McElroy In Field User manual

Manual: S03401 Revision: D 12/18
In Field®Tensile
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 In Field®Tensile Tester provides a quick and easy
way to qualitatively test joints in the field. A hand pump
system tests coupons from 2” IPS and larger pipes (up
to 5” thick wall). To create the coupon, a template is
attached to the pipe’s outer wall, where a drill and
reciprocating saw produce the coupon in minutes. The
coupon is then inserted into the hand pump tensile test
unit. The dual reduced section coupon allows failure
in either the parent pipe material or the fusion joint,
depending on joint quality. This makes a quick and easy
evaluation of joint integrity compared to the pipe.
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.
TX04070-02-24-15
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
Lifting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Overview
Tensile Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unloading Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Directional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Clevis and Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Drill Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Coupon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Additional Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Operation
Read Before Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Attach Template to Pipe (4" or Larger) . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Attach Template to Pipe (2" to 3" Pipe). . . . . . . . . . . . . . . . . . . . . . . . 3-2
Drill Holes in the Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Saw the Coupon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Remove the Coupon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Inspect the Coupon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Mount the Coupon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Perform Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Inspect Coupon/Interpret Result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Maintenance
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Check Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Check Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fasteners Must Be Tight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
COPYRIGHT © 2018, 2015, 2011
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
Hydraulic Fluids
Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance Checklist
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Specifications
Field Tensile Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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 drill and saw. Failure to follow all the
drill and saw instructions, may result in electric
shock, fire and/or serious personal injury.
TX04087.3-2-11
WR00080-4-12-93WR00055-4-7-93
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

1 - 3
Fusion Equipment Safety
Lifting Safety
The machine weighs 105 lbs. (48 Kg). Using one
person to lift the machine may result in injury.
Two people are required to lift the machine.
TX04091-5-25-10
HeavyLifting5-25-10

Overview
2 - 1
Tensile Tester
The tensile tester is a hydraulic hand pump machine that is
used to test fusion joint coupons. The coupon is loaded into the
machine and the hand pump is used to pressure a hydraulic
cylinder that pulls the fusion coupon to test it.
IMPORTANT: The tensile tester should only be used to perform
tests on coupons that were created from fusions of like pipes.
The tester has a gauge and DataLogger® port on the machine.
These items are used for reference and are not considered part of
the qualitative testing process.
TX04065-1-31-11
PH04521-3-2-11
Pump
The tensile tester has a manually operated hydraulic pump that is
used to apply hydraulic pressure to the hydraulic cylinder in order
to move the clevis. The pump has a pressure release valve on the
lower left side of the pump.
TX04066-5-25-10
PH04522-3-2-11

Overview
2 - 2
Pressure Relief Valve
Used to unload pressure in the hydraulic cylinder. Push toward the
machine to unload pressure and pull toward to close the valve.
TX04067-5-25-10
PH04154-5-20-10
Directional Valve
The directional valve that controls the direction of the cylinder.
Move the valve to the left to move the cylinder left and move the
valve to the right to move the cylinder right.
The center position is a neutral position.
TX04068-5-25-10
Clevis and Pins
Used for the mounting of coupons to be tested. One pin inserts
through the clevis and holds one end of the coupon and the other
pin inserts through the end of the machine and holds the other
end of the coupon.
TX04069-5-25-10
Drill Bit
The drill bit provided with the package is 1"dia with a 1/2" shank
12" long with 9" of flute length.
The long flutes allow the shavings to be cleared in pipe up to 5" wall
thickness. When used properly this drill will leave a smooth surface in
the drilled holes and provide good tool life in polyethylene.
If the holes in the coupon become rough or "fuzzy", the drill should
be inspected for chips or wear on the cutting edges and replace as
necessary.
TX04088-5-25-10
PH04155-5-20-10PH04524-3-2-11
PH04164-5-20-10

Overview
2 - 3
Template
The template is used to position the holes to be drilled for the
coupon over the fusion joint.
The template is attached to the pipe with two long wood
screws.
For smaller pipe, the template is attached using two long
U-bolts and wood screws.
There is an alignment mark on the template that is lined up
with the center of the fusion joint.
There are templates available for producing coupons with
different width relationships. The coupon will have a fusion
joint reduced area and a pipe material reduced area that
has a width that is a percentage of the fusion joint reduced
area. This gives an advantage to the fusion joint over the pipe
material.
Templates are available in 95%, 90%, and 85% width
relationships with others upon request. The In Field Tensile
Tester includes the 95% coupon template to test the fusion joint
reduced area for strength that is equal or exceeds the strength
of the pipe material ensuring a high performance fusion joint.
If you receive inconsistent results while performing the test, a
different percentage template can be used to better understand
the performance of the fusion joint.
TX04072-02-24-15-
Coupon
The coupon is the result of using the template and drilling and
sawing out the pipe. The coupon has two reduced areas to test
the joint and the pipe.
TX04073-5-25-10
PH04157-5-20-10PH04159-5-20-10 PH04157-5-20-10CD01275-02-18-15
FUSION
JOINT PIPE
(% of FUSION JOINT)

Additional Tools
There are some tools that will be required (not included) to complete
the preparation of the coupon for testing.
• A reciprocating saw with a coarse woodcutting blade.
• A 1/2" chuck, heavy duty, 650 rpm drill.
• Two #10 deck screws that are 3.5" or longer.
• Electric screwdriver and correct driver bit.
• Needle nose pliers.
TX04089-1-31-11
Overview
2 - 4
PH04162-5-20-10 PH04168-5-20-10
PH04169-5-20-10

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
Attach Template to Pipe (4" or Larger)
Place the template on the pipe, saddle side down. Align the
alignment marks on the template with the center of the fusion joint.
Carefully apply deck screws (tighten fully) to fix the template to the
pipe without moving the template out of alignment with the fusion.
TX04074-5-25-10
PH04160-5-20-10
PH04162-5-20-10
PH04161-5-20-10
PH04162-5-20-10
3 - 1

Attach Template to Pipe (2" to 3" Pipe)
Place the template on the pipe, saddle side down. Align the
alignment marks on the template with the center of the fusion joint.
Attach the two U-bolts around the pipe and through the template with
the washers and nuts. Tighten the nuts until the pipe is held firmly in the
template.
TX04085-5-25-10
PH04181-5-20-10PH04178-5-20-10
3 - 2
Operation

Operation
Drill Holes in the Pipe
Read and understand the all instructions provided
with your drill and saw. Failure to follow all the
drill and saw instructions, may result in electric
shock, fire and/or serious personal injury.
With the drill bit provided, drill the four innermost large holes first
then the remaining holes through the pipe wall.
Take particular care with the four inner holes to drill smoothly,
ensuring a good surface finish.
IMPORTANT: On thick wall pipe, drill partially through the pipe
then clear the shaving with a pair of needle nose pliers and then
continue to drill through the pipe. This will prevent the drilling from
over heating the pipe and melting the material or marring the
surfaces of the reduced sections.
On small pipes, you may only be able to drill the 6 innermost
holes.
Remove the two wood screws or U-bolts and lift the template from
the pipe. Clear the template of shaving and clear the pipe of any
shaving.
TX04075-02-24-15
PH04164-5-20-10PH04165-5-20-10PH04182-5-25-10
3 - 3
PH04161-5-20-10PH04166-5-20-10

3 - 4
Operation
Saw the Coupon
Mark the saw cuts to be made with a paint pen, grease pencil or other legible marking instrument.
Read and understand the all
instructions provided with your
drill and saw. Failure to follow
all the drill and saw instructions,
may result in electric shock, fire
and/or serious personal injury.
Using a reciprocating saw, make saw cuts from the inner four holes out to the corners, then make the remaining cuts.
Don't nick or gouge the narrow parts of the inner four holes.
PH04167-5-20-10
PH04166-5-20-10
PH04168-5-20-10 PH04169-5-20-10 PH04166-5-20-10

Operation
Remove the Coupon
After all the saw cuts are made, the coupon is freed from the fused
pipe.
Remove the coupon.
TX04077-5-25-10
Saw the Coupon (cont'd)
For smaller pipe, saw out the section of pipe and then saw the
pipe in half long ways so that you have your holes all on one side
of the cut pipe.
Saw cut one end of the pipe so that it is 1.25" away from the
edge of the outer hole.
Make saw cuts on the inner holes from the inside out making sure
to completely cut all the way through. This will allow the coupon to
break in the inner reduced section only.
TX04076-02-24-15
PH04170-5-20-10 PH04179-5-25-10
PH04171-5-20-10 PH04183-5-25-10
3 - 5
1.25"

Operation
3 - 6
Inspect the Coupon
Inspect the narrow sections of the coupon.
The surface finish on all four narrow section holes should be
smooth.
Inspect for notches or gouges in the narrow section holes.
Notches or gouges could effect the test results. If notches or
gouges exist, cut another coupon from the pipe.
It may be helpful to measure the widths of the reduced sections
of the coupon at the inner diameter and the outer diameter of
the pipe with calipers, to ensure that the widths are in proper
relationship to each other.
NOTICE: Ensure joint temperature and pipe temperature are
the same. Failure to do so may result in a false failing result.
NOTICE: Temperature substantially affects the strength
and ductility of polyethylene pipe. If results are confusing,
condition samples carefully and retest.
TX04078-02-24-15
Mount the Coupon
After inspection is complete, load the coupon into the clevis and pins
of the tensile tester. Use the pump to move the clevis to align the pins to
the holes of the coupon.
TX04079-5-25-10
PH04523-3-2-11 PH04159-5-20-10
PH04155-5-20-10

Perform Test
Move the directional valve to the right position.
Slowly pump the handle until the coupon breaks or until you reach
the end of the cylinder stroke. The flow of the pump is limited in
this direction to provide a slow tensile load to the coupon.
Remove the coupon.
NOTICE: The gauge does not provide significant information
during a test and should be ignored.
TX04080-1-31-11
Additional Coupons
Your quality control procedures may require additional coupons
from the unused circumference of the same fusion joint. Move the
template to the next required position on the joint and repeat the
steps to produce a coupon.
TX04090-5-25-10
Operation
3 - 7
PH03982-7-14-09
CD00850-5-25-10 PH04523-3-2-11