McElroy 28, 250 Operator's Manual

Operator’s

Manual

28 and 250

Fusion Machine

Manual: 861101 Revision: P 04/17

Original Language: English

California

Proposition 65 Warning

This product could expose you to
chemicals known to the State of
California to cause cancer, birth
defects, or other reproductive harm.

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

Introduction

Thank you for purchasing this
McElroy product

The McElroy 28 hydraulically operated fusion machine
will butt fuse all pipe sizes from 2" IPS through 8" DIPS
(63 mm - 225 mm).

The 250 model fuses 2” IPS (63mm) minimum to 250mm
maximum pipe.

The combination unit adds saddle fusion capability of up
to an 8" DIPS outlet with up to 9 5/8" diameter base on
any size main. The machine also allows for butt fusion of
most fittings without special holders or removal of outer
jaws. Mitered inserts are also available for fabricating
ells in the shop or in the field. With reasonable care and
maintenance, this machine will give years of satisfactory
service.

TX02502-6-5-13

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.

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.

PH02481-07-08-03

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.

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).

TX02486-11-4-13

Model No.

Serial No.

Date Received

Distributor

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 . . . . . . . . . . . . . . . . . . . . . . . 1-2

Pipe Handling Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Units with Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Facer Blades are Sharp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Have Tires Properly Serviced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Do Not Tow Fusion Machine at Speeds Greater then 5 MPH . . . . . . . . 1-5

Heater is Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Fusion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Positioning Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Table of Contents

Overview

Theory of Heat Fusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Introduction to the 28 and 250 Fusion Machine . . . . . . . . . . . . . . . . . . 2-2

Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Motor and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Heater Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Pipe Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Insulated Heater Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Electrical Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

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.

COPYRIGHT © 2017, 2015, 2014, 2013, 2008

McELROY MANUFACTURING, INC.

Tulsa, Oklahoma, USA

All rights reserved

Butt Fusion Procedure

Read Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Check Hydraulic Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Connecting Machine to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Set up Pipe Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Install Clamping Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Loading Pipe Into Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Positioning Pipe In Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Begin Facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

After Facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Determine Drag Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Set Fusion Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Check for Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Check Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Position Carriage for Heater Insertion . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Check Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Select the Fusion Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Inserting Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Heat Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Fusing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Opening Movable Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Opening Fixed Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Raise Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Position Pipe for Next Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Install Next Piece of Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Table of Contents

Special Operations - In Ditch

Remove Facer from Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Remove Carriage Assembly from the Chassis . . . . . . . . . . . . . . . . . . . . 4-1

Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Remove 3-Jaw Assembly from the Carriage . . . . . . . . . . . . . . . . . . . . . 4-3

Manual Facer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Removing Top Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Lower 3-Jaw or 4-Jaw Carriage into the Ditch . . . . . . . . . . . . . . . . . . . 4-5

Lower Carriage into Ditch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Clamp Carriage Assembly to Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Make Fusion Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Remove Carriage Assembly from Ditch . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Reassemble Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Special Operations - Saddle Fusion Procedures

Saddle Fusion Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Clamp Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table of Contents

Special Operations - Saddle Fusion Procedures (Continued)

Test for Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Heat Pipe and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Remove Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Fuse Fitting to Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Allow Joint to Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Special Operations - Lifting Fusion Machine

Lifting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Install Pipe Pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Ready the Unit for Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Attach Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Lift Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Maintenance

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Washing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Change Hydraulic Fluid and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Check Gauge Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Clean Jaws and Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Clean Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Clean Eyebolt Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Clean the Clamping Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Fasteners Must Be Tight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Facer Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Clean Heater Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Bleeding Air From Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Installing Butt Fusion Heater Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Adjusting Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Heater Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Machine Maintenance Checklist

Fusion Machine Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Determining Fusion Pressure

Determining Fusion Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Hydraulic Fluid

Hydraulic Fluid Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Specifications

Fusion Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Generator Sizing Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

TX02308-05-09-14

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.

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.

TX02946-4-15-09

WR00052-12-1-92

1 - 1

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.

TX00114-4-22-93

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.

SAFE1ST-12-22-92

WR00053-12-2-92

TX00032-4-7-93

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.

When 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.

TX04467-03-24-14

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

WR00034-11-30-92

WR00080-4-12-93

1 - 2

Fusion Equipment Safety

Pipe Handling Safety

Do not position yourself under supported or raised
pipe. Pipe is heavy and could result in serious injury
or death.

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 could cause serious
injury or death when that energy is released.

It is recommended that the pipe is always be held securely by either
being clamped securely in the fusion machine jaws or attached to the
lifting device.

Ensure all portions of the pipe and fittings are clear before lifting the pipe from the machine. If the pipe becomes
bound in the machine, do not continue to lift the pipe. Lower the pipe into the machine and ensure the pipe is clear
before lifting again.

Keep persons that are not involved in handling pipe away from handling operations. Persons that are involved with
handling operations keep away from the pipe when the pipe and handling equipment are in motion. When the
pipe and handling equipment are 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.

NOTICE: Do not leave machine unattended while the Power Pack is running. When not operating the machine, turn
off the Power Pack. This will prevent accidental or unintentional movement of the machine.

Never push, roll, dump or drop pipe lengths, bundles or coils off the
truck, off handling equipment or into a trench. Always use appropriate
equipment to lift, move and lower the pipe.

WR00097-4-17-13

TX04586-07-24-14

Units With Hydraulics

For 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

TX03077-2-16-10

1 - 3

Fusion Equipment Safety

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.

Disconnect the machine from the power source
before attempting to service the control panel.
Failure to disconnect the power could result
in electric shock. Refer service to a qualified
technician.

WR00055-4-7-93

WR00025-11-30-92

TX00105-5-6-13

Crush Points

Hydraulically operated jaws are operated under
pressure Anything caught in the jaws will be
crushed. Keep all body parts out of the jaw area.
Always check pipe alignment with a pencil or
similar object.

TX03091-4-7-10

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.

NOTICE: Never extend the blade beyond the inner or outer
circumference of the facer.

TX02378-1-24-05

WR00012-12-4-92

WR00073-4-6-93

1 - 4

Fusion Equipment Safety

Have Tires Properly Serviced

Failure to follow proper procedures when
mounting a tire on a wheel or rim can produce
an explosion which may result in serious injury
or death. Have tires mounted by someone that is
experienced, and has the proper equipment to
perform the job safety.

TX00118-4-22-93

Do Not Tow Fusion Machine at Speeds Greater
than 5 MPH

WR00083-4-22-93

The chassis is not designed for over-road towing.
Towing at speeds greater than five miles per hour
can result in machine damage as well as injury.
Always transport the machine by flatbed truck or
similar means, and make sure that unit is properly
secured.

TX00101-4-12-93

Heater Is Hot

The heater is hot and will burn clothing and skin.
Keep the heater in its insulated heater shroud
when not in use, and use care when heating the
pipe.

NOTICE: Use only a clean non-synthetic cloth to clean the heater
plates.

TX04244 -10-12-10

Fusion Procedures

CD00189-1-24-96

WR00030-2-10-93

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

WR00079-1-24-96

1 - 5

Fusion Equipment Safety

Positioning Fusion Machine

Place fusion machine on as level ground as possible, and set the
brake on the rear wheel. If it is necessary to operate machine on
unlevel grade, chock the wheels and block the unit to make it as
stable as possible.

TX00112-9-15-94

WR00076- 4-7-93

1 - 6

Overview

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. A strong,
fully leak tight connection is the result.

The principal 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.

Aligning 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.

Inspecting Visually examine the entire circumference of the joint

for compliance with standards established by your
company, customer, industry, federal, state, or local
regulations.

PH00363B-1-4-96

TX02476-04-28-14

2 - 1

Overview

Introduction to the 28 and 250 Fusion
Machine

The McElroy 28 hydraulically operated fusion machine will butt
fuse all pipe sizes from 2" IPS through 8" DIPS (63 mm - 225
mm). The combination unit adds saddle fusion capability of
up to an 8" DIPS outlet with up to 9 5/8" diameter base on
any size main. The machine also allows for butt fusion of most
fittings without special holders or removal of outer jaws.

The 250 model fuses 2” IPS (63mm) minimum to 250mm
maximum pipe.

TX01309-06-05-13

Carriage Assembly

PH02481-07-08-03

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.

PH02505-09-18-03

A

PH02499-09-18-03

B

PH02500-09-18-03

TX01891-11-15-00

2 - 2

Overview

Chassis

The carriage assembly is mounted on a four wheel chassis for
mobility and movement along the pipe line.

There is a pinned wheel lock on the left rear wheel to prevent
rolling.

The chassis is not designed for over-road towing.
Towing at speeds greater than five miles per hour
can result in machine damage as well as injury.
Always transport the machine by flatbed truck or
similar means, and make sure that unit is properly
secured.

The tongue on the tow bar has a ring to slip over a ball hitch so
that the machine may be conveniently maneuvered at the job site.

The tow bar acts as front pipe lift when raised.
The chassis is not designed for over-road towing.

PH02969-3-29-05

PH02484-07-08-03

TX02129-07-08-03

Hydraulic Fluid Reservoir

The reservoir is incorporated in the chassis. The fluid level should
remain visible in the sight gauge in the side of the filler spout.

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.

TX00353-04-28-14

PH02483-07-08-03

2 - 3

Overview

Filter

This machine is equipped with a 10 Micron filter on
the return line.

TX02132-07-08-03

Motor and Pump

The pump is powered by a TEFC capacitor start motor. The pump
is a Hi/Low Gear Pump and is set to give maximum flow up to
300 psi. At this pressure, an internal sequence valve shifts to a
lower flow and reduces the load on the motor.

PH02485-07-08-03

PH02486-07-08-03

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.

Do not adjust the sequence valve (A) higher on
the pump. This will overload the motor.

TX00355-1-14-14

Relief Valve

The overall system pressure is set with the relief valve (B) mounted
off the pump. This pressure is set at 900 psi and is sufficient for
most pipe.

When working with heavy wall pipe, it may be necessary to
increase the pressure to 1200 psi for the facing operation. Reduce
the pressure to 900 psi when facing is completed.

NOTICE: Prolonged operation at increased pressure can over-heat
the oil.

A

PH02487-07-08-03

PH02488-07-08-03

B

TX02131-07-08-03

2 - 4

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.

PH02489-07-08-03

CD00138A-9-12-94

TX02133-07-08-03

Hydraulic Cylinders

The two carriage cylinders have air bleed screws and must be
bled if the system ever runs low on oil or leaks air on inlet side
of pump. Air in the system is indicated when carriage movement
becomes jerky and erratic.

Consult the "Maintenance" section of this manual for procedure to
follow when bleeding air from system.

TX01137-10-23-96

PH02490-07-08-03

2 - 5