McElroy Sidewinder Operator's Manual

Operator’s

Manual

Fusion Machine

SIDEWINDER

Patent No. 4,533,424

Manual: SW00301 Revision: M 05/17

®

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 Sidewinder is a manually operated fusion machine
for fusing 4" and smaller branch saddles, tapping tees and
smaller saddle fittings onto all main sizes.

Units with a sidewall clamping assembly will quickly and easily
adjust to any size main.

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.

TX00901-8-15-96

PH01477-11-3-98

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.

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).

TX02486-12-17-13

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

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Heater is Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Fusion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Overview

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

Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Drive Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Pivot Release Master Insert Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Master Fitting Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Service Saddle Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Line Pipe Bolster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Sidewall Clamping Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Line Pipe Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Heater Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Insulated Heater Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

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

Table of Contents

Machine Setup

Install Heater Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Install Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Jaw Clamp Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Chain Clamp Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Cold Weather and Coiled Pipe Clamping Procedure . . . . . . . . . . . . . . 3-2

COPYRIGHT © 2017, 2016, 2014, 2013, 2010

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.

TX02499-5-27-05

Operation

Maintenance

Table of Contents

Read Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Install Clamping Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Attaching Machine to Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Preparing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Preparing the Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Tighten Fitting Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Installing the Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Seating the Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Inserting Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Removing Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Fusing Fitting to Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Disengage Pivot Release Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Unclamp and Remove Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Washing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Clean Guide Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Lubricate Wipers, Seals and Bearings . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Remove Dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Clean and Lubricate Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Clean Eyebolt Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Fasteners Must Be Tight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Clean Split Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Clean Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Check the Hydraulic Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Checking Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Dry Gauge Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Oil Jaw Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Clean Heater Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Adjusting Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Heater Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Maintenance Checklist

Fusion Machine Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Specifications

Sidewinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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.

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

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.

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.

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.

WR00053-12-2-92

WR00034-11-30-92

TX00100-04-28-14

1 - 2

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.

Disconnect the equipment from the power
source before attempting any maintenance or
adjustment. Failure to disconnect the power
could result in electric shock.

WR00055-4-7-93WR00030-2-10-93WR00079-2-7-96

WR00025-11-30-92

TX 02947-6 -6 -13

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

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

1 - 3

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 thermoplastic 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 thermoplastic 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 principle operations include:
Clamping The pipe and fitting must be held firmly to allow all

subsequent operations to take place.

Cleaning The area of pipe that the fitting will come in contact

with must be cleaned and roughed up, as well as the
base of the fitting.

Aligning The fitting must be properly seated on the pipe and

then clamped in the machine for proper alignment.

Heating A melt pattern must be formed that penetrates into the

pipe and into the fitting.

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.

PH00784-4-1-96

TX02497-06-17-14

2 - 1

Nomenclature

1 Jaw clamp assembly

2 Jaw clamp Knob

3 Chain clamp assembly

4 Chain vice clamp knob

5 Pivot release master clamp knob

6 Moveable jaw clamp knob

7 Load cell pressure gauge

8 Guide rods

9 Drive screw knob

10 Reaction spring

11 Load Cell

12 Moveable jaw

13 Pivot release master insert assembly

Overview

CD00197-7-30-10

14 Heater guide

15 Tailstock chain

16 Chain hook

17 Split Nut Assembly

18 Sidewall insert

19 Line pipe insert

TX00904-3-17-99

Drive Screw

The drive screw is used to apply pressure. Turning the drive screw
knob clockwise will apply pressure.

To release pressure, turn the drive screw knob counterclockwise
until the gauge reads zero.

To disengage and move the drive screw, pull the drive screw out
against the reaction spring until it clears the split nut assembly.

18

19

PH03045-5-27-05

TX00903-4-2-96

2 - 2