Mueller D-5 Administrator Guide

MUELLER®
opERation instRUctions ManUaL
Customer Service Center
Decatur, Illinois
800.423.1323
www.muellercompany.com
[e-mail]
All warranties, expressed or implied, for Mueller Drilling Machines are
rendered null and void if the machines are used with shell cutters or
equipment manufactured by someone other than Mueller Co.
WARNING:
1. Read and follow instructions carefully. Proper training and periodic
review regarding the use of this equipment is essential to prevent possible
serious injury and/or property damage. The instructions contained
herein were developed for using this equipment on ttings of Mueller
manufacturer only, and may not be applicable for any other use.
2. DO NOT exceed the pressure ratings of any components or equipment.
Exceeding the rated pressure may result in serious injury and/or property
damage.
3. Safety goggles and other appropriate protective gear should be used.
Failure to do so could result in serious injury.
4. Pressure test, check for and repair leaks in all ttings and components
each time one is installed or any joint or connection is broken. Failure
to nd and repair a leak from any source in the ttings, by-pass lines
or equipment could result in an explosion and subsequent serious injury
and/or property damage.
5. Mueller®Drilling Machines and Equipment have been carefully
designed and engineered to work together as a unit. The use of
equipment manufactured by someone other than Mueller Co. may cause
excessive wear or a malfunction of the Mueller machines.
!
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TM
E-5TM and D-5TM
Drilling
Machines
TABLE OF CONTENTS PAGE
E-5 General Information 2
D-5 General Information 3
Operating Instructions 4-5
E-5 Parts 6
D-5 Parts 7

Shipping Specications
 
Machine and
Equipment 591/2lbs (27 kg)
Furnished in
Metal Case
Machine ONLY 25 lbs (11 kg)
Shipping Length 22”
Extended Length 32”
MUELLER®E-5TM Drilling Machine
General Information
2
Capacity and Use
The E-5 Drilling Machine is hand
or power operated for drilling holes
1/2” – 2” inclusive, in any size or kind
of pipe. (Under certain conditions
the maximum size may be increased
to 33/4”.)
Maximum Working Pressure
500psi at 100° F.
375psi at 250° F.
The working pressure or
temperature rating is reduced
accordingly if any attachment, valve
or tting, subjected to pressure
when using the machine, has a
maximum working pressure or
temperature rating less than that
specied above.
Length of Travel – 121/8”
Equipment Furnished with
Each Machine
• Ratchet Handle
• Body Gasket
• Adjustable Wrench
• 2 End Wrenches
• Cutting Grease
The machine adapter nipple, drill
holder and drill shown at left are not
included in the equipment furnished
with this machine. These items must
be ordered according to the size and
type of valve and pipe to be tapped.
3/4” & 1” tools and equipment for this
machine are the same as above for
the E-4 Drilling Machine in the latest
Mueller water and gas catalogs.
For operating instructions see pages
4 – 5 and for E-5 Drilling Machine
Parts see page 6.
Machine Adapter
Nipple
Drill Holder
Crank Handle
Collar
Feed Nut and Yoke
Oil Hole
Clean Out Notch
O-ring
Drill
Ratchet Handle
Small Drilling Machine Selection Guide
     
      
     CastIron,Cement- Makingmain
E-5Drilling7/16”–17/8” 500psig HandorlinedCastIron,Ductile toservice 
Machine  (3450kPa) PowerIron,Cement-lined connectionsin
    DuctileIron,A-C, pressurizedmain
    Concrete,Steel&PVC
Locking
Mechanism

MUELLER®D-5TM Drilling Machine
General Information
3
Capacity and Use
The D-5 Drilling Machine is hand
or power operated for drilling holes
1/2” – 2” inclusive, in any size or kind
of pipe. (Under certain conditions
the maximum size may be increased
to 33/4”.)
Maximum Working Pressure
500psi at 100° F.
375psi at 250° F.
The working pressure or
temperature rating is reduced
accordingly if any attachment, valve
or tting, subjected to pressure
when using the machine, has a
maximum working pressure or
temperature rating less than that
specied above.
Length of Travel – 14”
Equipment Furnished with
Each Machine
• Ratchet Handle
• Body Gasket
• Adjustable Wrench
• End Wrench
• Cutting Grease
The machine adapter nipple, cutter
arbor, shell cutter and pilot drill
shown at right are not included in
the equipment furnished with this
machine. These items must be
ordered according to the size and
type required.
Tools and equipment for this machine
are the same as those listed for the
D-4 Drilling Machine in the latest
Mueller water and gas catalogs.
For operating instructions see pages
4 – 5 and for D-5 Drilling Machine
Parts see page 7.
Shipping Specications
 
Machine and
Equipment 601/2lbs (27 kg)
Furnished in
Metal Case
Machine ONLY 35 lbs (16 kg)
Shipping Length 22
1
/2”
Extended Length 37”
Machine
Adapter Nipple
Cutter Arbor
Locking Mechanism
Collar
Feed Nut and Yoke
O-ring
Pilot Drill
Ratchet Handle
Shell Cutter
Small Drilling Machine Selection Guide
     
      
     CastIron,Cement- Makingmain
D-5Drilling5/8”–2” 500psig HandorlinedCastIron,Ductile toservice 
Machine  (3450kPa) PowerIron,Cement-lined connectionsin
    DuctileIron,A-C, pressurizedmain
    Concrete,Steel&PVC

MUELLER®D-5TM and E-5TM Drilling Machines
Operating Instructions
4
4. Coat drill, or shell cutter, and pilot
drill thoroughly with Mueller cutting
grease. (DO NOT us cutting grease
when drilling A-C or concrete pipe.)
5. Attach proper size machine
adapter nipple to the body of the
machine making sure that the body
gasket or washer is in place and in
good condition.
6. Retract boring bar to its rearmost
position.
7. Attach drilling machine and
machine adapter nipple to the valve,
stop or tting that is to be drilled
through.
8. Open valve, stop or tting being
used.
9. Advance boring bar until drill or
pilot drill contacts the pipe to be
drilled.
10. Adjust feed tube and yoke (or
feed nut and yoke) so that the yoke
is engaged with the top of the friction
collar on boring bar. Raise pivot arm
of locking mechanism on side of
yoke so that it is positioned under
friction collar and lock in place with
operating screw.
11. Retract boring bar a slight
amount.
12. Measure and mark the travel
required to complete the drilling
operation. (Mark the point on the
body that the feed tube will reach
when drilling is completed.)
13. DRILL THE MAIN
Power Operated Method Using
Mueller H-603 Electric Power
Operator, H-604 Air Power
Operator, or H-705 Hydraulic
Power Operator
The E-5 and D-5 Drilling Machines
have been designed to permit the
addition of a power operator. The
power operator will drive the tools
and provide automatic feed during
the drilling operation. The power
operator consists of a gear case
and motor using an electric, air, or
hydraulic motor for the power source.
1. Oil all working parts. Keep all
threaded surfaces and boring bar
well lubricated and free from dirt
and foreign material. The feed tube
on the E-5 and D-5 is designed to
aid in cleaning the threads when
advancing or retracting the feed
tube and yoke. If equipped, keep
the clean-out notch and oil holes
of these machines clean at all
times. E-5 and D-5 Machines are
equipped with O-ring packing.
Under normal conditions the only
maintenance required for the O-rings
is lubrication. If the O-rings should
become excessively worn they
should be replaced.
2. Advance boring bar until drilling
tools may be attached.
3. Attach drilling tools to boring
bar. If drilling tools to be used will
not pass completely through the
machine adapter nipple to be used,
attach the machine adapter nipple
before attaching the drilling tools
(see instruction 5).
Flat drills are used for drilling
through straightway or atway stops.
Measure dimensions “A” and “C” on
the at drill to be sure that they are
less than minimum dimensions “a”
and “c” through the body and key of
the stop to be used.
When advancing or retracting the
boring bar equipped with a at drill,
make sure that the drill is in the
proper position to pass through the
port opening in the key and body
of the stop being used. (Before
advancing the boring bar the correct
position can be marked on collar of
boring bar.)
IMPORTANT: When using H-604
Air Motor Power Operator. Install
an in-line lubricator as close to
the unit as practical and adjust
for slight oil mist from exhaust –
maintain pressure of 90psig. We
recommend the use of a gauge at
the throttle to determine the actual
pressure of air at the air motor.
The gear case attaches to the
machine by the means of two
sockets. The inner or small socket
drives the boring bar. The outer
or large socket drives the feed
yoke through a gear reduction
as the boring bar is rotated. The
resulting feed on the drill is 0.10” per
revolution of the boring bar.
The operator takes the torque of
the motor resulting from the drilling
operation, so the motors are equipped
with a squeeze type trigger throttle. If
for some reason a drill should stick,
the motor can be shut off quickly.
a) Place the gear case and motor on
the drilling machine aligning the
sockets with the square shanks
on the boring bar and feed yoke.
Socket which contacts feed yoke
should be closed and wing nut
securely.
b) Set position of air or electric motor
switch to give clockwise rotation
of boring bar.
NOTE: Feed the yoke by hand
when using 11/2” and 2” drill bits.
Hand Operation
Drill the hole by operating the ratchet
handle clockwise and turning the
feed tube and yoke (or feed nut and
yoke) clockwise a little at a time.
Use a light, even feed and nish
with a light, even feed. The special
locking mechanism that locks the
boring bar to the feed yoke prevents
the drill from spiraling into the hole
before the hole is completely drilled.
To prevent over-feeding when drilling
small holes and also when starting
to drill larger holes, apply the feed by
gripping the knurled section of the
feed tube instead of feed handles.
5



MUELLER®D-5TM and E-5TM Drilling Machines
Operating Instructions
5
The pressure inside of the drilling
machine will tend to raise the boring
bar. Hold down on the boring bar
or use the feed yoke to control the
upward motion of the boring bar
thereby preventing shock or damage
to the drilling machine.
16. Close valve, stop or tting being
used.
17. Remove drilling machine and
machine adapter nipple as a unit.
18. Advance boring bar and remove
machine adapter nipple and drilling
tools from machine.
19. After being used, clean dirt and
foreign material from machine and
equipment. Lubricate machine and
give drilling tools a light coat of oil
to protect them from rust. When not
in use, the machine and equipment
furnished with each machine should
be stored in the box furnished with
the machine. The machines should
be dis-assembled periodically, and
the boring bar and the machine
body thoroughly cleaned both inside
and out. By doing this, any dirt, grit,
chips, or other foreign material that
might have possibly accumulated
on the boring bar or in the body of
the machine may be detected and
removed before any damage is
done. An accumulation of foreign
material on either the boring bar or
inside of the body will restrict the
reverse travel of the boring bar.
This will apply a light, even feed.
Feed handles should be used to
apply a heavier feed.
NOTE: When nearing the
completion of the cut DO NOT
over-feed or the cutting tools may
be forced through before all the
material is drilled or cut out.
The E-5 Machine is now furnished
with a combination ratchet and crank
handle. When drilling small holes
the crank handle should be turned
upward and rotated in continuous
circles instead of ratcheting.
14. Continue drilling operation until
pipe is drilled through completely.
This can be determined by the
feel of the feeding mechanism, the
pull on the ratchet handle or by
measuring the advance of the boring
bar. If drilling is not completed,
retract boring bar slightly and ratchet
and feed slowly to remove the
remaining metal a little at a time.
15. When drilling operation is
completed turn operating screw
on locking mechanism counter-
clockwise to unlock pivot arm.
Remove feed-yoke from friction
collar and retract boring bar to its
rearmost position. Be sure that the
drill or pilot drill clears the valve gate
or key of stop if a stop is being used.
NOTE: If the pressure in the
main is 90psi or over, the locking
mechanism on the feed yoke
may be used to control the
upward movement of the boring
bar by leaving it attached until
uppermost position is reached,
then disconnect as described
above.
CAUTION: DO NOT reverse
rotation of ratchet handle when
retracting the boring bar.
SPECIAL NOTE: In general, the
machines should be lubricated
as described in instruction
No.1. However, due to extreme
conditions in some areas (dust,
sand, etc.) it may be advisable
not to lubricate the feed sleeve or
threaded parts of these machines
since it would tend to increase the
abrasive or wearing action. This
procedure, of course, must be at
the discretion of the operator.
!

MUELLER®D-5TM and E-5TM Drilling Machines
E-5 Parts
6 7
ID PART NAME PART No.
parts List
1
7
6
2
3
8
9
15
11
12
13
14
33
10
20
21 22
23
24
25
26 27
19
18
17
32
34
35
30
29
28
5
16
31
4
E-5 Machine Complete
1 RatchetHandleComplete 580897
 2 CrankHandle 50085
 3 HandlePin 500635
 4 Handle 51484
 5 DetentKnob 37863
 6 Spring 37883
 7 OperatingPin 500803
 8 RatchetDog 51426
 9 Knob 83431
10 FrictionCollarPin 48130
11 FrictionCollar 580610
12 BoringBar 580999
13 AdjustableWrench 91664
14 EndWrench 96536
15 EndWrench 59767
16 CuttingGrease 88366
17 PackingGland 51432
18 O-RingPacking 46726
19 Body 503159
20 BodyGasket 47756
21 LockNut 502029
22 OperatingScrew 502028
23 RetainingScrew(2) 79745
24 Washer(2) 50133
25 DetentSpring(2) 59810
26 DetentScrew(2) 305006
27 DetentPin(2) 500651
28 Plug 51427
29 RatchetWheel 503162
30 WheelBushing 503163
31 RetainingRing 51428
32 PivotArmPin 502027
33 PivotArmSpring 502026
34 PivotArm 502025
35 FeedTube&YokeComplete 580895
36 MetalCase(notshown) 580971

MUELLER®D-5TM and E-5TM Drilling Machines
D-5 Parts
7
ID PART NAME PART No.
1 RatchetHandle 85308
 2 HandleBar 50111
 3 SpringPin 40006
 4 Spring 40007
 5 RatchetDog 40004
 6 Nut 45255
 7 Stud 40139
 8 RatchetWheel 40737
 9 RetainingNut 46029
10 FrictionCollarRollPin 48130
11 FrictionCollar 580610
12 Bolt 40138
13 AdjustableWrench 91664
14 EndWrench 58196
15 CuttingGrease 88366
16 HandleExtension 86391
17 BoringBar 503141
18 BoringBar 580945
19 PackingGland 51377
20 O-Ring 51458
21 Body 36758
22 BodyGasket 33278
23 RetainingScrew(2) 79745
24 Washer(2) 50133
25 DetentSpring(2) 59810
26 DetentScrew(2) 305006
27 Detent(2) 500651
28 RollPin 502027
29 PivotArmSpring 502026
30 PivotArm 502025
31 LockNut 502029
32 OperatingScrew 502028
33 FeedTube&YokeComplete 580946
34 MetalCase(notshown) 580969
parts List
9
12
13
14
20
21
22
23
24
25
26
27
19
18
17
32
30
29
28
5
15
16
31
4
D-5 Machine Complete
1
3
2
6
7
8
10 11 33

Water (North America)
1.800.423.1323
www.muellercompany.com
[e-mail]
Form 9335 - 01/17
Copyright © 2017 Mueller Co., LLC. All Rights Reserved.
The trademarks, logos and service marks displayed in this document herein are the property of Mueller Co., LLC, its afliates or other third parties.
Products marked with a section symbol ( § ) are subject to patents or patent applications. For details, visit www.mwppat.com. These products are
intended for use in potable water applications. Please contact your Mueller Sales or Customer Service Representative concerning any other application(s).
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1.423.490.9555
www.mueller-international.com
[e-mail]