Mueller Mega-Cut 039432 Administrator Guide

MUELLER®
opERation instRUctions ManUaL
Customer Service Center
Decatur, Illinois


[e-mail]



WARNING:
         

       
          

2. 



Failure to do so could result in serious injury.

            
             
or equipment could result in an explosion and subsequent serious injury

5. Mueller®       
           


!
Reliable Connections
TM
Mega-CutTM
Drilling
Machine
  PAGE
General Information 2
Installation / Operating Instructions 3
Parts 4

3
MUELLER®Mega-CutTM Drilling Machine
General Information
2
Capacity and Use
The Mueller®Mega-Cut™ Drilling
Machine is used to install up to 2"
corporation valves using a service
saddle on PVC plastic, cast or
ductile iron, or steel water main.
The maximum hole size is 17/8". The
machine operates easily by hand,
and allows independent control of
tool rotation (cutting action) and
boring bar feed (tool advancement).
It includes a feature that allows the
boring bar to be disconnected from
the feed sleeve and repositioned
quickly.
CAUTION: Use of serrated jaw
wrenches or pipe wrenches on
any machine parts or accessories
may result in deformation or
other damage which would render
the machine or an accessory
unusable. Use only smooth jawed
wrenches with this equipment.
Working Pressure and
Temperature Rating
200 psi Maximum Working Pressure
150º F Maximum Temp. Rating
The working pressure or temperature
rating is reduced accordingly if any
attachment, valve, or tting subjected
to pressure or temperature during
the drilling operation has a maximum
working pressure or temperature
rating less than that specied above.
Length of Travel – 121/8" (308 mm) Boring Bar
Feed Sleeve
Drive Nut
Body
Gasket
Other Equipment Required
The following items are not
supplied with the machine and are
purchased separately, according to
the application — see the current
Mueller Water Distribution Products
Catalog.
• Machine Adapter
Machine Adapter Gasket (Supplied
with Adapter)
• Shell Cutter or Drill
• Wrench/Socket*
To drive Boring Bar
• Cutting Grease
Also Needed: Smooth-jawed wrench
to tighten Machine Adapter and
Shell Cutter to Mega-Cut™ Drilling
Machine and adapter to corporation
valve outlet. Also, when working on
PVC plastic pipe a Drift Pin (Part
Number 63264) or Coupon Removal
tool (Part Number 681242) are
needed to remove coupon from
Shell Cutter.
*Machine Drive Nut will accommodate
7/8" socket.
Mega-CutTM Drilling Machine Guide
     
      
 Mega-Cut  200psig  
 Drilling 7/16"–17/8" (1379kPa/ HandOnly AllTypes* Pressurizedor
 Machine  13.80bar)   DryMains
*UseoncastironO.D.PVCpipe,aswellascastironorductileironpipe,cementlinedcastironorductileiron
pipe,A-Cpipe,steelpipe,orconcretepipe.
Feed Sleeve
Connector
!
Shipping Specications
 
Total Shipping
Weight 29 lbs (13 kg)
Machine ONLY
Weight 19 lbs (9 kg)
Shipping Length 21
1
/
2
"
Extended Length 32"

3
Installation of Corporation Valve with Service Clamp on Water Main
MUELLER®Mega-CutTM Drilling Machine
Installation / Operating Instructions
9. Cut hole by turning Boring Bar
clockwise, while turning Feed
Sleeve clockwise a little at a time.
DO NOT force Cutter into the main.
Use a light even feed at the start,
then a somewhat heavier feed and
nish with a light even feed.
Completion of hole through the main
will be accompanied by an obvious
reduction in resistance felt while
turning Boring Bar and Feed Sleeve.
IMPORTANT: Continue turning
Boring Bar and Feed Sleeve a few
additional revolutions to make
sure the coupon is completely
removed from the wall of the
main.
CAUTION: To avoid possible
injury, keep head and body away
from the end of Boring Bar at all
times. Once hole has been cut
through the wall of the main, the
Boring Bar will be under full line
pressure, resulting in a piston
action that will tend to force
the Boring Bar to the rearmost
position. Control or restrain
rearward movement of Boring Bar
at all times by keeping the Feed
Sleeve Connector engaged with
the Feed Sleeve, and by turning
the Feed Sleeve in a counter-
clockwise direction to back the
Cutter out of the main and clear of
the corporation valve.
10. Using both hands, turn Feed
Sleeve in counter-clockwise
direction to move Boring Bar to
the rearmost position and retract
Cutter from main. For larger holes or
thicker pipe, a smooth-jawed wrench
may be used on Feed Sleeve ats to
facilitate turning Feed Sleeve.
Machine Set Up
1. Attach service saddle and
corporation valve at the appropriate
angle to the water main using
accepted installation procedures,
and tighten all components to
specied torque requirements. Make
sure corporation valve is in fully
open position.
2. Attach proper Machine Adapter
and Gasket to Machine Body wrench
tight using a smooth-jawed wrench.
Selection of Adapter depends
upon the type and size of outlet
connection on the corporation valve.
3. Attach proper Shell Cutter or Drill
to Boring Bar. Use wrench ats on
tool and Machine Body to tighten
securely — DO NOT use any tool in
the slots of the Shell Cutter.
4. Lightly lubricate outside of Shell
Cutter or Drill using Mueller®Cutting
Grease.
5. Disengage Feed Sleeve
Connector from Feed Sleeve and
pull Boring Bar to the rearmost
position and hold in this position
during the next step.
6. Check to be sure corporation
valve is open. Attach Machine
assembly (with Cutter, Adapter, and
Gasket) to corporation valve outlet
and tighten wrench tight.
7. Push Boring Bar forward until
Feed Sleeve Connector can be
engaged in slot at top of Feed
Sleeve (turn the Sleeve counter-
clockwise if necessary).
8. Turn Connector clockwise in
slot, then advance Feed Sleeve
by turning clockwise until Cutter
contacts main.
11. Make sure Cutter is clear of
corporation valve, then close valve
and remove Machine and Adapter as
a unit.
12. Remove plastic coupon using
one of the following methods:
a) Use Drift Pin (Part Number
63264) to pry between the coupon
and the top (or root) of the cutter
slot and push the coupon from the
cutter. If plastic lls the entire slot
area, engage the plastic in the slot
with the tip of the Drift Pin to drive
the coupon from the cutter.
CAUTION: Prying against
the sides of the cutter slot or
using a prying tool that is wider
than the slot can damage the
cutter and make it unusable.
b) With the cutter removed from the
machine, use a Coupon Removal
Tool (Part Number 681242)
inserted through the tapped hole
in the cutter shank to drive the
coupon out of the cutter.
13. Clean and relubricate cutting tool
before using it to make another cut,
or before storing tool for future use.
!
!

Gas (North America)
1.800.798.3131
www.muellergas.com
[e-mail]
Water (North America)
1.800.423.1323
www.muellercompany.com
[e-mail]
Form 12092 – Rev 01/18
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).
Reliable Connections
TM
International
1.423.490.9555
www.mueller-international.com
[e-mail]
ID PART NAME PART No.
 – MachineComplete 039432
 1 HandleExtension 528094
 2 RetainingCollar 52809
 3 Pin 48130
 4 ConnectorAssembly 682091
 5 BearingAssembly 580610
 6 Pin 503158
 7 PackingGland 51432
 8 O-Ring 46726
 9 FeedSleeve 528095
 10 Body 503159
 11 BoringBarToolEnd 503161
 12 BodyGasket 47756
3

10
5
MUELLER®Mega-CutTM Drilling Machine
Parts
8

1
4
2
Parts List
TO ORDER: Specify Quantity, Part
Number and Part Name (include
catalog number and model number
of machine).
NOTE: These illustrations are
for parts identication only. DO
NOT use these illustrations for
assembly or disassembly of
machine. Mueller Co. offers a
machine repair service. Contact
Mueller Customer Service Center
for details.
6
12
6
11