McElroy DynaMc HP Series User manual

Manual: 1270901 Revision: E 10/18
28, 250 and 412
Hand Pump Fusion
Machines
Operator’s
Manual
Original Language: English

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

Introduction
Thank you for purchasing this McElroy
Product
The McElroy DynaMc® HP fusion machines are manual
hydraulic operated fusion machines designed to butt fuse
polyethylene pipe.
If fusing other thermoplastic pipe materials, refer to the
pipe manufacturer's fusion procedures or appropriate
joining standard.
The DynaMc 28HP model fuses 2" IPS through 8" DIPS
(63 mm - 200 mm).
The DynaMc 250HP model fuses 2" IPS (63mm)
minimum to 250mm maximum pipe.
The DynaMc 412HP model fuses 4" IPS through 12"
DIPS (110mm - 340mm)
With reasonable care and maintenance, this machine
will give years of satisfactory service.
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.
TX02945-01-02-14
PH03877-4-15-09
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
Fusion Equipment Safety
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Read and Understand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Heater is Not Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Electric Motors are Not Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . 1-3
Pipe Handling Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Units with Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Facer Blades are Sharp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Heater is Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Personal Lifting Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Fusion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Overview
Theory of Heat Fusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Introduction to the DynaMc 28, 250 and 412
Hand Pump Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Carriage Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Heater Stripper Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Insulated Heater Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
COPYRIGHT © 2018, 2017, 2014, 2010
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.

Table of Contents
Butt Fusion Procedure
Read Before Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Set up Pipe Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Install Clamping Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Check Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Jaw Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Loading Pipe Into Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Facing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Remove Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Position Carriage for Heater Insertion . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Check Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Inserting Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Heating the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Fusing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Opening Movable Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Opening Fixed Jaws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Position Pipe for Next Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Install Next Piece of Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Special Operations - In Ditch
Remove Carriage from Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Lower the Carriage into Ditch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Clamp Carriage Assembly to Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Make Fusion Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Remove Carriage Assembly from Ditch . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Reassemble Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Special Operations - Lifting Fusion Machine
Lifting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Manual Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Powered Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Table of Contents
Maintenance
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Washing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Check Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Check Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Clean Jaws and Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Clean Thrust Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Clean Eyebolt Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fasteners Must Be Tight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Facer Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Clean Heater Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Installing Butt Fusion Heater Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Adjusting Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Heater Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Bleeding Air From Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Machine Maintenance Checklist
Fusion Machine Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Determining Fusion Pressure
Determining Fusion Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Hydraulic Fluid
Hydraulic Fluid Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Specifications
Fusion Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
TX02980-4-15-09

1 - 1
Fusion Equipment Safety
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.
¡PELIGRO!
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.
¡PELIGRO!
WR00051-11-30-92
WR00052-12-1-92
TX00030-12-1-92
TX02946-4-15-09

1 - 2
Fusion Equipment Safety
General Safety
Safety is important. Report anything unusual that you notice during
set up or operation.
LISTEN for thumps, bumps, rattles, squeals, air leaks, or unusual
sounds.
SMELL odors like burning insulation, hot metal, burning rubber, hot
oil, or natural gas.
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.
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.
WR00053-12-2-92
TX00114-4-22-93
TX00032-4-7-93
Heater is Not Explosion Proof
This heater is not explosion proof. Operation
of heater in an explosive atmosphere without
necessary safety precautions will result in
serious injury or death.
When operating in an explosive atmosphere, the heater
should be brought up to temperature in a safe environment,
then unplugged before entering the explosive atmosphere for
fusion.
TX04467-03-24-14
WR00034-11-30-92
¡PELIGRO!

Fusion Equipment Safety
1 - 3
Electric Motors are Not Explosion Proof
Electric motors are not explosion proof.
Operation of these components in an explosive
atmosphere without necessary safety precautions
will result in serious injury or death.
See Section "Facer" in the Overview section for instructions on
removing brushes from facer motor.
TX02979-04-02-14
WR00080-4-15-09
¡PELIGRO!
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.
It is recommended that the pipe is always held securely by either
being clamped in the fusion machine jaws or properly attached to a
lifting device.
NOTICE: Do not leave machine unattended to unauthorized
personnel. Do not allow unauthorized personnel to operate the
machine.
Keep persons that are not involved in handling pipe away from pipe
handling operations. Keep away from the pipe when the pipe and
handling equipment are in motion. When in motion, all persons
involved in handling pipe should be able to see all other persons
at all times. If any handling person is not in sight, immediately stop
moving equipment and pipe and locate that person. Do not continue
until all persons are accounted for and in sight.
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.
TX04882-04-18-16
WR00097-4-17-13

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.
Do not carry electrical devices by the cord.
NOTICE: Disconnect the equipment from the power source before
attempting any maintenance or adjustment.
TX02947-4 -15-09
WR00055-4-7-93
WR00025-11-30-92
Units With Hydraulics
Although the hydraulic pressures in this machine are low compared to
some hydraulically operated equipment, it is important to remember that
a sudden hydraulic oil leak can cause serious injury, or even be fatal if
the pressure is high enough.
Escaping fluid under pressure can penetrate the skin
causing serious injury. Keep hands and body away
from pinholes which eject fluid under pressure. Use
a piece of cardboard or paper to search for leaks. If
any fluid is injected into the skin, it must be immediately
removed by a doctor familiar with this type of injury.
NOTICE: wear safety glasses, and keep face clear of area when
bleeding air from hydraulic system to avoid spraying oil into eyes.
TX00110-8-23-95
WR00078-4-8-93
1 - 4
Fusion Equipment Safety
Crush Points
Hydraulically operated equipment is operated
under pressure. Anything caught in the machine
will be crushed. Keep fingers, feet, arms, legs,
and head out of the machine while operated.
TX03004-8-11-09
WR00012-12-4-92

Fusion Equipment Safety
Fusion Procedures
Obtain a copy of the pipe manufacturer's procedures or
appropriate joining standard for the pipe being fused. Follow the
procedure carefully, and adhere to all specified parameters.
NOTICE: Failure to follow pipe manufacturer's procedure
could result in a bad joint. Always follow pipe
manufacturer's procedures.
TX04469-10-24-12
WR00079-1-24-96
1 - 5
Facer Blades Are Sharp
Facer blades are sharp and can cut. Never attempt
to remove shavings while the facer is running, or is
in the facing position between the jaws. Use care
when operating the facer, and when handling the
unit.
NOTICE: Disconnect power from the facer, and remove the facer
blades before attempting any maintenance or adjustment.
NOTICE: Never extend the blade beyond the inner or outer
circumference of the facer.
TX02378-1-24-05
WR00073-4-6-93
Heater is Hot
The heater is hot and will burn clothing and skin.
Keep the heater in its insulated heater stand or
blanket when not in use, and use care when
heating the pipe.
NOTICE: Use only a clean non-synthetic cloth to clean the heater
plates.
TX00104-01-03-14
WR00030-2-10-93
Personal Lifting Safety
The machine components are heavy. Using one
person to lift the facer or carriage may result in
an injury. Use a lifting strap and an overhead
lifting device to lift facer or carriage. For manual
lifting, two people are required to lift the facer or
carriage.
TX05159-09-22-16
HeavyLifting5-25-10

Overview
2 - 1
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.
When fusion pressure is applied, the molecules from each
thermoplastic part mix. As the joint cools, the molecules return
to their form, the original interfaces are gone, and the fitting
and pipe have become one monolithic unit. A strong, fully
leak tight connection is the result.
The principal operations include:
Clamping The pipe pieces are held axially and radially to
allow all subsequent operations to take place.
Facing The pipe ends are faced to establish clean,
parallel mating surfaces perpendicular to the
centerline of the pipes.
Aligning The pipe ends are aligned with each other to
minimize mismatch of the pipe walls.
Heating A melt pattern that penetrates into the pipe is
formed around both pipe ends.
Fusing The melt patterns are joined with a specified
force, which is constant around the pipe interfacial
area.
Cooling The fusion joint is held immobile with a specified
force until adequately cooled.
Inspecting Visually examine the entire circumference of the
joint for compliance with the standard or fusion
procedure used.
TX04660-04-18-16
PH00363B-1-4-96

Carriage Assembly
The DynaMc HP fusion machines are available in a 4-Jaw and
2-Jaw model and are hydraulic hand pump operated.
The 4-Jaw HP carriage assembly consists of two fixed jaws and
two hydraulically operated movable jaws bolted to a skid.
For fittings, the inner fixed jaw can be connected to the movable
jaws on the carriage for a 3 movable 1 fixed jaw configuration.
The 2-Jaw HP carriage assembly consists of one fixed jaw and one
hydraulically operated movable jaw bolted to a skid.
All HP carriage assemblies have a hydraulic hand pump to
pressure the hydraulic cylinders to move the jaws.
TX02949-4-15-09
Overview
Introduction to the DynaMc 28, 250 and
412 Hand Pump Fusion Machine
The McElroy DynaMc HP fusion machines are manual hydraulic
operated fusion machines designed to butt fuse polyethylene pipe.
If fusing other thermoplastic pipe materials, refer to the pipe
manufacturer's suggested procedures or appropriate joining
standard.
The DynaMc 28HP model fuses 2" IPS through 8" DIPS (63 mm -
200 mm).
The DynaMc 250HP model fuses 2" IPS (63 mm) minimum to 250
mm maximum pipe.
The DynaMc 412HP model fuses 4" IPS through 12" DIPS (110
mm - 340 mm)
TX02948-4-15-09
PH05032-01-03-14PH05032-01-03-14PH05033-01-03-14
2 - 2

Pump
The carriage assembly has a manually operated hydraulic pump
that is used to apply hydraulic pressure to the carriages hydraulic
cylinders in order to move the jaws. The pump has a pressure
release valve on the lower left side of the pump.
TX02951-4-15-09
Overview
Hydraulic Fluid 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 Hydraulic Fluid Level" section for instructions
on checking and filling the hydraulic fluid.
Refer to the "Hydraulic Fluids" section of this manual for hydraulic
fluid recommendations.
TX02950-08-08-14
PH03860-4-15-09
2 - 3
PH03861-4-15-09
Hydraulic Cylinders
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 side
of pump. Air in the system is indicated when carriage movement
becomes jerky and erratic.
Consult the "Maintenance" section of this manual for procedure to
follow when bleeding air from system.
TX01137-10-23-96
PH03872-4-15-09 PH05031-01-03-14

Overview
2 - 4
Facer
Electric motors are not explosion proof. Operation of
these components in a hazardous environment without
necessary safety precautions will result in serious injury
and death.
Ensure facer power switch is in the off position.
Connect facer to proper power source.
Don't turn on facer until ready to face.
Remove brushes on the Milwaukee facer motor:
The armature brushes must be removed from the electric motor when
manually operating in a hazardous condition. Unscrew the brushes from
both sides of the motor. (Both brushes must be removed). A 1-1/8" hex
shaft allows for manual operation in hazardous conditions.
Remove brushes on the Eibenstock facer motor:
The armature brushes must be removed from the electric motor
when manually operating in a hazardous condition.
Remove the rear cover of the motor.
Slide the spring clip away from the brush and pull the brush out
(A).
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.
TX04004-04-07-14
PH04125-4-12-10
¡PELIGRO!
PH01847-7-25-00PH04129-4-12-10PH04130-4-12-10PH04130-4-12-10
B
A

Overview
2 - 5
Heater Stripper Bar
The heater is equipped with a stripper bar that is used to separate
the heater from the pipe ends after the heating cycle. When the
inner jaws are opened, the jaws lift and press against the stripper
bar separating the heater from pipe ends.
TX02982-4-27-09
PH03906-4-17-09
Heater
Heater is not explosion proof. Operation of heater
in an explosive atmosphere without necessary safety
precautions will result in serious injury or death.
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.
The heater has a green indicator light which will flash on and off. This
indicates that the controller is operating normally. 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.
When the heater is plugged in and preheating the light glows steadily
until the set temperature is reached. The light then goes off and on
slowly as the heater maintains temperature.
The heater body is not coated. Coated butt fusion heater plates are
available for all butt fusion applications.
NOTICE: The heater should never be used without butt fusion heater
plates installed.
To prevent a build-up of plastic pipe residue from accumulating on the
heater plates (loss of surface temperature and pipe sticking may result),
the heater plates should be cleaned with a non-synthetic cloth before
every fusion joint.
TX02981-01-03-14
PH03874-4-15-09
¡PELIGRO!
PH03875-4-15-09

Insulated Heater Stand
The heater should always be stored in the insulated heater stand
or blanket for protection of the operator and to minimize heat loss
and risk of mechanical damage.
TX00363-9-15-94
PH03874-4-15-09
Overview
2 - 6

Check Hydraulic Fluid Level
Check fluid level by removing the plug on the top of the hydraulic
pump's reservoir. The reservoir should be approximately half full of
fluid. Do not overfill.
Refer to the "Hydraulic Fluids" section of this manual for hydraulic
fluid recommendations.
TX02954-08-08-14
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.
TX02953-4-15-09
Butt Fusion Procedure
STOP-12-22-92
3 - 1
Prepare Heater
Heater is not explosion proof. Operation of heater
in an explosive atmosphere without necessary safety
precautions will result in serious injury or death.
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.
Install butt fusion heater plates.
NOTICE: The heater should never be used without butt fusion heater
plates installed. Refer to the "Maintenance" section of this manual
for installation procedure.
Place heater in insulated heater stand.
Plug heater into a proper power source.
Allow heater to warm-up to operating temperature.
Refer to the "Maintenance" section of this manual for instructions on
how to adjust heater temperature.
TX02310-03-24-14
PH02312-4-24-02
¡PELIGRO!
PH00420-11-1-94 PH03861-4-15-09

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
Butt Fusion Procedure
3 - 2
PH03879-4-15-09
Install Clamping Inserts
Select and install appropriate clamping inserts for the pipe that is
being fused.
Clamping inserts are required for all sizes except sizes that match
the size of the jaw without inserts.
TX02956-4-15-09
PH00304-9-24-93
Pump
Use the carriage control valve to select desired carriage direction.
The neutral position does not apply pressure to the cylinders. With
the valve in the appropriate position, actuate the pump handle to
build pressure. The pump applies pressure in both strokes of the
handle.
There is a pressure release valve on the bottom left side of the
pump. Rotate the lever counter-clockwise to release pressure.
TX02957-4-27-09
PH03888-4-15-09
PH03892-4-15-09
PH05031-01-03-14