McElroy Pit Bull 28 User manual

Manual: T5034102 Revision: H 01/19
Pit Bull®
FUSION MACHINES
Operator’s
Manual
Original Language: English

This product and other products
could be protected by patents or
have patents pending. All the latest
patent information is available at
patent.mcelroy.com
Cancer and Reproductive Harm -
www.P65warnings.ca.gov
8163361

Introduction
Thank you for purchasing this McElroy product.
The McElroy Pit Bull®close quarter hydraulically operated fusion
machine is designed to be used in-ditch or above ground and is
easily moved by two operators.
The Pit Bull 28 model fuses 2" IPS (63mm) minimum to 8" DIPS
(225mm) maximum pipe.
The Pit Bull 250 model fuses 2" IPS (63mm) minimum to 250mm
maximum pipe.
The Pit Bull 412 model fuses 4" IPS (110mm) minimum to 12"
DIPS (340mm) maximum pipe.
The Pit Bull 618 model fuses 6" IPS (180mm) minimum to 18" OD
(450mm) maximum pipe.
The Pit Bull 500 model fuses 6" IPS (180mm) minimum to 20" OD
(500mm) maximum pipe.
Each fusion machine consists of:
1) Heater
2) Facer and Facer Stand
3) Carriage Assembly
Required and sold separately are:
1) Hydraulic Power Unit (HPU)
2) Hydraulic Hoses
With reasonable care and maintenance, this machine will give years of satisfactory service.
Before operating this machine, please read this manual thoroughly, and keep a copy with the machine for future
reference. This manual is to be considered part of your machine. A replacement manual can be obtained online at:
www.mcelroy.com TX02264-3-8-04
PH02978-3-18-05
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
Heater is Not Explosion Proof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Electric Motors are Not Explosion Proof. . . . . . . . . . . . . . . . . . . . . . . 1-3
Pipe Handling Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Units with Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrical Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Facer Blades are Sharp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Heater is Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Fusion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Overview
Theory of Heat Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Filter and Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Motor and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Manifold Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Insulated Heater Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Electrical Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
COPYRIGHT © 2019, 2017, 2015, 2014, 2013, 2012, 2008
McELROY MANUFACTURING, INC.
Tulsa, Oklahoma
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
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Check Hydraulic Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Connecting Machine to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Pump Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Install Clamping Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Loading Pipe Into Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Positioning Pipe In Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Begin Facing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
After Facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Determine Drag Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Set Fusion Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Check for Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Check Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Position Carriage for Heater Insertion . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Check Heater Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Inserting Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Heat Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Fusing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Opening Movable Jaws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Opening Fixed Jaws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Install Next Piece of Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Special Operation - In Ditch
Remove 3-Jaw Assembly From the Carriage . . . . . . . . . . . . . . . . . . . 4-1
Remove Facer From Pit Bull 28 and 250 . . . . . . . . . . . . . . . . . . . . . . . 4-2
Remove Facer From Pit Bull 412 and 618 . . . . . . . . . . . . . . . . . . . . . . 4-3
Manual Facer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Removing Top Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Lower 3-Jaw or 4-Jaw Carriage into Ditch . . . . . . . . . . . . . . . . . . . . . . 4-5
Clamp Carriage Assembly to Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Attach Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Make Fusion Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Remove Carriage Assembly from Ditch . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Reassemble Carriage and Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Table of Contents
Special Operations - Saddle Fusion Procedure
Saddle Fusion Procedure for Pit Bull 28CU . . . . . . . . . . . . . . . . . . . . . 5-1
Install Heater Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Assure Saddle Will Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Install Clamping Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Attach Carriage Assembly to Main . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Set Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Clean Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Clamp Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Test for Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Heat Pipe and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Remove Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fuse Fitting to Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Allow Joint to Cool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Special Operations - Lifting
Lifting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance
Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Washing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Change Hydraulic Fluid and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Check Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Clean Jaws and Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Clean Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Clean Eyebolt Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Fasteners Must Be Tight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Facer Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Clean Heater Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Bleeding Air From Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Installing Butt Fusion Heater Plates . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Adjusting Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Heater Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Maintenance Checklist
Fusion Machine Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Determining Fusion Pressure
Determining Fusion Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Determining Fusion Pressure - Sidewall . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Hydraulic Fluid
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Specifications
Fusion Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Generator Sizing Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
TX02280-1-16-12

Fusion Equipment Safety
1 - 1
Safety Alerts
This hazard alert sign appears in this manual.
When you see this sign, carefully read what it says.
YOUR SAFETY IS AT STAKE.
You will see the hazard alert sign with these words:
DANGER, WARNING, and CAUTION.
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
Indicates a hazardous situation which,
if not avoided, may result in minor or
moderate injury.
In this manual you should look for two other words:
NOTICE and IMPORTANT.
NOTICE: can keep you from doing something that might
damage the machine or someone's property. It may also
be used to alert against unsafe practices.
IMPORTANT: can help you do a better job or make
your job easier in some way.
¡PELIGRO!
Read and Understand
Do not operate this equipment until you have carefully read, and
understand all the sections of this manual, and all other equipment
manuals that will be used with it.
Your safety and the safety of others depends upon care and
judgment in the operation of this equipment.
Follow all applicable federal, state, local, and industry specific
regulations.
McElroy Manufacturing, Inc. cannot anticipate every possible
circumstance that might involve a potential hazard. The warnings
in this manual and on the machine are therefore not all inclusive.
You must satisfy yourself that a procedure, tool, work method, or
operating technique is safe for you and others. You should also
ensure that the machine will not be damaged or made unsafe by
the method of operation or maintenance you choose.
¡PELIGRO!
WR00051-11-30-92
WR00052-12-1-92
TX00030-12-1-92
TX02946-4-15-09

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.
TX0114--4-22-93
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, do not wear loose-fitting clothing,
and tie back long hair that could catch on controls or moving
machinery.
TX00032-04-18-16
WR00053-12-2-92
1 - 2
Fusion Equipment Safety
Heater Is Not Explosion Proof
This heater is not explosion proof. Operation
of heater in an explosive atmosphere without
necessary safety precautions will result in serious
injury or death.
If operating in an explosive atmosphere, the heater should be
brought up to temperature in a safe environment, then unplugged
before entering the explosive atmosphere for fusion.
TX00100-04-28-14
¡PELIGRO!
Wr00034-11-30-92

Electric Motors are Not Explosion Proof
Electric motors are not explosion proof. Operation
of these components in an explosive atmosphere
without necessary safety precautions will result in
serious injury or death.
When operating in an explosive atmosphere, keep pump motor
and chassis in a safe area by using hydraulic extension hoses.
TX00424-04-28-14
Fusion Equipment Safety
¡PELIGRO!
WR00080-4-12-93
1 - 3
Pipe Handling Safety
Do not position yourself or any other personnel under
supported or raised pipe. Pipe is heavy and could
fall unexpectedly.
Pipe that is bent can store a great amount of energy.
Do not bend and force the pipe into the machine.
A bent pipe with stored energy can generate
tremendous force when that energy is released.
It is recommended that the pipe is always held securely by either
being clamped in the fusion machine jaws or properly attached to a
lifting device.
NOTICE: Do not leave machine unattended to unauthorized personnel. Do not allow unauthorized personnel to
operate the machine.
Keep persons that are not involved in handling pipe away from pipe handling operations.
Keep away from the pipe when the pipe and handling equipment are in motion. When in
motion, all persons involved in handling pipe should be able to see all other persons at all
times. If any handling person is not in sight, immediately stop moving equipment and pipe
and locate that person. Do not continue until all persons are accounted for and in sight.
Never push, roll, dump or drop pipe lengths, bundles or coils off the
delivery truck, off handling equipment, or into a trench. Always use
appropriate equipment to lift, move, and lower the pipe.
TX04882-04-18-16
WR00097-4-17-13

Electrical Safety
Always ensure 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.
Disconnect the machine from the power source before attempting
to service the control panel. Failure to
disconnect the power could result in
serious injury or death due to electric
shock. Refer service to a qualified technician.
TX03003-3-30-11
WR00055-4-7-93
WR00025-11-30-92
Fusion Equipment Safety
1 - 4
Units With Hydraulics
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.
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.
NOTICE: Wear safety glasses, and keep face clear of area when
bleeding air from hydraulic system to avoid spraying oil into eyes.
TX03007-10-12-10
WR00078-4-8-93

Fusion Equipment Safety
1 - 5
Heater Is Hot
The heater is hot and will burn clothing and skin.
Keep the heater in its insulated heater frame or stand
when not in use, and use care when heating the
pipe.
NOTICE: Use only a clean dry lint free non-synthetic cloth to clean the
heater butt plates.
TX04244-04-18-16
WR00030-2-10-93
Fusion Procedures
Obtain a copy of the pipe manufacturer's procedures or
appropriate joining standard for the pipe being fused. Follow the
procedure carefully, and adhere to all specified parameters.
NOTICE: Failure to follow pipe manufacturer's procedure
could result in a bad joint. Always follow pipe manufacturer's
procedures.
TX04469-10-24-12
WR00079-2-7-96
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: Turn machine off, disconnect machine power, and remove
the facer blades before attempting any maintenance or adjustment.
NOTICE: Never extend the facer blades beyond the inner or outer
circumference of the facer.
TX02378-04-18-16
WR00073-4-6-93
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
operated. Always ensure machine power is off
before entering the machine for any reason.
TX03004-04-18-16
WR00012-12-4-92

Overview
Theory of Heat Fusion
The principle of heat fusion is to heat two pipe surfaces to
a designated temperature, and then fuse them together by
application of force. This develops pressure which causes flow
of the melted materials, which causes mixing and thus fusion.
When the thermoplastic material is heated, the molecular
structure is transformed into an amorphous condition.
When fusion pressure is applied, the molecules from each
thermoplastic part mix. As the joint cools, the molecules return
to their form, the original interfaces are gone, and the fitting
and pipe have become one monolithic unit. A strong, fully
leak tight connection is the result.
The principal operations include:
Clamping The pipe pieces are held axially and radially to
allow all subsequent operations to take place.
Facing The pipe ends are faced to establish clean,
parallel mating surfaces perpendicular to the
centerline of the pipes.
Aligning The pipe ends are aligned with each other to
minimize mismatch of the pipe walls.
Heating A melt pattern that penetrates into the pipe is
formed around both pipe ends.
Fusing The melt patterns are joined with a specified
force, which is constant around the pipe interfacial
area.
Cooling The fusion joint is held immobile with a specified
force until adequately cooled.
Inspecting Visually examine the entire circumference of the
joint for compliance with the standard or fusion
procedure used.
TX04660-04-18-16
PH00363B-9-12-94
2 - 1

2 - 2
Carriage Assembly
The carriage assembly consists of two fixed jaws and two
hydraulically operated movable jaws.
TX01542-5-6-98
Overview
PH02649-3-8-04
Hydraulic Fluid Reservoir
The reservoir is incorporated in the hydraulic power unit.
The fluid level should remain visible between the top and bottom
of the sight gauge in the side of the reservoir.
Never allow dirt or other foreign matter to enter the open tank.
Refer to the "Hydraulic Fluids" section of this manual for hydraulic
fluid recommendations.
Filter and Filler Cap
This machine is equipped with a 10 Micron filter (A) on the
return side of the hydraulic system.
Change filter when the indicator gauge (B) reads between 20 psi
and 25 psi (yellow range).
The reservoir is filled by removing the cap (A) and the filter.
PH02974-3-18-05PH02975-3-18-05
TX04380-05-06-14
TX02267-3-8-04
A
B

2 - 3
Motor and Pump
The pump is powered by a TEFC motor mounted inside the
reservoir.
The pump is pressure compensated with an external pressure
adjustment.
Overview
PH02976-3-18-05
TX02266-1-20-12
Relief Valve
The overall system pressure is set with the relief valve mounted on
top of the reservoir. This pressure is set at 1500 psi (10,340 kPa)
and is sufficient for most pipe.
PH02977-3-18-05
TX02268-3-8-04

2 - 4
Hydraulic Cylinders
HIGH FORCE hydraulic carriage cylinders are painted green.
High force cylinders are used when higher interfacial 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).
IMPORTANT: Use the correct total effective piston area to calculate the
gauge pressure.
TX01270-3-30-11
Overview
PH02682-3-8-04
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.
G) DataLogger port
TX00357-1-12-11
CD00138H-1-12-11 PH00797-4-10-96

2 - 5
Heater
Heater is not explosion proof. Operation of
heater in an explosive atmosphere without
necessary safety precautions will result in
serious injury or death.
If operating in an explosive atmosphere, heater should
be brought up to temperature in a safe environment, then
unplugged before entering the explosive atmosphere for fusion.
The heater has a green indicator light which will flash on and
off. This indicates that the controller is operating normally. If
the green indicator is not flashing then the controller may not
be operating properly. If this occurs, disconnect power and
have the heater repaired by an McElroy Authorized Service
Center.
The heater temperature is controlled by a microprocessor.
It has a red indicator light on the handle at the bottom of
the temperature scale. When the heater is plugged in and
preheating the light glows steadily until the set temperature is
reached. The light then goes off and on slowly as the heater
maintains temperature.
The heater body is not coated. Coated butt fusion heater
plates are available for all butt fusion applications.
NOTICE: The heater should never be used without butt fusion
heater plates installed.
To prevent a build-up of plastic pipe residue from accumulating
on the heater plates (loss of surface temperature and pipe
sticking may result), the heater plates should be cleaned with a
non-synthetic cloth before every fusion joint.
TX02309-04-28-14
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 412 or 618 move
the facer blades to the inboard position.
NOTICE: Never extend the blade beyond the inner or outer
circumference of the facer.
TX02361-12-15-04
Overview
PH02663-3-8-04
PH02313-3-8-04
¡PELIGRO!
PH02333-3-8-04 PH03874-4-15-09

2 - 6
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.
Overview
TX00363-9-15-94
Electrical Box
The start and stop push buttons are located on the front of the
electrical box.
Located below the start and stop push buttons is an hour meter
that indicates how many hours the unit has been in operation.
TX02289-3-8-04
PH02658-3-8-04
PH02654-3-8-04 PH03874-4-15-09

Operation
Check Hydraulic Fluid Level
Check fluid level in sight gauge on reservoir and add fluid if
necessary.
Refer to the "Hydraulic Fluids" section of this manual for hydraulic
fluid recommendations.
Do not overfill reservoir. The fluid will expand as it heats up.
Never allow dirt, water, or other foreign matter to enter the tank.
Use only clean fluid from an unopened container.
Setup
There are four hydraulic hoses that connect the facer and the
carriage to the hydraulic power unit. The unit must be off to
connect or disconnect the hoses.
Connect the 3/8" quick disconnects on the hydraulic power unit
to the facer and the 1/4" quick disconnects to the carriage.
Read Before Operating
Before operating this machine, please read this manual
thoroughly, and keep a copy with the machine for future
reference.
Return manual to the protective storage box when not in use. This
manual is to be considered part of your machine.
STOP-9-22-95
PH01908-3-8-04
PH02974-3-18-05
TX00401-9-15-94
TX02270-3-8-04
TX04377-05-06-14
3 - 1

Operation
Connecting Machine to Power
All electrical equipment and power
sources must be located in a non-explosive
atmosphere. Failure to do so will result in
serious injury or death.
Plug machine’s electrical cord into a proper power source.
The reverse phase relay ensures correct rotation of the pump
motor so damage to the hydraulic system does not occur.
If unit fails to start, check to see if the light on the reverse
phase relay inside the electrical box is on, indicating correct
phasing. Do not touch components inside the electrical box
when visually inspecting the reverse phase relay.
If the reverse phase relay light is not on, disconnect the power source
and switch any two incoming power leads and try again. If the unit
still doesn't start and the light is on, call qualified service personnel for
assistance.
Disconnect the machine from the power source before
attempting to service the electrical box. Failure to disconnect
the power could result in serious injury or death due to
electric shock. Refer service to a qualified technician.
TX04381-05-06-14
¡PELIGRO!
3 - 2
Pump Motor
Pump motor is not explosion proof. Operation of
pump motor in an explosive atmosphere without
necessary safety precautions will result in serious
injury or death.
Locate pump motor in a safe environment. Turn on hydraulic pump
motor and note pressure at the gauge.
IMPORTANT: Unplug heater when starting pump motor. This will
reduce the load on the power supply.
TX04382-05-06-14
WR00080-4-12-93
PH02976-3-18-05
¡PELIGRO!
PH02686-3-8-04