McElroy TracStar i Series User manual

1TracStar® 630i, 900i, 1200i
TracStar®iSeries
Fusion Machines
Models: AT24P0817487, AT24P0888638, AT24P0888654,
AT24P0888656, AT900P0807623, AT900P0888634,
AT900P0888648, AT900P0888650, AT48P0888642
AT48P0808167, AT48P0888644, AT48P0888646
Manual: T48P0898411
Revision: B 08/22
Original Language: English
Operator’s
Manual

Copyright 2021 McElroy Manufacturing, Inc.
All rights reserved.
P.O. Box 580550
Tulsa, Oklahoma 74158-0550, USA

Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or
precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person
must be alert to potential hazards. This person should also have necessary training, skills and tools to perform these functions properly.
Advanced training is offered through McElroy University. Course offerings are meant to enhance your efficiency, productivity and safety
in the proper use of McElroy equipment.
Improper operation, maintenance or repair of this product can be dangerous and could result in injury or death.
Do not operate this product until you have carefully read, and understand all the sections of this manual, and all
other equipment manuals that will be used with it.
Follow all applicable federal, state, local, and industry specific regulations.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or
“CAUTION”. The Safety Alerts are shown below.
The meaning of these safety alert symbols are as follows:
- 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.
Signal words “NOTICE” and “IMPORTANT” are used to bring attention to important information.
The meaning of these signal words are as follows:
“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.
McElroy cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this
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
and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation,
maintenance or repair procedures that you choose.
The information, specifications, and illustrations in the publication are on the basis of information that was available at the time that the
publication was written. The specifications, pressures, measurements, adjustments, illustrations, and other items can change at any time.
These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any
job. The most current information is available at our website
www.mcelroy.com.
When replacement parts are required for this
product McElroy recommends using McElroy
replacement parts or parts with equivalent
specifications including, but not limited to,
physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature
failures, product damage, personal injury or death.
¡PELIGRO!
¡PELIGRO!
PERICOLO
¡ADVERTENCIA!
AVVERTIMENTO
¡ADVERTENCIA!
AVVERTIMENTO
¡PRECAUCIÓN!
ОСТОРОЖНО
ATTENTION
ATTENZIONE
TX05337-04-18
Cancer and Reproductive Harm -
www.P65warnings.ca.gov
8163361

TABLE OF CONTENTS
FOREWORD
Literature Information ......................................................................................1-1
Safety ..................................................................................................1-1
Operation ...............................................................................................1-1
Maintenance ............................................................................................1-1
McElroy University........................................................................................1-1
Patent Information ........................................................................................1-2
Replacement Literature.....................................................................................1-2
Nameplate Location ......................................................................................1-2
Replacement Parts ........................................................................................1-2
Limited Warranty .........................................................................................1-3
SAFETY
General Safety...........................................................................................2-1
Safety Equipment .........................................................................................2-1
Do Not Operate in a Hazardous Environment .................................................................2-2
Fuel Handling ............................................................................................2-2
Units With Engine.........................................................................................2-2
Carbon Monoxide........................................................................................2-3
Pipe Handling Safety......................................................................................2-3
Crush Points .............................................................................................2-3
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Do Not Ride Machine .....................................................................................2-4
Electrical Safety ..........................................................................................2-4
Unit With Hydraulics ......................................................................................2-5
Facer Blades Are Sharp....................................................................................2-5
Positioning and Setting Fusion Machine.......................................................................2-5
Stand Clear .............................................................................................2-5
Keep Machine Away From Edge of Ditch .....................................................................2-6
Lifting Safety .............................................................................................2-6
Personal Lifting Safety .....................................................................................2-6
Heater is Hot ............................................................................................2-6
Sound Information ........................................................................................2-7
Fusion Procedures ........................................................................................2-7
GENERAL INFORMATION
Theory of Butt Fusion ......................................................................................3-1
Nomenclature............................................................................................3-2
Vehicle Console ..........................................................................................3-2
Fuse and Relay Panel......................................................................................3-3
Carriage Fuse and Relay Block..............................................................................3-3
Radio Remote ............................................................................................3-4
Outboard Vehicle.........................................................................................3-5

Carriage Bulkhead........................................................................................3-6
Carriage Control Panels ...................................................................................3-7
Carriage Control Pads.....................................................................................3-8
Carriage Assembly .......................................................................................3-9
Facer ...................................................................................................3-10
Heater..................................................................................................3-11
Heater Bag Frame ........................................................................................3-11
Diesel Engine ............................................................................................3-12
Hydraulic Fluid Reservoirs ..................................................................................3-13
Hydraulic Fluid Filters......................................................................................3-13
Vehicle Outriggers (1200i).................................................................................3-14
Operator Platform (1200i).................................................................................3-15
Vehicle Display Navigation Map ............................................................................3-17
Vehicle Display Screens....................................................................................3-19
OPERATION - BUTT FUSION
Read Before Operating ....................................................................................4-1
Starting Instructions .......................................................................................4-1
Driving Vehicle ...........................................................................................4-2
Prepare Heater...........................................................................................4-3
Controls for Indexer.......................................................................................4-3
Jaws ...................................................................................................4-4
Jaw Inserts ..............................................................................................4-4
Loading Pipe into Machine .................................................................................4-4
Closing Jaws.............................................................................................4-5
Positioning Facer .........................................................................................4-5
Begin Facing.............................................................................................4-6
After Facing .............................................................................................4-7
Check Pipe Alignment .....................................................................................4-8
Setup Fusion Process ......................................................................................4-9
Level 2 Fusion Process .....................................................................................4-15
Level 1 Fusion Process .....................................................................................4-18
Joint Report..............................................................................................4-20
SPECIAL OPERATIONS
Special Operations Overview ..............................................................................5-1
Outer Fixed Jaw Removal ..................................................................................5-1
4-Jaw Carriage Removal ..................................................................................5-3
Facer Removal ...........................................................................................5-4
Heater Removal ..........................................................................................5-8
3-Jaw Carriage Removal ..................................................................................5-11
Remove Upper Jaws ......................................................................................5-13
For Digital Copy: Press Alt + Left Arrow to return to the link that was clicked.

LIFTING AND TRANSPORT
Lifting Safety .............................................................................................6-1
Lifting Device Shackles ....................................................................................6-1
Lifting Entire Machine (630iand 900i).......................................................................6-2
Lifting Vehicle (630iand 900i).............................................................................6-3
Lifting 4-Jaw Carriage (630iand 900i)......................................................................6-4
Lifting 3-Jaw Carriage (630iand 900i)......................................................................6-5
Lifting Entire Machine (1200i)...............................................................................6-6
Lifting Vehicle (1200i).....................................................................................6-7
Lifting 4-Jaw Carriage (1200i)..............................................................................6-8
Lifting 3-Jaw Carriage (1200i)..............................................................................6-9
Securing Indexer for Transport ..............................................................................6-10
Securing for Reduced Width (1200i).........................................................................6-10
COWLINGS
Opening Dome ..........................................................................................7-1
Removing Outboard Side Panel .............................................................................7-2
Removing Grill Panel ......................................................................................7-2
Removing Inboard Side Panel...............................................................................7-2
LABELS AND MARKINGS
Labels and Markings ......................................................................................8-1
MAINTENANCE
Maintenance Task Schedule ................................................................................9-1
Preventative Maintenance..................................................................................9-3
Clean Machine ..........................................................................................9-3
Engine Maintenance Tasks .................................................................................9-3
Check Machine Operation .................................................................................9-3
Inspect Facer Blades ......................................................................................9-3
Changing Heater Plates....................................................................................9-3
Grease .................................................................................................9-3
Check Hydraulic Fluid .....................................................................................9-4
Check Track Tension.......................................................................................9-4
Adjusting Track Tension ....................................................................................9-4
Inspect Heater Plates ......................................................................................9-5
Inspect Wiring and Cables .................................................................................9-5
Inspect Hydraulic Components and Hoses ....................................................................9-5
Bleeding Air From Carriage Cylinders ........................................................................9-5
Adjust Hydraulic Cylinder Cushion...........................................................................9-5
Adjusting System Pressure ..................................................................................9-6
Check Fasteners Are Tight ..................................................................................9-6
Change Hydraulic Fluid and Filters...........................................................................9-6
Checking Track Gearbox Oil ...............................................................................9-7

Replacing Track Gearbox Oil ...............................................................................9-7
Clean Heater Surfaces ....................................................................................9-8
Radio Remote Batteries ....................................................................................9-8
Battery Replacement and Charging ..........................................................................9-9
FAULTS
Faults ...................................................................................................10-1
HYDRAULIC FLUIDS
Hydraulic Fluids ..........................................................................................11-1
SPECIFICATIONS
TracStar®630i, 900iand 1200iSpecifications ................................................................12-1
NOTES
Notes ..................................................................................................13-1
For Digital Copy: Press Alt + Left Arrow to return to the link that was clicked.

Foreword
1-1Foreword TracStar® 630i, 900i, 1200i
FOREWORD
Literature Information
This manual should be stored in a protected location for
future reference. Use the literature holder if provided with the
product. Digital copy will contain hyperlinks. Press Alt + Left
Arrow to return to the selected hyperlink.
This manual contains safety information, operation instructions,
transportation information, lubrication information and
maintenance information.
Some photographs or illustrations in this publication show
details or equipment that can be different from your machine.
Guards and covers might have been removed for illustrative
purposes.
Continuing improvement and advancement of product design
might have caused changes to your machine which are not
included in this publication. Read, study and keep this manual
with the machine.
Whenever a question arises regarding your machine, or this
publication, please contact McElroy Technical Services at
918-831-9224 or [e-mail]
Safety
The safety section lists basic safety precautions. In addition,
this section identifies the text and locations of warning signs
and labels used on the machine.
Read and understand the basic precautions listed in the safety
section before operating or performing maintenance and
repair on this machine.
Operation
The operation section is a reference for the new operator
and a refresher for the experienced operator. This section
includes a discussion of gauges, switches, machine controls,
accessories and transportation.
Photographs and illustrations guide the operator through
correct procedures of setting up, checking and operating the
machine.
Operating techniques outlined in this publication are basic.
Proficiency develops as the operator gains knowledge and
experience with the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment care. The
maintenance schedule lists the items to be maintained at a
specific service interval. Items without specific intervals are
listed under the “As Needed” service interval. The schedule
lists the page for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the schedule as
an index for all maintenance procedures.
Some maintenance procedures may be referenced in a
manual pertaining to that component of the machine. For
example, maintenance for an engine component would have
its intervals and procedures in the engine operator’s manual.
Use the hour meter (if equipped) to determine servicing
intervals. Calendar intervals will be used instead of hour
meter intervals if no hour meter is equipped on a machine.
Recommended service should always be performed at the
interval that occurs first.
Under extremely severe, dusty or wet operating conditions,
more frequent lubrication than is specified in the maintenance
schedule might be necessary.
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.

Foreword
1-2 ForewordTracStar® 630i, 900i, 1200i
Patent Information
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
Replacement Literature
This product is shipped with a printed operator’s manual. If
the manual becomes lost or damaged, order a replacement
manual or download and print a copy of the manual at
www.mcelroy.com.
Nameplate Location
Every machine has a name plate that includes the machine’s
model number, serial number, and power requirements. The
model and serial numbers can be used to register the machine
online and activate the warranty. Reference warranty card for
information on registering your product.
Replacement Parts
Refer to the McElroy parts finder at
www.mcelroy.com to locate parts for purchase. Reference the
model number on the nameplate of the machine when using
the parts finder.
Contact your McElroy distributor to order replacement parts.
Find your closest distributor on our website at
www.mcelroy.com.
CD02508-11-23-20
CD02651-05-18-21
Vehicle Nameplate
Carriage Nameplate
TX05338-04-18

Foreword
1-3Foreword TracStar® 630i, 900i, 1200i
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.
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
TX05339-04-18

Safety
2-1 SafetyTracStar® 630i, 900i, 1200i
SAFETY
There can be several specific safety messages on this machine.
The exact location of the hazards and the description of
the hazards are reviewed in this section. Please become
familiarized with all safety messages.
Make sure that all of the safety messages on the machine
are legible. Clean the safety messages or replace the
safety messages if you cannot read the words. Replace if
the illustrations are not legible. When you clean the safety
messages, use a cloth, water and soap. Do not use solvent,
gasoline, or other harsh chemicals to clean the safety
messages. Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message or damage the
print of the safety message.
Replace any safety message that are damaged, or missing.
If a safety message is attached to a part that is replaced,
install a safety message on the replacement part. New safety
messages can be ordered from McElroy using the part number
listed.
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.
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. Remove any loose safety equipment during an
operation that could be drawn into or caught in the machine.
Ensure proper fire prevention or other fire-fighting equipment
is available and all personnel know how and when to use it.
ДУМАЙТЕ
О
БЕЗОПАСНОСТИ
В ПЕРВУЮ
ОЧЕРЕДЬ
PENSEZ
Sécurité
en
1er
SAFE1ST-2-21-18

Safety
2-2Safety TracStar® 630i, 900i, 1200i
Do Not Operate in a Hazardous
Environment
Electric motors and heaters are not explosion proof.
Operation of these components in an explosive
atmosphere will result in serious injury or death.
If operating in an explosive atmosphere, the carriage must be
removed from the vehicle and the vehicle must be operated
in a non-explosive atmosphere. The heater should be brought
up to temperature in a non-explosive atmosphere, then
unplugged before entering the explosive atmosphere for
fusion.
Fuel Handling
Gasoline and diesel fuels are extremely flammable,
and their vapors will explode if ignited.
Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
higher sulfur content. Avoid death or serious injury
from fire or explosion; consult with your fuel or
fuel system supplier to ensure the delivery system
is in compliance with fueling standards for proper
grounding and bonding practices.
Do not fill the fuel tank while the engine is hot or running, as
spilled fuel could ignite.
Refuel in a well ventilated area. Do not smoke or allow flames
or sparks in the area where the engine is refueled, or where
fuel is stored.
Do not start the engine near spilled fuel. Wipe up spills
immediately.
Make sure the fuel tank cap is closed tightly and properly
secured.
Avoid repeated or prolonged fuel contact with skin or
breathing of fuel vapor.
Units With Engine
Combustion engines can cause explosions when
operated in an explosive atmosphere. Do not operate
gas or diesel powered machines in an explosive
atmosphere.
When operating in an explosive atmosphere, keep vehicle in a
safe area by using hydraulic extension hoses to the carriage.
Help prevent fires by keeping machine clean of accumulated
trash, debris and facer shavings.
¡PELIGRO!
¡PELIGRO!
PERICOLO
¡PELIGRO!
¡PELIGRO!
PERICOLO
¡PELIGRO!
¡PELIGRO!
PERICOLO
¡ADVERTENCIA!
AVVERTIMENTO
WR00080-2-21-18
WR00080-2-21-18
FUEL
CD00365-2-19-97

Safety
2-3 SafetyTracStar® 630i, 900i, 1200i
Carbon Monoxide
Engine exhaust gases contain poisonous carbon
monoxide. Carbon monoxide can cause severe
nausea, fainting and death. Avoid inhaling exhaust
fumes, and never run the engine in a closed or
confined area.
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.
Crush Points
Hydraulically operated equipment operates under
high pressure and generates extremely high forces.
Anything inadvertently caught in the machine will
be crushed. Keep fingers, feet, arms, legs, and head
out of the machine while hydraulics are activated.
Always ensure machine power is off before entering
the machine for any reason.
¡PELIGRO!
¡PELIGRO!
PERICOLO
¡ADVERTENCIA!
AVVERTIMENTO
¡ADVERTENCIA!
AVVERTIMENTO
¡ADVERTENCIA!
AVVERTIMENTO
WR00093-5-14-96
WR00097-4-17-13
WR00012-12-4-92

Safety
2-4Safety TracStar® 630i, 900i, 1200i
Battery
Do not expose the battery to flames or electrical
sparks. Hydrogen gas generated by the battery
is explosive. Serious injury can result from an
exploding battery.
The battery contains acid that can cause burns. Do
not allow battery fluid to contact your skin, eyes,
fabrics, or painted surfaces. After touching a battery
or battery cap, do not touch or rub your eyes.
Eye Contact: Flush eyes with large amounts of water for at
least 15 minutes. Seek immediate medical attention if eyes
have been exposed directly to acid.
Skin Contact: Flush affected area(s) with large amounts of
water using deluge emergency shower, if available, for at
least 15 minutes. Remove contaminated clothing. If symptoms
persist, seek medical attention.
Do Not Ride Machine
Do not ride on the machine while it is moving. Riding
on the machine could cause the person to fall from
or into the machine. Do not drive or tow the machine
while persons are on the machine.
Electrical Safety
Always ensure equipment is 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.
NOTICE: Always connect units to the proper power source as
listed on the unit, or in the owner's manual.
NOTICE: Disconnect the machine from the power source
before attempting any maintenance or adjustment.
¡ADVERTENCIA!
AVVERTIMENTO
¡ADVERTENCIA!
AVVERTIMENTO
¡ADVERTENCIA!
AVVERTIMENTO
CD00176-9-14-95 CD00177-9-14-95
¡ADVERTENCIA!
AVVERTIMENTO
WR00115-01-25-16
WR00065-2-21-18

Safety
2-5 SafetyTracStar® 630i, 900i, 1200i
Unit With Hydraulics
It is important to remember that a sudden hydraulic oil leak
can cause serious injury, or even be fatal if the pressure or oil
temperature 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.
Unwanted movement of the machine could result
in serious injury or damage to machine. Unwanted
movement of the machine may take place if switches
do not match machine state when the machine power
is turned on.
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: Never extend the facer blades beyond the inner or
outer circumference of the facer.
Positioning and Setting Fusion
Machine
Place fusion machine on as level ground as possible.
If it is necessary to operate machine on unlevel grade, make
sure that the ground is stable. Some unstable conditions may
be ice, snow, mud and loose gravel.
For operation safety, never operate the machine on a grade
steeper than 30 %. (A 3 foot elevation change in 10 feet)
Stand Clear
Jaws, heater and facer pivot rapidly and can cause severe
bodily injury if someone is standing too close. All personnel
must stand clear of the back of the machine when operating.
Be aware of yourself and others when operating this machine
and when sections of pipe are being moved.
¡ADVERTENCIA!
AVVERTIMENTO
¡ADVERTENCIA!
AVVERTIMENTO
¡ADVERTENCIA!
AVVERTIMENTO
¡ADVERTENCIA!
AVVERTIMENTO
¡ADVERTENCIA!
AVVERTIMENTO
WR00078-4-8-93
WR00073-2-21-18
10
3
CD02511-11-30-20

Safety
2-6Safety TracStar® 630i, 900i, 1200i
Keep Machine Away From Edge
of Ditch
Heavy equipment too close to a ditch can cause the
walls of the ditch to cave-in. Keep the machine far
enough away from the edge of the ditch to prevent
personnel injury and equipment damage resulting
from a cave-in.
Lifting Safety
Follow all applicable federal, state, local, and industry specific
regulations when lifting.
Safety warnings:
1. Do not exceed rated load or lift loads greater
than the rated load of the lifting device.
2. Do not operate a damaged or malfunctioning
lifting device.
3. Do not lift persons.
4. Do not lift a suspended load over persons.
5. Do not leave a suspended load unattended.
6. Do not remove or obscure warning labels.
7. Read and understand the lifting device
operator’s manual before use.
8. Stay clear of the suspended load.
9. Lift loads only as high as necessary.
10. Do not alter or modify the lifting device.
11. Employ generally accepted safe lifting practices.
12. Do not shock or impact load the lifting device.
13. Inspect all lifting pins for damage.
Personal Lifting Safety
The machine components are heavy. Using one
person to some machine components may result
in an injury. Use two people to lift those machine
components.
Heater is Hot
The heater is hot and will burn clothing and skin.
Keep the heater protected from personnel when
not in use and use care when handling heater and
heating pipe.
NOTICE: Use only a clean dry lint free non-synthetic cloth to
clean the heater plates.
¡ADVERTENCIA!
AVVERTIMENTO
¡ADVERTENCIA!
AVVERTIMENTO
WR00115-01-25-16
¡PRECAUCIÓN!
ОСТОРОЖНО
ATTENTION
ATTENZIONE
¡PRECAUCIÓN!
ОСТОРОЖНО
ATTENTION
ATTENZIONE
HeavyLifting-05-21-18
WR00030-2-21-18

Safety
2-7 SafetyTracStar® 630i, 900i, 1200i
TX05340-04-18
Sound Information
The operator position Equivalent Sound Pressure Level is 84
dB(A) max at full engine RPM and 76 dB(A) max at low
engine RPM. This is measured from the operator location at the
carriage of the machine.
At the vehicle console the Equivalent Sound Pressure Level is
85 dB(A) max at full engine RPM and 77 dB(A) max at low
engine RPM. This is measured from the operator location at the
vehicle console.
Hearing protection may be needed when the machine is
operated at full engine RPM or in a noisy environment.
Fusion Procedures
Obtain a copy of the pipe manufacturer’s fusion procedures
or appropriate joining standard for the pipe being fused.
Follow the procedure carefully, and adhere to all specified
parameters.
NOTICE: Failure to follow the pipe manufacturer’s fusion
procedures or appropriate joining standard could result in a
bad fusion joint.
Do Not Modify Machine
Make no modifications to your equipment unless specifically
recommended or requested by McElroy.

General
Information
3-1General Information TracStar® 630i, 900i, 1200i
Theory of Butt 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.
GENERAL INFORMATION
PH01269-2-1-98

General
Information
3-2 General InformationTracStar® 630i, 900i, 1200i
Nomenclature
Vehicle Console
A - Vehicle Controls Cover
Contains the vehicle controls and rotates to reveal the controls
and can be stowed and locked below the top cover.
B - Vehicle Controls Lock
Locks the vehicle controls below the top cover.
C - Vehicle Display
Touch screen that displays vehicle information and also has
some vehicle controls (refer to Vehicle Display screens for an
index of screens).
D - Emergency Stop Button
Button used to completely shut off and disable the machine in
case of an emergency.
E - Engine Keyswitch
Keyswitch used to start and stop the engine.
F - Track Drive Paddle Levers
Paddle levers used to drive the vehicle. Move the lever in
the direction you want to drive the vehicle. The levers offer
proportional control of the track movement. The track speed
can be changed on the vehicle display.
G - Fixed End Drive Lights
Drive lights are attached to the fixed end bumper. The lights
are turned on and off from the vehicle display on the vehicle
console.
H - Lifting Point Covers
Covers for the fixed end engine side lifting point. There are
two covers
1) 630iand 900ilifting point
2) 12 0 0 ilifting point
The cover will have a lift point label on the cover for the lift
point used on that machine.
I - Vehicle Remote Storage Access Door
Locking door that accesses the remote storage and also
remote battery charging. There is also a diagnostic connector
for the engine controller.
J - Electrical Fuse and Relay Access Door
Locking door that accesses the fuses and relays. The
DataLogger®tablet can be stored in the panel. There is a
vehicle diagnostic port in this location. An electrical panel
layout label is on the inside of the access door.
K - Vehicle Radio Remote
Used to drive the vehicle by remote. It is powered by
rechargeable battery packs.
L - Remote Battery Charger
Used to charge the radio remote battery pack. The battery will
charge when the machine is running. The remote comes with
two battery packs and one can be charged while the other is
being used.
M - Engine Controller Diagnostic Connector
Used to connect to the engine controller for engine
troubleshooting.
A
BCD
F
E
G
H
1
2
I
J
I
KL
M
CD02512-01-07-21
CD02513-01-07-21

General
Information
3-3General Information TracStar® 630i, 900i, 1200i
Fuse and Relay Panel
N - Fuse and Relay Legend Label
Lists all the fuses and relays contained in this area. Each
component is labeled with identifiers, names and any
amperage information for fuses.
O - Vehicle Controller
Controller for all the functions and components on the vehicle.
P - DataLogger®Tablet Storage
Storage area for tablet when the tablet is not being used.
Q - Vehicle Controller Diagnostic Port
Used to connect to the vehicle controller for diagnostics and
software updates.
R - Fuse and Relay Block
Contains several different fuses and relays for machine
components.
S - Fuse Block
Contains three engine system related fuses.
T - Relays
Four single component relays.
U - Radio Remote Receiver
Receives commands from the radio remote and sends the
command to the vehicle controller.
Carriage Fuse and Relay Block
V - Fuse and Relay Block
Contains several different fuses and relays for carriage
components. Location of block may vary slightly depending
on fusion machine carriage.
N O Q R T U P S
CD02514-01-07-21
CD02630-01-07-21
V