McElroy TracStar 500 Operator's Manual
Operator’s
Manual
Fusion Machine
Original Language: English
Manual: T5019210 Revision: Rev C 11/18
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 TracStar® 500 series 3 is a self-contained, self-propelled, all
terrain fusion machine, and is designed to produce consistently
high quality polyolefin pipe butt fusion joints with a minimum of
operator effort.
The TracStar® 500 series 3 fuses 6” IPS (180mm) minimum to 20”
IPS (500mm) maximum pipe.
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.
Always return the manual to the literature compartment.
TX04535-10-24-12
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: (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).
TX02486-11-4-13
Model No.
Serial No.
Date Received
Distributor
Fusion Equipment Safety
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Read and Understand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fuel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Units with Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Carbon Monoxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Heater is Not Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Units with Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Pipe Handling Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Facer Blades Are Sharp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Keep Machine Away From Edge of Ditch . . . . . . . . . . . . . . . . . . . . . . 1-6
Operating Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Heater is Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Do Not Attempt to Tow Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fusion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Table of Contents
Overview
Theory of Heat Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
TracStar® 500 series 3 Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Auto Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Alternate Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pipe Lift Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Indexer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Inlet Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
COPYRIGHT © 2018, 2016, 2014, 2012, 2011, 2010
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
McELROY MANUFACTURING, INC.
Tulsa, Oklahoma, USA
All rights reserved
notice.
TX04540-05-05-14
Operation
Table of Contents
Read Before Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Check Hydraulic Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Moving Machine Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Install Clamping Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Set up Pipe Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Loading Pipe Into Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Positioning Pipe In Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Begin Facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
After Facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Check Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Determine Drag Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Set Fusion Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Check for Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Position Carriage for Heater Insertion . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
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
Raise Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Position Pipe for Next Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Install Next Piece of Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Special Operations - In Ditch
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Remove Hydraulic Hoses and Cables . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removing 4 Jaw Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removing Heater and Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Removing 3 Jaw Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Lift 3-Jaw Carriage from Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Removing Top Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Position Carriage Under Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Attach Upper Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Attach Hydraulic Hoses and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Make Fusion Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Remove Upper Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Remove Hydraulic Hoses and Cables . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Remove Carriage From Ditch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Table of Contents
Special Operations - Lifting the Machine
Lifting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Attach Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Maintenance
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Washing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Change Hydraulic Fluid and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Adjusting System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Bleeding Air From Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Facer Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Clean Jaws and Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Bleeding Air From Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Installing Butt Fusion Heater Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Clean Heater Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Fasteners Must Be Tight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Checking Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Checking Oil Level in Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Changing Oil in Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Adjusting Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Heater Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Maintenance Checklist
TracStar® 500 series 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Determining Fusion Pressure
Determining Fusion Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Hydraulic Fluids
Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Specifications
TracStar® 500 series 3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 10-1
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
FUEL
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
Fuel Handling
Gasoline and diesel fuel are extremely flammable
and their vapors will explode if ignited.
Do not fill the fuel tank while the engine is hot or running, as
spilled fuel could ignite.
Refuel in a well ventilated area. Do not smoke or allow flames or
sparks in the area where the engine is refueled, or where gasoline
is stored.
Do not start the engine near spilled fuel. Wipe up spills
immediately.
Maker sure the fuel tank cap is closed and properly secured.
NOTICE: Avoid repeated or prolonged contact with skin or
breathing of vapor.
WR00053-12-2-92
CD00365-2-19-97
TX00953-3-30-11
1 - 2
Fusion Equipment Safety
Units With Engines
Combustion engines can cause explosions when
operated in an explosive atmosphere. Do not
operate gas or diesel powered machines in an
explosive atmosphere.
When operating in an explosive atmosphere, keep engine and
chassis in a safe area by using hydraulic extension hoses.
Help prevent fires by keeping machine clean of accumulated
trash, debris and facer shavings.
TX04466-05-05-14
Carbon Monoxide
Engine exhaust gases contain poisonous carbon
monoxide. Carbon monoxide can cause severe
nausea, fainting and death. Avoid inhaling
exhaust fumes and never run the engine in a
closed or confined area.
WR00080-4-12-93
WR00093-5-14-96
TX00954-5-14-96
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
Crush Points
Hydraulically operated equipment is operated
under pressure. Anything caught in the machine
will be crushed. Keep fingers, feet, arms, legs,
and head out of the machine while operated.
WR00034-11-30-92
WR00012-12-4-92
TX03004-8-11-09
1 - 3
Battery
Fusion Equipment Safety
Do not expose the battery to flames or electrical
sparks. Hydrogen gas generated by battery action is
explosive. Blindness or serious injury can result from
an exploding battery.
Do not allow battery fluid to contact your skin, eyes,
fabrics, or painted surfaces. Sulfuric acid can cause
burns. After touching a batter or battery cap, do not
touch or rub your eyes.
Eye Contact: Flush eyes with large amounts of water
for at least 15 minutes. Seek immediate medical
attention if eyes have been exposed directly to acid.
Skin Contact: Flush affected area(s) with large
amounts of water using deluge emergency shower,
if available, shower for at least 15 minutes. Remove
contaminated clothing. If symptoms persist, seek
medical attention.
CD00176-9-14-95
CD00177-9-14-95
TX00650-3-7-11
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 battery before attempting any
maintenance or adjustment.
WR00055-4-7-93WR00025-11-30-92
TX04468-10-24-12
1 - 4
Fusion Equipment Safety
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.
WR00078-4-8-93
TX03007-10-12-10
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.
Keep persons that are not involved in handling pipe away from
handling operations. 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
TX04586-4-17-13
1 - 5
Fusion Equipment Safety
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
Keep Machine Away From Edge of Ditch
Heavy equipment too close to a ditch can
cause the walls of the ditch to cave-in. Keep the
machine far enough away from the edge of the
ditch to prevent injury to personnel and damage
to the equipment from a cave-in.
WR00073-4-6-93
CD00408-12-31-97
TX01447-3-30-11
Operating Fusion Machine
Place fusion machine on as level ground as possible.
If it is necessary to operate machine on unlevel grade, chock
the tracks and block the unit to make it as stable as possible.
Some unstable conditions may be ice, snow, mud and loose
gravel.
Operating machine on a grade steeper than
30% could cause the machine to tip over.
Never operate the machine on a grade
steeper than 30 % (A 3 foot elevation change
in 10 feet). Always operate fusion machine
from the highest level, on an unlevel grade.
Failure to do so could result in serious injury
or death.
CD00402B-12-30-97
TX01902-3-30-11
1 - 6
Fusion Equipment Safety
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
Do Not Attempt to Tow Fusion Machine
NOTICE: The machine is not designed for towing. Attempting to
tow the machine can result in machine damage. Always transport
the machine by flat bed truck or similar means, and make sure
that unit is properly secured.
WR00030-2-10-93
CD00401-12-30-97
TX01888-3-30-11
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
1 - 7
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
TracStar® 500 series 3 Console
FUEL
LIGHT
GAUGE
WORK
LIGHT
ON
LIGHTS
OFF
BACKWARD
HIGH
(Power for
heater)
LOW
(No power
for heater)
AUTO
(Cycles
engine
throttle on
demand)
HEADLIGHTS
VEHICLE
THROTTLE
LIGHT
FUSION
ENGINE OIL
PRESSURE
1/2
1/4
3/4
E
F
FUEL VOLTS
VEHICLE
LIGHT
THROTTLE
FORWARD
LEFT TRACK
CONTROL
50
25
75
100
0
350
PSI
0
700
kPa
FUSION
LIGHT
1/2
1/4
25
3/4
E
0
F
PSI
0
FUEL VOLTS
kPa
QUARTZ
1
10
1
0001
HOURS
Patent No.'s 5,814,182 - 6,212,748 - 6,212,747 - 6,021,832
Patent No.'s 5,814,182 - 6,212,748 - 6,212,747 - 6,021,832
Japanese Patent No. 4285806 - OTHER PATENTS PENDING
®
FORWARD
BACKWARD
COOLANT
TEMPERATURE
180
210
150
250100
80
°F
40
120
°C
50
180
14
12
210
75
150
10
100
350
700
®
16
250100
18
8
80
°F
40
120
°C
FORWARD
RIGHT TRACK
CONTROL
BACKWARD
14
12
10
16
18
8
T5055102
T5017103
VOLT
METER
PREHEAT
PLUG
CD00407e-10-8-12
OFF
RUN
START
IGNITION PREHEAT
PLUG
LIGHT
Auto Throttle
Pressing the throttle switch on the dashboard to the bottom position
turns on the auto throttle setting.
The auto throttle setting is used to vary the speed of the engine
depending on the load needs of the machine. The machine will use
high speed while facing, moving the carriage, or when the heater
controller cycles on.
Auto throttle will reduce the amount of noise and fuel usage.
TX04470-10-24-12
Alternate Drive Controls
Alternate track drive controls are located on the operator side
of the machine. Each lever controls one track. Both levers must
be moved together to go forward or backward in a straight line.
Moving levers in opposite directions makes the machine turn
sharply.
PH04789-10-8-12
PH04729-10-1-12
TX02002-4-24-02
2 - 2
Overview
Pipe Lift Controls
The pipe lift controls are located on the operator side of the
machine to the right of the alternate drive controls. Moving the
right lever up and down moves the rear pipe lift up and down.
Moving the left lever up and down moves the forward pipe lift up
and down.
TX02003-4-24-02
Carriage Assembly
The carriage assembly consists of two fixed jaws and two
hydraulically operated movable jaws. The carriage assembly
can be used in a 4 jaw and 3 jaw configurations. The 4 jaw
configuration includes the use of the indexer for the heater and
facer. The 4th jaw can be removed on the 4 jaw configuration for
fusions of ells and tees.
The 3 jaw configuration is removed from the 4 jaw skid and does
not use the indexer for the heater and facer. The 3 jaw is a compact
fusion configuration for use in close quarters where space is
limited.
The carriage assembly can be removed from the machine for
remote operation. An optional hydraulic extension and electric
cable extension kit is required when using the carriage remotely.
TX04472-10-24-12
PH04730-10-1-12
PH04739-10-24-12
Indexer Controls
The indexer controls are located on the movable jaws of the
carriage at the operator position.
1 Controls the movement of the indexer to the left and right.
2 Controls the movement of the heater, moving the heater in and out of the
carriage.
3 Controls the movement of the facer, moving the facer in and out of the
carriage.
During transport, the heater, heater shroud, and facer can be
rotated into the carriage and the carriage closed on all three
capturing them between the jaws keeping them secure during the
moving of the machine or transporting the machine.
TX04474-10-24-12
1
CD01037-10-1-12
2 3
PH04814-10-24-12
2 - 3
Overview
Inlet Fans
Inlet fans are used to draw cooler air from the outside of the
machine to the generator compartment.
NOTICE: Never obstruct the fans. Allow enough area for air to
circulate into the machine. Restricting air to the fans could cause
components to overheat and fail.
TX04990-04-27-16
Facer
The facer is a McElroy rotating planer-block design. The blade
holders each contain three cutter blades. The block rotates on ball
bearings and is chain driven (enclosed in lubricant) by a hydraulic
motor. The facer is removable for in-ditch operation and features a
lifting point for lifting the facer in and out of the ditch.
NOTICE: Never extend the blade beyond the inner or outer
circumference of the facer.
TX04473-10-24-12
PH04741-10-8-12 PH05507-04-27-16
Hydraulic Manifold Block
Mounted on this block are a carriage directional control valve, a
pressure reducing selector valve, three pressure reducing valves,
and a 3000 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 3000 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 2300
psi, which is the set system pressure.
G) DataLogger port
PH04731-10-1-12
CD00138H-1-12-11
TX04541-10-24-12
2 - 4
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