McElroy Guided Side Bend Tester User manual

Manual: S07101 Revision: D 12/18
Guided Side Bend
Tester
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 Guided Side Bend Tester provides a quick and easy
way to qualitatively test joints in the field.
The Guided Side Bend Tester is a hydraulic hand pump
machine that is used to test fusion joint coupons. It can
be used to test joints made from pipe up to 7 inches
wall thickness. It tests the coupon to see if it will fail
under a three point bend test. The coupon is loaded into
the machine and the hand pump is used to pressure a
hydraulic cylinder that bends the coupon demonstrating
ductility in the joint.
With reasonable care and maintenance, this equipment
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. TX04376-11-7-11
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
Power Tool Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Overview
Guided Side Bend Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pressure Release Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Coupon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Additional Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operation
Read Before Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Cutting Rough Cut Segment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Plane the Rough Cut Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Test the Coupon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inspect Coupon/Interpret Result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Maintenance
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Check Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fasteners Must Be Tight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Checklist
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Specifications
Guided Side Bend Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TX04404-3-9-12
COPYRIGHT © 2018, 2015, 2014, 2012
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.

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

Power Tool Safety
Read and understand the all instructions provided
with your accessory equipment. Failure to follow
all the equipment instructions, may result in electric
shock, fire and/or serious personal injury.
TX04087-11-1-11
AEM0001r-11-1-11WR00055-4-7-93
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

Overview
2 - 1
Guided Side Bend Tester
The Guided Side Bend Tester is a hydraulic hand pump machine
that is used to test fusion joint coupons. It can be used to test
joints made from pipe up to 7 inches wall thickness. It tests
the coupon to see if it will fail under a three point bend test.
The coupon is loaded into the machine and the hand pump
is used to pressure a hydraulic cylinder that bends the coupon
demonstrating ductility in the joint.
TX04361-11-1-11
Tester
The Guided Side Bend Tester is equipped with a 1 inch diameter ram and two supporting pins. A
hydraulic cylinder moves the ram up and down along a guide in the fixture. The hydraulic cylinder
is mounted on the top of the fixture and connects to a hydraulic hand pump.
Support pins are mounted in bearings that allow the support pins to rotate, reducing friction on the
coupon during the test.
There are two different bend angle labels. The yellow bend angle label indicates the exterior bend
angle and the white bend angle label indicates the interior bend angle (included angle). Use the
appropriate label that matches the standard being used.
TX04362-02-10-15
Support Pins
Hydraulic
Cylinder
Fixture
Bend Angle
Label
Ram Guide
Ram

Pump
The guided side bend tester has a manually operated hydraulic
pump that is used to apply hydraulic fluid to the cylinder in order
to move the ram. The pump has a pressure release valve on the
right side of the pump.
The tester hydraulic pump has a gauge. The gauge is used for
reference and is not considered part of the qualitative testing
process.
TX04363-11-1-11
PH04572-10-10-11
Overview
2 - 2
Pressure Release Valve
The pressure release valve is used to unload pressure in the
hydraulic pump. The valve turns clockwise to close and counter-
clockwise to open.
TX04364-11-1-11
PH04570-10-10-11
Coupon
The coupon is the result of making a cross section cut, sawing
out a rough cut segment. The coupon is planed to a specified
thickness with the fusion joint in the center.
TX04365-11-1-11
PH04563-10-10-11

Overview
2 - 3
Additional Tools
There are some tools that will be required (not included) to
complete the preparation of the coupon for testing.
A drill may be used to produce starting points for saw cuts.
• Marking tool and straight edge to layout the rough cut
segment.
• A reciprocating saw with a coarse woodcutting blade,
chain saw, or band saw is used to cut a rough cut segment
from the fusion joint.
• A small table planer is used to produce smooth and
parallel surfaces to a specified thickness.
• Hand calipers to measure the thickness of the coupon.
TX04366-11-1-11
PH04168-5-20-10
PH04169-5-20-10
PH04573-10-10-11 PH04561-10-10-11

Operation
Read before Operating
Before operating this machine, please read this manual thoroughly
and keep a copy with the machine for future reference.
TX00838-1-5-96
PH01054-2-20-97
Cutting Rough Cut Segment
Allow the joint to cool before producing
samples.
Mark out a 1 inch section of the pipe
about 12 inches to 18 inches long with
the fusion joint centered between the
ends of the pipe. Testing specifications
may require multiple coupons from the
same fusion joint.
Cut the pipe on the designated markings using a reciprocating saw,
chain saw, or band saw.
IMPORTANT: The use of a drill to make saw starting holes may be
useful if sawing from a large section of pipe.
The result should be a rough cut segment that is roughly 1 inch thick
and 12 to 18 inches wide.
TX04367-11-1-11
3 - 1
PH04560-10-10-11 CD00986-11-7-11
PH04559-10-10-11
12" to 18"
310mm to 450mm
Fusion joint centered
1" (25.4mm)
1" (25.4mm)
Cut straight
and parallel
cross section
1"
Pipe Thickness
12" to 18"

Plane the Rough Cut Segment
Once cut out, inspect the rough cut segment.
Make sure there are no distinct ridges or parts of the pipe that
will get snagged in the planer. The planer will make deep
gouges into the coupon if such ridges exist.
Ridges on the coupon could be caught in the
planer forcing the coupon toward the user
causing minor injury. Ensure the coupon has no
ridges before planing.
Use the planer to create smooth and parallel surfaces of the
specified thickness.
Begin slowly, using small increments of adjustment to the planer
each time the coupon passes through the planer. Start the planer
depth slightly larger than the maximum thickness of the coupon.
Insert the coupon into the planer.
Repeat inserting the coupon into the planer, making small
adjustments to the depth each time it is inserted. Periodically flip
the coupon to the opposite side to ensure that both sides achieve
the same flatness.
The planer will pull the coupon through, there is no need to force
the coupon.
Plane the coupon to the specified thickness within the tolerance of
your bend test specifications. Tighter tolerances will improve the
precision of your results. Measure at the bead.
The unit ships with a 1 inch diameter ram. Bend test specifications may require you to use a specific radius/thickness
ratio*. The table below gives the coupon thickness based on the radius/thickness ratio with a 1 inch diameter ram.
Coupon thickness should not exceed 0.5" (12.70mm). A 2 inch ram is available as an optional accessory.
* The appropriate ratio is under development by the industry. If there is no other guidance or specification we
recommend a radius/thickness ratio of 1.
TX04368-3-29-12
3 - 2
Operation
PH04561-10-10-11PH04562-10-10-11
1 inch Diameter Ram
Desired radius/
thickness ratio Ram Diameter Coupon Thickness
1 1" (25.4mm) 0.5" (12.70mm)
1.6 1" (25.4mm) 0.31" (7.87mm)
2 1" (25.4mm) 0.25" (6.35mm)
2.5 1" (25.4mm) 0.20" (5.08mm)
2 inch Diameter Ram (Optional)
Desired radius/
thickness ratio Ram Diameter Coupon Thickness
2 2" (50.8mm) 0.5" (12.70mm)
2.5 2" (50.8mm) 0.4" (10.16mm)

Operation
Test the Coupon
Allow the coupon to come to temperature in a 73°F ± 5°
(23°C ± 2.8°) environment.
IMPORTANT: In the field, a truck cab or temporary building can be used to
bring the coupon to temperature.
Insert the coupon into the guided side bend tester, laying flat with the
beaded section directly under the top bar, and on top of the side bars.
The alignment here is critical so as to test the right portion of the pipe.
Misalignment can cause flawed results and errors in testing.
Turn the pressure release valve to close. Pump the hydraulic pump handle at
a medium speed, keeping a constant pace.
Stop pumping the handle when the coupon has been bent up to the angle
required by the test specifications. The bend angle label on either side of the
tester will help determine if you reached the desired bend angle. The yellow
label will indicate the exterior bend angle and the white label will indicate
the interior bend angle. If there is no other guidance or specification we
recommend a bend angle of 90°-120° (yellow label) or 90°-60° (white
label).
NOTICE: Do not exceed specified bend angle. Excessive pressure will
damage the tester and/or invalidate results.
Release pressure in the tester by opening the pressure release valve.
Remove the coupon from the tester.
TX04369-02-10-15-
3 - 3
PH04664-04-04-14
PH04666-04-04-14PH04667-04-04-14
PH04567-10-10-11 PH04665-04-04-14
(Interior Angle)
Bend Angle
Bend Angle
90°
Interior Angle
(white label)
120°
Bend Angle
(yellow label)

3 - 4
Operation
Interpretation of Results
Inspect Coupon/Interpret Result
A)The coupon breaks in the joint which is a failing result.
B) The coupon has tears in the joint which is a failing result.
C) The coupon stretches but does not break or crack in the fusion.
If the coupon does not pass, examine that you are doing everything properly
and isolate the cause of the failing result.
Areas to Examine
• Testing Procedure
— Was coupon to specifications?
— Were there scratches?
— Was surface smooth?
— Were widths correct?
— Were the pipe and joint temperatures the same?
— Was test performed at too cool a temperature?
• Fusion Procedure
— Is the fusion procedure you are using a qualified procedure?
— Are you following the procedure properly?
— Use a DataLogger® with the fusion machine to verify the procedure
is correct.
— Was the proper cooling time for the joint used?
• Adverse Conditions
— Was the fusion joint made in an extreme ambient temperature
situation?
— Was the fusion joint made in inclement weather (rain/snow etc)?
— Was the fusion joint made during excessive wind?
• Joint Contamination
— Did the ends of the pipe have contamination before the fusion took
place?
• Operator Qualification
— Is the operator qualified to perform the procedure and visually
inspect the resultant fusion?
• Fusion Equipment
— Is the equipment in good repair?
— Is the equipment clean?
— Does the equipment perform to specifications?
• Handling
— Was the pipe with the fusion joint subjected to any rough handling?
• Material
— Is the material in accordance with specifications?
TX04370-11-7-11
FAIL
FAIL
PASS
FAIL
PH04607-11-7-11PH04606-11-7-11PH04605-11-7-PH04604-11-7-11

Preventative Maintenance
To insure optimum performance, the machine must be kept clean
and well maintained.
With reasonable care, this machine will give years of service.
Therefore, it is important that a regular schedule of preventive
maintenance be kept.
Store machine inside, out of the weather, whenever possible.
TX00428-8-10-95
Maintenance
Cleaning the Machine
Clean the machine with a soap and water wash as needed.
TX04082-5-25-10
CD00142-11-2-94
CD00178-5-3-96
4 - 1
Check Hydraulic Fluid
The hydraulic fluid level should be checked periodically.
If the hydraulic oil is not full when the cylinder is retracted, oil must
be added. Do not overfill.
If the pump and cylinders are empty, fill pump with oil and
move the cylinder fully 3 times and check the fluid level and
fill. Bleeding the hydraulic system is required when system has
been empty. Refer to "Bleeding the Hydraulic System" section for
instructions on bleeding the hydraulics.
Refer to the pump manufacturers recommendation for hydraulic
fluid.
TX04371-11-7-11
PH04569-10-10-11

4 - 2
Maintenance
Fasteners Must Be Tight
Check all nuts, bolts, and snap rings to make certain they are
secure and in place.
TX00437-9-13-94
Bleeding the Hydraulic System
Pump the machine moving the cylinder down and releasing the
pressure several times.
When bled, the machine should move immediately when pumped.
Any pause may indicate that there is air still in hydraulic system.
Repeat the pumping of the machine and then check the pump
again.
If the cylinder moves immediately then there is no air left in the system.
TX04372-11-7-11
PH044666-3-9-12 PH04572-10-10-11

Guided Side Bend Tester Checklist
Item to Check Satisfactory Needs Repair Comments
Repair
UNIT
Machine is clean
Support pins rotate freely
Machine is free of hydraulic leaks
Hydraulic pump is filled to correct level
All hardware is on the machine
Hydraulic gauge shows pressure
All nuts and bolts are tight
Hydraulic pump handle is in place
Ram moves smoothly through guides
Maintenance Checklist
5 - 1
TX04373-11-7-11

6 - 1
Guided Side Bend Tester
Specifications:
Designed to field test fusion joint coupons
• Qualitative testing of a joint in the field
• Can produce coupons from up to 7" thick pipe wall
• Hand pump system tests coupon
Pressure Rating: 200 psi (13.8 bar) - 1st Stage
10,000 psi (700 bar) - 2nd Stage
Max. Handle Effort 78 lbs. (35.4 Kg)
Stroke 5" (127mm)
Usable Oil Capacity 20 in³ (328 cm³)
Dimensions:
Width: 10.04" (255.0mm)
Length: 6.00" (152.4mm)
Height: 14.59” (370.6mm)
Weight: 31 lbs. (14.1 Kg) Guided Side Bend Tester
TX04374-3-29-12
Specifications
10.04"
255.0mm
14.59"
370.6mm
6.00"
152.4mm

About this manual . . .
McElroy Manufacturing continually strives to give customers the best quality products available.
This manual is printed with materials made for durable applications and harsh environments.
This manual is waterproof, tear resistant, grease resistant, abrasion resistant and the bonding
quality of the printing ensures a readable, durable product.
The material does not contain any cellulose based materials and does not contribute to the
harvesting of our forests, or ozone-depleting constituents. This manual can be safely disposed
of in a landfill and will not leach into ground water.
TX001660-8-19-99