!
Equipment Safety
1 - 3

Equipment Safety
1 - 4
Cutting Pipe Bands
Do not stand within the danger area of the racks while pipe
is on or being loaded on to racks.
Always cut pipe bundle from the stanchion side of the PolyHorse with stanchions in place. Stanchions will prevent
injury by not allowing pipe to roll towards the operator. If bundles cannot be reached from the rear then cut the
bundles from the front of the PolyHorse standing outside of the roller assemblies.
NOTICE: Only single stack pipe bundles on the roller side of the PolyHorse.
Cut only single stacked bundles from the roller side of the PolyHorse, and only without pipe in the roller.
When it is necessary to cut bands from the roller side, cut all the inner banding on the pipe bundle then cut the outer
two bands last. Use caution when cutting the last bands
TX02697-12-6-06
CUT BANDS HERE
CUT BANDS HERE
Stanchion
Outer
Band
Outer
Band
Inner
Band
CD00730-12-6-06
¡PELIGRO!
DANGER
HAZARD
AREA
AREA
CD00731-12-6-06

Overview
2 - 1
PolyHorse
The Polyhorse is a pipe rack system designed to stage multiple sticks of plastic pipe
at the proper height for feeding directly into a McElroy fusion machine. By doing
this, the time consuming task of pipe loading into the fusion machine is greatly
reduced increasing overall productivity.
PolyHorse Assembly - 1875501
The PolyHorse Assembly consists of 3 Truss Assemblies with
6 Screw Jack Assemblies. Attached to one side of Screw
Jack Assemblies is a Pivot Roller Support Assembly and
two Stationary Roller Support Assemblies. Three Stanchions
fit opposite the roller assemblies. The PolyHorse can also
be configured in other ways because of the modular
construction (See Section - Additional Pipe Staging Options).
CD00732-12-6-06
PH03497-10-22-07

PolyHorse (continued)
Truss Assembly - 1875601
The Truss Assembly is used with 2 Screw Jack Assemblies.
Pipe is held across three Truss Assemblies to distribute the
weight of the pipe. Additional Truss Assemblies can be
used to provide room for additional pipe (See Section -
Additional Pipe Staging Options).
Screw Jack Assembly - 1875901
The Screw Jack Assembly is used to support the Truss
Assembly. The screw jack also allows the operator to level
the PolyHorse on uneven terrain and control the roll of the
pipe.
Pivot Roller Support Assembly - 1876301
The Pivot Roller Support Assembly is positioned on the truss
that is closest to the fusion machine. It allows the operator
to lift up the end of the pipe to position it in the jaws. The
support has a drop down foot that is used to prevent tipping
of the PolyHorse.
PH03498-10-22-07PH03500-10-22-07 PH03499-10-22-07
Overview
2 - 2

PolyHorse (continued)
Stationary Roller Support Assembly - 1876302
The Stationary Roller Support Assembly is positioned on
the two farthest trusses from the fusion machine. It allows
the operator to roll the pipe to position it in the jaws. The
support has a drop down foot that is used to prevent tipping
of the PolyHorse.
Stanchion - 1877101
The Stanchion is an upright that is used on the rear portion
of the PolyHorse to prevent pipe from rolling off the rear.
There is one Stanchion used for each Truss Assembly. The
Stanchion should always be in place when pipe is on the
PolyHorse.
Speed Wrench Assembly - 1818501
The Speed Wrench Assembly is used to raise or lower each
Screw Jack Assembly.
TX02684-12-6-06
PH03501-10-22-07
PH03502-10-22-07
PH03347-1-4-07
Overview
2 - 3

Overview
PolyHorse Power Assist (Optional)
The optional PolyHorse Power Assist can be connected
to the fusion machine's hydraulic system to power the
front pipe roller on the PolyHorse. The Power Assist is
used to aid in feeding pipe into the fusion machine by
powering the front pipe roller and has controls to raise
and lower the pipe.
The Power Assist roller can move the pipe in or out of the
machine.
The Power Assist roller can also lift the pipe up or down to
position the pipe in the jaws.
TX03028-9-30-09
PH04010-9-29-09PH04012-9-29-09 PH04011-9-29-09
2 - 4

3 - 1
Initial Setup
Truss Assembly
Insert bottom truss assembly shaft into the j-hook
on screw jack assembly.
Align the upper holes and insert the detent pin.
TX02685-12-6-06
Roller Assembly
Insert bottom roller assembly shaft into the j-hook on
screw jack assembly.
Align the upper holes and insert the detent pin.
Insert the handle into the pivot lift roller assembly.
Be sure to line up and engage the handle detent.
TX02686-12-6-06
PH03503-10-22-07
PH03307-10-16-06 PH03303-10-16-06
PH03304-10-16-06
PH03306-10-16-06

3 - 2
Initial Setup
Truss Assembly Positioning
Position the truss assemblies with the pivot lift roller assembly on the left end.
Truss assemblies should be positioned approximately 15 feet apart for 50 to 40
foot lengths of pipe. For shorter lengths of pipe a closer spacing can be used.
Additional truss assemblies can be used to provide support if conditions warrant.
Set up on solid ground if possible. In soft ground conditions it may be necessary to
place screw jack assemblies on a large base to spread out the load and help prevent
Polyhorse from sinking into the ground when loaded with pipe.
TX02687-12-6-06
PH03302-10-16-06

3 - 3
Initial Setup
Adjusting the Front Height
Before loading any pipe, adjust the height of each front screw
jack using speed wrench.
The height of the pipe rollers should allow the pipe to be inline
with the fusion machine jaws.
IMPORTANT: A string or a low cost laser level can be used
to check the height of each roller to the height of the fusion
machine jaws.
TX02688-12-6-06
PH03308-10-16-06
Adjusting the Rear Height
Adjust the height of each rear screw jack using speed wrench.
The height of the pipe rollers should allow the pipe to be inline
with the fusion machine jaws.
When adjusting the height you can use the spirit levels to
determine amount of incline away from the roller end.
NOTICE: Adjusting the three truss assemblies with a slight decline
away from the roller end will help control the dispensing of the
pipe.
TX02689-12-6-06
PH03309-10-16-06PH03310-10-16-06
Adjusting Roller Assembly Drop Foot Height
Remove the pin and allow the drop foot to touch the ground.
Find the nearest holes that line up and insert the detent pin in
that position.
Never use pipe racks without drop foot
properly in place. Failure to do so may cause
racks to tip and injury may occur.
TX02690-12-6-06
PH03311-10-16-06
Direction pipe
will roll
Raise Jacks
PH03341-1-4-07

3 - 4
Initial Setup
Stanchions
Insert stanchions in the rear stanchion sockets on each of the truss
assemblies.
Use stanchions while pipe is on racks. Do not
stack pipe above stanchion height. Failure to do
so may result in serious injury or death.
TX02691-05-30-14
Additional Truss Assemblies
"Piggy-back" additional truss assemblies to the rear for additional
pipe holding capacity.
Insert bottom truss assembly shaft into the j-hook on screw jack
assembly (both ends).
Align the upper holes and insert the detent pin (both ends).
Adjust the height of the rear screw jacks using the speed wrench.
TX02692-12-6-06
PH03313-10-16-06
PH03312-10-16-06
PH03315-1-4-07PH03316-1-4-07
¡PELIGRO!
PH03434-12-22-06

3 - 5
Initial Setup
Additional Roller Assemblies
"Piggy-back" additional pipe roller assemblies to the rear
for dual fusion machine operation (See Section - Additional
Pipe Staging Options).
Insert bottom roller assembly shaft into the j-hook on screw
jack assembly.
Align the upper holes and insert the detent pin.
Adjust the height of the roller assembly drop foot.
Remove the pin and allow the drop foot to touch the
ground.
Find the nearest holes that line up and insert the detent pin
in that position.
TX02693-12-6-06
PH03317-10-16-06PH03319-10-16-06 PH03318-10-16-06
PH03320-10-16-06

4 - 1
Fusion Machine Setup
Position Fusion Machine
Position fusion machine to the left of the PolyHorse so the movable jaws are facing toward the pivot roller of the
PolyHorse.
Fusion machine should be in line with the PolyHorse pipe rollers.
NOTICE: Pipe should be positioned as shown, being careful not to hit the fusion machine
TX02694-12-6-06
PH03321-10-16-06PH03322-10-16-06

Powered Assist Setup
5 - 1
Connect Power Assist to Machine (Optional)
The optional PolyHorse Powered Assist can be connected to the fusion machine's hydraulic system to power the
pipe roller on the PolyHorse. The Powered Assist is used to aid in moving pipe in and out of the fusion machine by
powering the front pipe roller and has controls to raise and lower the pipe.
Connecting to Machine:
Ensure that there is no pipe on the PolyHorse.
NOTICE: Removing the support assemblies may cause the PolyHorse to tip with pipe on the PolyHorse.
Remove the Pivot Roller Support Assembly from the PolyHorse truss assembly.
Attach the Power Assist Roller to the front of the PolyHorse truss assembly closest to the fusion machine. The Power
Assist Roller connects to the truss assembly in the same way as the Pivot Roller Support Assembly.
Ensure the fusion machine is off, disconnect the hydraulic hoses (A) from the fusion machine's facer
Connect the machine's facer hoses to the tee connections (B) at the end of the hoses (C) from the PolyHorse Power
Assist.
Connect the hoses from the tee connections (B) to the fusion machine's facer (D).
TX03029-9-29-09
PH04009-10-13-09
D - Hoses from Tee
Connection to Facer.
C - Hoses from PolyHorse
Power Assist.
A - Hoses from Machine
to Facer.
B - Tee Connections.