McElroy TracStar 28 User manual

Manual: T1210801 Revision: C 7/04
TracStar®No.28
TracStar®No.412
TracStar®No.618
Fusion Machines
Operator’s
Manual
Patent No’s. 5,814,182 6,212,748 6,212,747 6,021,832
(other patents pending)

California
Proposition 65 Warning
Engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.

Introduction
Thank you for purchasing this
McElroy product
The McElroy TracStar®No.28/No.412/No.618 self-
contained, self-propelled, all terrain fusion machine,
and is designed to produce consistently high quality
polyolefin pipe butt fusion joints with a minimum of
operator effort.
The TracStar®No.28 model fuses 2” IPS (63mm)
minimum to 8” DIPS (225mm) maximum pipe.
The TracStar®No.412 model fuses 4” IPS (110mm)
minimum to 12” DIPS (340mm) maximum pipe.
The TracStar®No.618 model fuses 6” IPS (180mm)
minimum to 18”IPS (450mm) maximum pipe.
With reasonable care and maintenance, this machine
will give years of exemplary 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.
Always return the manual to the literature compartment.
World Class Training
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.
McElroy Manufacturing, Inc., offers advanced training
classes to enhance efficiency, productivity, safety and
quality. Training is available at our facility or on-site at
your location. Call [phone].
PH00917-8-15-97
TX01315-4-7-97
TX01853-9-27-00
PH01894-9-27-00
Patent No’s. 5,814,182 6,212,748 6,212,747 6,021,832
(other patents pending)

Warranty
LIMITED WARRANTY
McElroy Manufacturing, Inc. guarantees this product to
the original purchaser against workmanship and material
defects for three (3) years from date of shipment, with the
exception of purchased items (such as electronic devices,
pumps, switches, etc.), in which case that manufacturer's
warranty applies. This warranty does not apply to any
product or component which has been repaired or
altered by anyone other than McElroy Manufacturing,
Inc., or has become damaged due to misuse, negligence
or casualty, or has not been operated or maintained
according to McElroy Manufacturing, Inc.'s printed
instructions and warnings.
Claims cannot be allowed until the questioned product
has been received, freight prepaid, at the manufacturer's
factory, with complete information and data regarding
the failure. Materials returned to McElroy Manufacturing,
Inc. for warranty work, repair, etc., must have a Return
Material Authorization (RMA) number, and be so noted
on the package at time of shipment. This number may be
obtained by calling [phone]. If seller's review
indicates that warranty applies, the defective product
will be repaired or replaced and returned to purchaser
F.O.B. Tulsa, Oklahoma.
McElroy Manufacturing, Inc. is not responsible or
liable for loss of any sort including incidental and
consequential damages.
McElroy Manufacturing, Inc. specifically disavows any
other representations as to warranty or liability, related to
the condition or use of the product.
For assistance, inquiries shall be directed to McElroy
Manufacturing, Inc., P.O. Box 580550, 833 North
Fulton, Tulsa, Oklahoma 74158-0550, [phone],
Fax No. [phone], www.mcelroy.com
Register Your Warranty Online:
www.mcelroy.com
DISCLAIMER OF LIABILITY
McElroy Manufacturing, Inc. 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 Manufacturing, Inc. 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.
TERMS AND CONDITIONS
Net 30 Days - Subject to credit approval. A carrying
charge of 1-1/2% per month computed from invoice
date will apply to invoices not paid within 30 Day Terms.
McElroy Manufacturing, Inc. must be notified of any
discrepancy in shipment, order, and/or invoice within 10
days after receipt.
Freight is F.O.B. Tulsa, Oklahoma - usually motor freight
collect or UPS unless otherwise specified.
Prices are subject to change without notice.
Minimum order is $50.00.
(Copy information listed on the Warranty Card for your
records).
Model No. ________________________________________
Serial No. ________________________________________
Date Received _____________________________________
Distributor_________________________________________
TX01901-11-15-00

Table of Contents
Equipment Safety
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Read and Understand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fuel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Units with Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Carbon Monoxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Heater is Not Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electric Motors and Alternators are Not Explosion Proof. . . . . . . . . . . . 1-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrical Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Facer Blades are Sharp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Units with Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Keep Machine Away from Edge of Ditch . . . . . . . . . . . . . . . . . . . . . . 1-6
Operating Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Do Not Attempt to Tow Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . 1-6
Heater is Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Fusion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Periodically Check Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hearing Protection Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Positioning Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Overview
Theory of Heat Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Gas Powered Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Tach and Hour Meter for Gas Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Diesel Powered Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Diesel & Gas Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Power for Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Oil Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Insulated Heater Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
COPYRIGHT © 2004
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
Operation
Read Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Gas Powered Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Moving Machine into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Set up Pipe Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Install Clamping Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Check Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Loading Pipe Into Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Positioning Pipe in Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Facing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Remove Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Position Carriage for Heater Insertion . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Check Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Select the Fusion Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Raise Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Hydraulic Pipelifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Position Pipe for Next Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Install Next Piece of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Special Operations - In Ditch
Disconnect Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Remove Carriage Assembly from the Chassis . . . . . . . . . . . . . . . . . . . 4-1
Remove 3-Jaw Assembly from the Carriage . . . . . . . . . . . . . . . . . . . . 4-2
Remove Facer from TracStar No.412 & No.618. . . . . . . . . . . . . . . . . 4-3
Remove Facer from TracStar No.28 . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Manual Facer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Removing Top Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Lower 3-Jaw or 4-Jaw Carriage into Ditch . . . . . . . . . . . . . . . . . . . . . 4-6
Clamp Carriage Assembly to Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Attach Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Make Fusion Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Remove Carriage Assembly from Ditch. . . . . . . . . . . . . . . . . . . . . . . . 4-8
Reassemble Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Special Operations - Saddle Fusion Procedures
Saddle Fusion Procedure for TracStar No.28 . . . . . . . . . . . . . . . . . . . 5-1
Install Heater Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Assure Saddle will Fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Install Clamping Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Remove Carriage Assembly from Vehicle . . . . . . . . . . . . . . . . . . . . . . 5-2
Attach Carriage Assembly to Main . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Set Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Clean Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table of Contents
Special Operations - Saddle Fusion Procedures - Continued
Clamp Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Test for Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Heat Pipe and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Remove Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Fuse Fitting to Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Allow Joint to Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Special Operations - Lifting the Machine
Heavy Overhead Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Attach Slings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Lifting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Maintenance
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Washing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Change Hydraulic Fluid and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Install/Remove Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Engine Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Tensioning the Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Adjusting System Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Engine Oil System - Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Engine Oil System - Gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Check Gauge Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Clean Jaws and Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Clean Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Clean Eyebolt Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Clean the Clamping Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Fasteners Must Be Tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Facer Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Check/Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Clean Heater Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Bleeding Air From Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Installing Butt Fusion Heater Adapter . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Adjusting Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Checking Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Setting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Machine Maintenance Checklist
Machine Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Determining Fusion Pressure
Determining Fusion Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Hydraulic Fluid
Hydraulic Fluid Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Specifications
TracStar®No.28 & No.412 Fusion Machine Specifications . . . . . . . . . 11-1
TracStar®No.618Fusion Machine Specifications . . . . . . . . . . . . . . . . 11-2
TX02032-7-8-02

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 the "Safety" and "Operation" 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
TX00031-12-8-92

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
Fuel Handling
Gasoline and diesel fuel are extremely flammable
and their vapors will explode if ignited.
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
gasoline is stored.
Do not start the engine near spilled fuel. Wipe up spills
immediately.
Maker sure the fuel tank cap is closed and properly secured.
Avoid repeated or prolonged contact with skin or breathing of
vapor.
FUEL
CD00365-2-19-97
TX00953-2-19-97
¡PELIGRO!

Electric Motors and Alternators are Not
Explosion Proof
Electric motors are not explosion proof. Operation
of these components in a hazardous environment
without necessary safety precautions will result in
explosion and death.
When operating in a hazardous environment, keep pump motor
and chassis in a safe area by using hydraulic extension hoses.
TX00424-8-12-94
Fusion Equipment Safety
¡PELIGRO!
WR00080-4-12-93
1 - 3
Heater Is Not Explosion Proof
The heater is not explosion proof. Operation
of heater is a hazardous environment without
necessary safety precautions will result in
explosion and death.
If operating in a hazardous environment, the heater should be
brought up to temperature in a safe environment, then unplugged
before entering the hazardous atmosphere for fusion.
TX00100-9-16-94
WR00034-11-30-92
¡PELIGRO!
Carbon Monoxide
Engine exhaust gases contain carbon monoxide
which can cause severe nausea, fainting and
death. Avoid inhaling exhaust fumes and never
run the engine in a closed or confined area.
TX00954-5-14-96
WR00093-5-14-96
Units With Engines
Combustion engines can cause explosions when
operated in a hazardous environment. Do not
operate gas or diesel powered machines in a
hazardous environment.
When operating in a hazardous environment, keep engine and
chassis in a safe area by using hydraulic extension hoses.
Help prevent fires by keeping machine clean of accumulated
trash, debris and facer shavings.
WR00080-4-12-93
TX01266-2-21-97
¡PELIGRO!
¡PELIGRO!

Fusion Equipment Safety
1 - 4
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: Always connect units to the proper power source as
listed on the unit, or in the owner's manual. On units with two
power cords, plug each cord into separate power circuits. Do not
plug into both outlets of one duplex receptacle.
NOTICE: Disconnect the machine from the power source before
attempting any maintenance or adjustment.
TX00105-4-12-93
WR00055-4-7-93
WR00025-11-30-92
Battery
Do not expose the battery to flames or electrical
sparks. Hydrogen gas generated by battery action
is explosive. Blindness or serious injury can result
from an exploding battery.
Do not allow battery fluid to contact your skin, eyes,
fabrics, or painted surfaces. Sulfuric acid can cause
burns. After touching a batter or battery cap, do not
touch or rub your eyes.
Thoroughly wash your hands. If the acid contacts
your eyes, skin or clothing, immediately flush with
water for at least 15 minutes and seek medical
attention.
CD00176-9-14-95
TX00650-9-14-95
CD00177-9-14-95

Crush Points
Hydraulically operated jaws are operated under
pressure. Anything caught in the jaws will be
crushed. Keep fingers, feet, arms, legs, and
head out of the jaw area. Always check pipe
alignment with a pencil or similar object.
TX00103-4-6-93
Fusion Equipment Safety
WR00012-12-4-92
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.
TX00102-4-16-93
WR00073-4-6-93
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.
WR00078-4-8-93
TX00110-8-23-95

Fusion Equipment Safety
1 - 6
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 such as a cotton
cloth to clean the heater plates.
TX00104-8-12-94
WR00030-2-10-93
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 injury to personnel and
equipment from a cave-in.
TX01447-12-30-97
CD00408b-9-27-00
Do Not Attempt to Tow Fusion Machine
The machine is not designed for towing.
Attempting to tow the machine can result in
machine damage. Always transport the machine
by flat bed truck or similar means, and make sure
that unit is properly secured.
TX01888-11-15-00
CD00401b-9-27-00
0
100
200
300
400 500 600
700
800
900
1000
DIRECTIONAL
CONTROL
VALVE
FACING
PRESSURE
HEATING
PRESSURE
FUSING
PRESSURE
SELECTOR
VALVE
Operating 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)
CD00402c-9-27-00
0
100
200
300
400500600
700
800
900
1000
DIRECTIONAL
CONTROL
VALVE
FACING
PRESSURE
HEATING
PRESSURE
FUSING
PRESSURE
SELECTOR
VALVE
10
3
TX011902-11-15-00

Fusion Equipment Safety
1 - 7
Periodically Check Temperature
NOTICE: Incorrect heating temperature can result in bad fusion
joints. Check heater plate surface temperature periodically with a
properly calibrated pyrometer, and make necessary adjustments.
The thermometer on heaters indicates internal temperature, and
should be used as a reference only.
TX00107-11-13-95
WR00077-4-16-93
Positioning Fusion Machine
Place fusion machine on as level ground as possible. If it is necessary to
operate machine on unlevel grade, chock the tracks and block the unit to
make it as stable as possible.
TX01889-11-15-00
CD00633-9-27-00
Fusion Procedures
Obtain a copy of the pipe manufacturer's procedures for the pipe
being fused. Follow the procedure carefully, and adhere to all
specified parameters.
Failure to follow pipe manufacturer's procedure
could result in a bad joint. Always follow pipe
manufacturer's procedures.
TX00113-4-12-93
WR00079-1-24-96
Hearing Protection Required
When operating machine for more than 4 hours per day wear
hearing protection.
TX01890-11-15-00
WR00028-1-24-96

Overview
2 - 1
Theory of Heat Fusion
The principle of heat fusion is to heat two surfaces to a
designated temperature, and then fuse them together by
application of force. This pressure causes flow of the melted
materials, which causes mixing and thus fusion. When the
polyethylene material is heated, the molecular structure is
transformed from a crystalline state into an amorphous condition.
When fusion pressure is applied, the molecules from each
Polyethylene part mix. As the joint cools, the molecules return to
their crystalline form, the original interfaces are gone, and the
fitting and pipe have become one homogeneous unit. The joint
area becomes as strong as the pipe itself in both tensile and
pressure conditions.
The principle operations include:
Clamping The pipe pieces held axially to allow all subsequent
operations to take place.
Facing The pipe ends must be faced to establish clean,
parallel mating surfaces perpendicular to the
centerline of the pipes.
Alignment The pipe ends must be aligned with each other to
minimize mismatch or high-low of the pipe walls.
Heating A melt pattern that penetrates into the pipe must be
formed around both pipe ends.
Joining The melt patterns must be joined with a specified
force. The force must be constant around the interface
area.
Holding The molten joint must be held immobile with a
specified force until adequately cooled.
Each pipe manufacturer has a slightly different approach for
fulfilling the heating, joining, and holding phases, but the end
result is the same -- a fusion joint that is as strong or stronger than
the pipe itself.
PH00363B-1-4-96
TX00441-9-22-94

Chassis
The carriage assembly is mounted on a track driven chassis for
easy loading and movement along the pipe line.
The engine powers an alternator, used to power the heater, and a
hydraulic pump, which powers the fusion machine and the track
drive. A belt drive is used to transfer the power. The hydraulic
reservoir is mounted above the engine. The fuel tank and battery
are installed between the tracks.
TX01854-11-15-00
PH01966-11-15-00
PH01959-11-15-00
Carriage Assembly
The carriage assembly consists of two fixed jaws and two
hydraulically operated movable jaws bolted to the skid. For
remote operation the carriage can be set in ditch and connected
to the machine with optional hydraulic extension hoses.The
carriage assembly (A) can be disconnected from the chassis (B)
and removed for remote operation. The optional extension hose
kit is required for this operation.
For tight installations the outer fixed jaw and skid can be removed
from the carriage for an even more compact fusion unit.
TX01891-11-15-00
Overview
2 - 2
PH01940-11-15-00
PH01953-11-15-00
A
B

Overview
2 - 3
Gas Powered Units
Read the operating and maintenance instructions for the engine
before operating.
The engine is a single cylinder, overhead valve, air cooled
design. It uses a vacuum operated fuel pump.
The fuel shutoff valve is located by the carburetor.
TX01987-1-10-02
PH01965-11-15-00
Diesel Powered Units
Read the operating and maintenance instructions for the engine
before operating.
The engine is a twin cylinder water cooled design. It uses an
electric fuel pump located near the fuel tank.
TX01855-11-15-00
PH01960-11-15-00
Tach and Hour Meter for Gas Unit
When the unit is running, the engine speed is displayed. When
the unit is not running, total hours of engine operation are
displayed.
On diesel powered units an hour meter is provided in the same
location.
TX01892-11-15-00
PH01988-11-15-00 PH02243-1-10-02

Overview
2 - 4
Hydraulic Oil Filter
This machine is equipped with a 10 Micron filter on the return
side of the hydraulic system.
TX01893-11-15-00
PH01916-11-15-00
Diesel Engine Controls
Read the operating and maintenance instructions for the engine
before operating.
There is a key ignition on the console that shows the preheat off,
run, and start positions.
Gas Engine Controls
Choke and throttle control is on the dash.
There is a key ignition on the console that shows the off, run, and
start positions.
TX01986-1-10-02
PH01969-11-15-00
Oil Reservoir
The oil reservoir is located above the engine.
TX02306-7-28-04
PH02709-07-29-04
Power for Heater
The heater cord plugs into a receptacle on the frame.
The 110V receptacle is used for the No.28 Butt Fusion Heater.
The 220V receptacle is used for the No.412 Butt Fusion Heater
and the No.28 Sidewall Heaters.
TX01856-9-28-00
PH01922-11-15-00

Overview
Hydraulic Manifold Block
Mounted on this block are a carriage directional control valve, a
pressure reducing selector valve, three pressure reducing valves,
and a 1500 psi gauge.
A) The carriage control valve, mounted on the top of the
manifold, determines whether the carriage is moving left,
right, or is in neutral.
B) A 1500 psi gauge is mounted on top of the manifold.
C) The selector valve, mounted on the front of the manifold,
selects a reduced pressure from one of the pressure reducing
valves.
Each pressure reducing valve is labeled with a different function:
D) The top valve adjusts facing pressure to a maximum of 400
psi.
E) The middle valve adjusts heating pressure to a maximum of
400 psi.
F) The bottom valve adjusts fusion pressure to a maximum of
1500 psi.
TX00357-11-3-94
Hydraulic Cylinders
HIGH FORCE hydraulic carriage cylinders are painted green.
High force cylinders are used when higher interfacil pressures are
required, when handling heavy wall pipe, or when large drag
factors need to be overcome.
MEDIUM FORCE cylinders are painted orange and have
approximately half the total effective piston area as High Force
cylinders. The cylinders move faster and are normally used for
medium density pipe and when lower interfacial pressures are
used.
LOW FORCE cylinders are painted yellow. These cylinders should
be selected when fusing pipe with a very low interfacial pressure
(22 psi).
TX01270-2-21-97
PH01924-11-15-00
PH00410-9-22-94
FACING
HEATING
FUSING
BC A
D
E
F
CD00138A-9-12-94
2 - 5

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
PH02334-07-08-02
Overview
Facer
The facer is a McElroy Rotating Planer-Block design. The block
rotates on a ball bearing and is chain driven by a hydraulic
motor.
When fusing 4” and 6” diameter pipe on the TracStar no.412 or
No.618 move the facer blades to the inboard position.
TX01989-1-10-02
PH01915-11-15-00
2 - 6