McElroy Hornet XL, ASW31401, ASW31402 Operator's Manual
Hornet™ XL
Fusion Machine
Models: ASW31401, ASW31402
Foreword
Manual: SW31301
Revision A 09/19
Original Language: English
Operator’s
Manual
1 Hornet™ XL
Copyright 2019 McElroy Manufacturing, Inc.
All rights reserved.
P.O. Box 580550
Tulsa, Oklahoma 74158-0550, USA
Important Safety Information
8163361
Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or
precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person
must be alert to potential hazards. This person should also have necessary training, skills and tools to perform these functions properly.
Advanced training is offered through McElroy University. Course offerings are meant to enhance your efficiency, productivity and safety
in the proper use of McElroy equipment.
Improper operation, maintenance or repair of this product can be dangerous and could result in injury or death.
Do not operate this product until you have carefully read, and understand all the sections of this manual, and all
other equipment manuals that will be used with it.
Follow all applicable federal, state, local, and industry specific regulations.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or
“CAUTION”. The Safety Alerts are shown below.
The meaning of these safety alert symbols are as follows:
- 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.
Signal words “NOTICE” and “IMPORTANT” are used to bring attention to important information.
The meaning of these signal words are as follows:
“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.
McElroy cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this
publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating
technique that is not specifically recommended by McElroy is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation,
maintenance or repair procedures that you choose.
The information, specifications, and illustrations in the publication are on the basis of information that was available at the time that the
publication was written. The specifications, pressures, measurements, adjustments, illustrations, and other items can change at any time.
These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any
job. The most current information is available at our website
www.mcelroy.com.
TX05337-04-18
Cancer and Reproductive Harm www.P65warnings.ca.gov
When replacement parts are required for this
product McElroy recommends using McElroy
replacement parts or parts with equivalent
specifications including, but not limited to,
physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature
failures, product damage, personal injury or death.
TABLE OF CONTENTS
FOREWORD
Literature Information ......................................................................................1-1
Safety ..................................................................................................1-1
Operation ...............................................................................................1-1
Maintenance ............................................................................................1-1
McElroy University ........................................................................................1-1
Patent Information ........................................................................................1-2
Replacement Literature .....................................................................................1-2
Nameplate Location ......................................................................................1-2
Replacement Parts ........................................................................................1-2
Limited Warranty .........................................................................................1-3
SAFETY
General Safety ...........................................................................................2-1
Safety Equipment .........................................................................................2-1
Heater Is Not Explosion Proof ...............................................................................2-2
Electric Motors are Not Explosion Proof ......................................................................2-2
Electrical Safety ..........................................................................................2-2
Power Tool Safety ........................................................................................2-2
Heater is Hot ............................................................................................2-2
Fusion Procedures ........................................................................................2-3
Do Not Modify Machine ...................................................................................2-3
GENERAL INFORMATION
Theory of Heat Fusion .....................................................................................3-1
Nomenclature ............................................................................................3-1
Attach Drill to Drill Adapter ................................................................................. 3-4
Attach Extension Chains ...................................................................................3-5
Install Heater Adapters ....................................................................................3-6
Detachable Handle .......................................................................................3-6
OPERATION - FUSION OUTLET
Attach Hornet™ XL to Pipe .................................................................................. 4-1
Prepare Heater ...........................................................................................4-2
Drill Main Pipe ...........................................................................................4-3
Insert Fitting ..............................................................................................4-4
Insert Heater ............................................................................................. 4-5
Heat Fitting and Pipe ......................................................................................4-5
Fuse Fitting and Pipe ......................................................................................4-6
Remove Hornet™ XL .......................................................................................4-6
OPERATION - SOCKET FUSE TO OUTLET
Prepare Pipe End .........................................................................................5-1
Prepare Heater ...........................................................................................5-1
Mark Insertion Depth ...................................................................................... 5-2
Clean Fitting and Pipe .....................................................................................5-2
Load Pipe ...............................................................................................5-2
Heat Fitting and Pipe ......................................................................................5-3
Fusion and Cooling .......................................................................................5-3
Remove Hornet™ XL .......................................................................................5-4
STORAGE/TRANSPORT
Storage/Transport ........................................................................................6-1
MAINTENANCE
Preventative Maintenance ..................................................................................7-1
Clean Machine ..........................................................................................7-1
Check Machine Operation .................................................................................7-1
Fasteners Are Tight ........................................................................................7-1
Changing Heater Plates/Adapters ...........................................................................7-1
Clean Chains ............................................................................................7-2
Clean Fitting Adapter ...................................................................................... 7-2
Clean Drill Adapter .......................................................................................7-2
Adjust Gearbox Chain Tension ..............................................................................7-2
SPECIFICATIONS
Specifications ............................................................................................8-1
NOTES
Notes ..................................................................................................9-1
For Digital Copy:
Press Alt + Left Arrow
to return to the link that was clicked.
FOREWORD
Literature Information
This manual should be stored in a protected location for
Foreword
future reference. Use the literature holder if provided with the
product. Digital copy will contain hyperlinks. Press Alt + Left
Arrow to return to the selected hyperlink.
This manual contains safety information, operation instructions,
transportation information, lubrication information and
maintenance information.
Some photographs or illustrations in this publication show
details or equipment that can be different from your machine.
Guards and covers might have been removed for illustrative
purposes.
Continuing improvement and advancement of product design
might have caused changes to your machine which are not
included in this publication. Read, study and keep this manual
with the machine.
Whenever a question arises regarding your machine, or this
publication, please contact McElroy Technical Services at 918831-9224 or techsupport@mcelroy.com
Safety
Some maintenance procedures may be referenced in a
manual pertaining to that component of the machine. For
example, maintenance for an engine component would have
its intervals and procedures in the engine operator’s manual.
Use the hour meter (if equipped) to determine servicing
intervals. Calendar intervals will be used instead of hour
meter intervals if no hour meter is equipped on a machine.
Recommended service should always be performed at the
interval that occurs first.
Under extremely severe, dusty or wet operating conditions,
more frequent lubrication than is specified in the maintenance
schedule might be necessary.
McElroy University
The safety section lists basic safety precautions. In addition,
this section identifies the text and locations of warning signs
and labels used on the machine.
Read and understand the basic precautions listed in the safety
section before operating or performing maintenance and
repair on this machine.
Operation
The operation section is a reference for the new operator
and a refresher for the experienced operator. This section
includes a discussion of gauges, switches, machine controls,
accessories and transportation.
Photographs and illustrations guide the operator through
correct procedures of setting up, checking and operating the
machine.
Operating techniques outlined in this publication are basic.
Proficiency develops as the operator gains knowledge and
experience with the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment care. The
maintenance schedule lists the items to be maintained at a
specific service interval. Items without specific intervals are
listed under the “As Needed” service interval. The schedule
lists the page for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the schedule as
an index for all maintenance procedures.
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.
1-1Foreword Hornet™ XL
Patent Information
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
Replacement Literature
This product is shipped with a printed operator’s manual. If
the manual becomes lost or damaged, order a replacement
manual or download and print a copy of the manual at www.
mcelroy.com.
Nameplate Location
Every machine has a name plate that includes the machine’s
model number, serial number, and power requirements. The
model and serial numbers can be used to register the machine
online and activate the warranty. Reference warranty card for
information on registering your product.
Foreword
Machine Nameplate
CD02423-02-12-19
Replacement Parts
Refer to the McElroy parts finder at
www.mcelroy.com to locate parts for purchase. Reference the
model number on the nameplate of the machine when using
the parts finder.
Contact your McElroy distributor to order replacement parts.
Find your closest distributor on our website at www.mcelroy.
com.
TX05397-03-15-19
1-2 ForewordHornet™ XL
Limited Warranty
McElroy Manufacturing, Inc. (McElroy) warrants all products
Foreword
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: (918) 836–8611, FAX: (918) 831–9285.
EMAIL: fusion@McElroy.com
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).
Model No.
Serial No.
Date Received
Distributor
TX05339-04-18
1-3Foreword Hornet™ XL
SAFETY
CD02424-02-12-19
Safety
410906
8163210
There can be several specific safety messages on this machine.
The exact location of the hazards and the description of
the hazards are reviewed in this section. Please become
familiarized with all safety messages.
Make sure that all of the safety messages on the machine
are legible. Clean the safety messages or replace the
safety messages if you cannot read the words. Replace if
the illustrations are not legible. When you clean the safety
messages, use a cloth, water and soap. Do not use solvent,
gasoline, or other harsh chemicals to clean the safety
messages. Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message or damage the
print of the safety message.
Replace any safety message that are damaged, or missing.
If a safety message is attached to a part that is replaced,
install a safety message on the replacement part. New safety
messages can be ordered from McElroy using the part number
listed.
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-2-21-18
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. Remove any loose safety equipment during an
operation that could be drawn into or caught in the machine.
Ensure proper fire prevention or other fire-fighting equipment
is available and all personnel know how and when to use it.
2-1 SafetyHornet™ XL
Heater Is Not Explosion Proof
This safety message is located on the cord of the heater.
This heater is not explosion proof. Operation of
heater in an explosive atmosphere without necessary
safety precautions will result in serious injury or
death.
Safety
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.
Electrical Safety
Always ensure equipment is properly grounded. It
is important to remember that if 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. Use GFCI
electrical connections when available.
WR00065-2-21-18
WR00080-2-21-18
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.
The drill motor cannot be used manually and must not be used
in an explosive atmosphere.
Power Tool Safety
Read and understand the all instructions provided
with your power tool. Failure to follow all the power
tool instructions, may result in electric shock, fire
and/or serious personal injury.
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 dry lint free non-synthetic cloth to
clean the heater plates.
WR00080-4-12-93
WR00080-2-21-18
WR00030-2-21-18
2-2Safety Hornet™ XL
Fusion Procedures
Obtain a copy of the pipe manufacturer’s fusion procedures
or appropriate joining standard for the pipe being fused.
Follow the procedure carefully, and adhere to all specified
parameters.
NOTICE: Failure to follow the pipe manufacturer’s fusion
procedures or appropriate joining standard could result in a
bad fusion joint.
Do Not Modify Machine
Make no modifications to your equipment unless specifically
recommended or requested by McElroy.
Safety
TX05398-03-15-19
2-3 SafetyHornet™ XL
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