T-Drill T-60 Guide

INSTRUCTION MANUAL
Version
3305-10-03
04.12.2002 LK
26.1.2004 /LK
Instruction Manual
This instruction manual includes a spare parts list and instructions for set-
up for operation, operation and maintenance of the T-DRILL T-60 tee
forming machine. Type code of manual is 3305-10-03
Manufacturer: Subsidiary: Covering North
America
OY
P.O BOX 20
FIN-66401 Laihia, Finland
Tel. Int [phone]
Telefax: (G3) [phone]
www.t-drill.fi
INDUSTRIES INC.
1740 Corporate Drive, Suite 820,
N
orcross, Georgia 30093, USA
Phone: [phone]
Fax: [phone]
www.t-drill.com
Your local representative is:
Copyright ©2002 T-DRILL Oy. All rights reserved. This manual, or parts thereof, may
not be reproduced in any form or by any means, nor translated into any other language
without a written permission of T-DRILL Oy.
This manual has been produced with a great deal of care and attention. All information
has been checked for accuracy. No liability will be accepted for any incorrect or
incomplete information.
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Table of contents
1. Notes on the use of the instruction manual ......................................5
1.1 Symbols for warning used in this manual ....................................5
1.2 Symbolism...................................................................................6
2. General safety instructions.................................................................7
2.1 General safety instructions for work area ....................................7
2.2 Safety instructions for tool ...........................................................8
2.3. Safety instructions for tee forming ............................................10
3. T-DRILL T-60, general........................................................................11
3.1 Introduction................................................................................11
3.2 The Parts of the T-60.................................................................11
3.3 Information about Accessories ..................................................12
3.4 Operating Range of the Machine...............................................13
3.5 Technical specifications.............................................................13
4. Transport, Handling and Storage .....................................................14
4.1 T-60...........................................................................................14
5. Preparing before use .........................................................................15
5.1 T-60, Detachment and attachment of the connecting cord........15
5.2 T-60:s start-up check.................................................................15
6. The operation of the machine...........................................................16
6.1 Description of the control devices..............................................16
6.2 Selection and adjustment of the T-DRILL heads .......................18
6.3 Chucking the T-DRILL head ......................................................21
6.4 The tee forming process with the T-DRILL T-60........................23
6.5 Annealing of tube.......................................................................26
7. Maintenance .......................................................................................28
7.1 The maintenance of the T-DRILL T-60......................................28
7.2 The replacement of the forming pins .........................................29
8. Trouble-shooting................................................................................30
9. Disposing............................................................................................32
10. Warranty............................................................................................33
11. Supplement.......................................................................................34
12. Spare parts list.................................................................................38
12.1. T-60........................................................................................38
12.2. The T-60 Tee Forming Unit ....................................................40
12.3 T-DRILL Head..........................................................................42
12.4 Counterplate ...........................................................................43
12.5 Optional Equipment.................................................................43
13. Ordering spare parts........................................................................45
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INSTRUCTION MANUAL
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1. Notes on the use of the instruction manual
1.1 Symbols for warning used in this manual
IMPORTANT! Gray base color is used to emphasize an important detail
NOTE! May cause an accident or damage other property, if the right
precautionary measures have not been taken.
DANGER! Will or may cause a serious accident or death, if the right
precautionary measures have not been taken.
This instruction manual includes instructions for set-up, operation and
maintenance of the T-DRILL T-60 tee forming machine. This book also
includes instructions on how to use and select T-DRILL heads for hand
tools.
NOTE! Before carrying out any actions, read chapter 2 ”Safety
Instructions”.
Get acquainted with the instruction manuals of the MILWAUKEE DRILL
delivered with the machine before using the T-60 machine.
Acquaint yourself with the machine before using it. Read the
operation sequence described in the instruction manual thoroughly before
preparing, operating or maintenance of the machine.
IMPORTANT! Save these instructions for future use!

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INSTRUCTION MANUAL
1.2 Symbolism
The following list defines the symbols on the tool.
Read the instruction manual carefully before using this
tool.
Double Insulated
130°Thermally protected to 130°C)
Warning! Do not throw to trash. Please recycle
Warning! Watch your fingers. Rotating tool.
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2. General safety instructions
Read all the instructions before using the machine.
Know your power tool - Read the instruction manual carefully. Learn to
know your own skill and limitations as well as the specific potential
hazards peculiar to this tool.
DANGER! - The use of any accessory or attachment other than the ones
recommended in this operating instruction or T-DRILL catalogue may
create a risk of personal injury.


NOTE! Never detach the MILWAUKEE power unit from the
T-DRILL tee forming unit. Detaching the power unit will damage the
alignment made in factory.
NOTE! - The T-DRILL T-60 is designed for use with MILWAUKEE
power unit. Using any other power units with the T-DRILL
T-60 tee forming unit is not allowed.
IMPORTANT! Warranty is void if the power unit is detached from the
tee forming unit!
2.1 General safety instructions for work area
Keep work area clean – Cluttered areas and benches invite injuries.
Consider work area environment – Don’t use power tool in humid or wet
conditions. Keep work area well illuminated. Don’t use power tool in the
presence of flammable liquids or gases.
Keep children away – Do not let visitors touch the tool or it`s extension
cord. All visitors should be kept away from work area.
Stay alert – Be aware of what you are doing. Use common sense. Do not
operate tool when you are tired.
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INSTRUCTION MANUAL
2.2 Safety instructions for tool
Store idle tools – when not in use, tools should be stored in dry, high, or
locked-up place, out of the reach of children.
Don’t force tool – It will do the job better and safer at the rate for which it
is intended.
Dress properly – Do not wear loose clothing or jewelry. They can be
caught in moving parts. Use appropriate gloves and footwear. Wear
protective hair covering to contain long hair.
Use safety glasses – Also use face or dust mask if cutting operation is
dusty.
Secure work – Use clamps or a vise to hold your work piece. It’s safer
than using your hand and it frees both hands to operate the tool.
Don’t overreach – Keep proper footing and balance at all times.
Maintain tools with care – Keep tools sharp and clean for better and
safer performance. Follow instructions for lubricating and changing
accessories. Inspect tool cords periodically and, if damaged, have them
repaired by authorised service workshop. Inspect extension cords
periodically and replace if damaged. Keep handles dry, clean and free
from oil and grease.
Don’t abuse cord – Never carry a tool by its cord or yank it to disconnect
it from receptacle. Keep cord from heat, oil and sharp edges.
Disconnect tools – When not in use, before servicing, and when
changing accessories such as blades, bits and cutters.
Remove adjusting keys and wrenches – Make it a rule to check that
keys and adjusting wrenches are removed from tool before turning it on.
Avoid accidental starting – Do not use a tool if the power switch does
not turn the tool on and off. Do not carry the tool with your finger on the
switch.
Outdoor use extension cords – When tool is used outdoors, use only
extension cords intended for use outdoors and so marked.
Check damaged parts – Before further use of tool, a guard or other part
that is damaged should be carefully checked to determinate that it will
operate properly and perform its intended function. Check for alignment of
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moving parts, binding of moving parts, breakage of parts, mounting, and
any other conditions that may affect its operation. A guard or other part
that is damaged should be properly repaired or replaced by an authorised
service unless otherwise indicated elsewhere in this instruction manual.
Have defective switches replaced by an authorised service. Do not use
tool if switch will not turn it on and off.
Have your tool repaired only by T-DRILL – This electric tool is in
accordance with the relevant safety requirements. Repairs should be
carried out only by certified persons using original spare parts; otherwise,
this may result in considerable danger to the user.
Keep tools away from items that may be damaged by magnets – The
motor contains a powerful magnet that may damage magnetic tape, credit
cards, computer disks and watches.
Use ear protectors. During operation the noise level of the collaring
machine may exceed 95dB(A).
The vibration excercised on the operator's hand is less than 2.5m/s.
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INSTRUCTION MANUAL
2.3. Safety instructions for tee forming
Do not touch the rotating tool when the work cycle is on.
When fixing the machine to the tube, be careful not to leave your fingers
between the machine and the tube
When handling the tools, be careful with the cutting blades. Use protective
gloves.
A falling machine or tool may damage your feet. Use protective shoes.
The lubricating oil you use may cause irritation of the skin. Use protective
gloves.
The fumes emitted by the lubricant may irritate your eyes and hinder your
respiration. Pay attention to an adequate ventilation.
Make yourself familiar with the contents of the safetly data sheet regarding
the lubricants.
The loosening chips are hot and sharp. Provide adequate protection in
order not to get damaged.
Be careful to avoid accidental starting of the machine when handling it.
Never carry the tool with your finger on the trigger.
When cleaning the collar always use protecting gloves. The edges of the
collar use to be sharp.
Do not use inadequate protecting gloves, because they may get caught by
the rotating tool. Keep your hands off the dangerous area.
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3. T-DRILL T-60, general
3.1 Introduction
The T-DRILL T-60 is a special tool intended for mechanically forming tees
in copper tube typically found in domestic, commercial and industrial
tubing systems. The T-60 extrudes in the run tube an outlet, to which the
branch tube can be joined by brazing.
Before attempting to put the T-60 into service, make sure you have read
and fully understood the safety instructions which apply to all power tools
and capabilities of this special tool.
The T-DRILL T-60 includes an electric network driven power unit with
accessories. The power unit is grounded 120V /60Hz or double insulated
110V /50Hz and 230V /50Hz.
3.2 The Parts of the T-60
43
51 2
Main parts: 1. T-DRILL tee forming unit, 2. Power unit, 3. Connecting cord,
4. T-DRILL head, 5. Tube support.
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INSTRUCTION MANUAL
3.3 Information about Accessories
For proper use of T-DRILL T-60 the following accessories are available:
Notcher ND-54
Tube end notcher forms the end of branch pipe to match inner curve of the
run tube. In this way maximum flow is achieved. The notcher also presses
two dimples simultaneously in the end of the branch tube, one acting as a
depth stop and the other one for inspection of the joint after brazing.
Gauge Block and rings
Correct size settings of the T-DRILL head for various tube sizes can easily
be checked with the gauge block. The range of size is NS 1/4"-1" with the
gauge block; 1¼”, 1½” and 2” with the rings).
Counter Plate
The counter plate assists forming of the outlet and improves the quality of
the outlet by supporting the tee forming machine against the run tube. The
counter plate is used for run tube sizes from NS 2 ½” (66.7 mm) to 4” (108
mm).
Lubrication for copper
A bottle of lubricant to be used for forming the outlet in copper tube, is
included.
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3.4 Operating Range of the Machine
The T-DRILL T-60 is intended for forming a tee in copper tube. The branch
tube is joined to the run tube by brazing.
The outlet size range of T-60 is NS 1/2" to 2" (10 – 54 mm).
The diameter of the run tube can be 1/2 " to 4" (15 – 108 mm). The
maximum wall thickness of the tube to be branched depends on the tube
diameter and the size of the T-DRILL head used.
Accurate capacity values: diameters and wall thicknesses of the tube are
specified in the capacity chart (chapter 11.1).
3.5 Technical specifications
T-60 Value NOTE!
Type Code 3305
Tee diameter NS 1/2” - 2” / 10– 54mm
Run tube NS 1/2” - 4” / 15– 108mm
Max. wall-thickness See Capacity chart (11.1)
Materials Copper (Cu)
Cycle 1 min. 45 s
Rotation speed of
spindle 500 / 50 RPM
A-accentuated
equivalent level of
sound pressure
82,5 dB (A) Use ear
protectors!
Vibration less than 2,5 m/s2
Dimensions of the unit 22.4”(l) x 4.9” (h) x 7.1” (d)
570 (l) x 125 (h) x 180 (d) mm
Weight of the unit 11,9 lbs /5,4 kg
Supply voltage of the
unit 120V / 60Hz / 7,0AMPS 230V / 50Hz / 4,0A
110V /50Hz 8,4AMPS
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INSTRUCTION MANUAL
4. Transport, Handling and Storage
4.1 T-60
The T-60 is delivered in a transport box, dimensions 25.2” (640mm) x 6.5”
(165mm) x 14.2” (360mm) (w x h x d). The weight of the box is, depending
on the accessories, between 29 - 49 lbs (13 and 23 kg) .
Storage
Keep the T-60 stored in a cool, dry place, covered against dust etc.
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5. Preparing before use
5.1 T-60, Detachment and attachment of the connecting cord
When delivered the T-60 power unit is fitted with a connecting cord, which
allows quick changing in field conditions.
Detachment of the cord
Turn the nut of the cord 1/2 turn to the left in order to loosen the cord.
Draw the cord out of the power unit.
Attachment of the cord
Push the connector of the cord into the socket of the power unit, pushing
the connector as far as it will go.
In order to lock the cord, turn the nut 1/2 turn to the right.
5.2 T-60:s start-up check
NOTE! Carry out the start-up checks before using the machine.
Before using the machine, proceed as follows:
1. Check that the cord is connected to the machine
2. Check that the cord is connected to the mains.

INSTRUCTION MANUAL
6. The operation of the machine
6.1 Description of the control devices
6.1.1 T-DRILL T-60
2 1
3
Control devices: 1. Trigger, 2. Speed selector 3. Feed mechanism
engagement lever
NOTE! Use maximum speed of rotation when drilling and forming the
outlet - when working press the trigger completely down!

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T
h
e
s
p
e
e
d
s
1. Speed selector 2. The feed mechanism lever
The speed selector knob is on the top of the gearbox of the T-60. Slow
speed is marked “I” and fast speed is marked “II”. To shift from fast to slow
speed, turn the selector knob 180 degrees. Drilling is always done in fast
speed (II). The forming of the tee is done in either slow speed or fast
speed depending on the run tube and outlet sizes. See the chart in
chapter 11.
If the speed selector knob does not engage smoothly, rotate the
motor by “bumping” the trigger.
The feed mechanism lever is situated near the chuck-ring. The feed
mechanism is engaged (on) when the lever is turned downward, i.e. as
shown on the illustration.
If the feed mechanism lever does not engage smoothly, rotate the
motor by “bumping” the trigger.
Do not force lever.

INSTRUCTION MANUAL
6.2 Selection and adjustment of the T-DRILL heads
6.2.1 The identification of the T-DRILL head
The size of the T-DRILL head is stamped on the cover plate:
5310401
15 1/2
12
3
Identification: 1. Actual size in millimetres, 2. Nominal size in inches (NS),
3. The ordering and identification number of the T-DRILL head
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6.2.2 The fine adjustment of the outlet diameter
NOTE! When adjusting the outlet diameter, extend the forming pins first.
Each T-DRILL head is adjusted at the factory to correspond to the nominal
size stamped on the cover of each T-DRILL head. Changing the tube
sizes or the way of joining may require adjustment of the T-DRILL head in
order to achieve the right joint.
To extend the forming pins (1) press
the cover (2) in direction of the
shank. Twist the shank (3) at the
same time clockwise until a positive
stop is reached, and the forming pins
extend.
1
23
T
Check the forming pin span diameter T with an adjusting ring or slide
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INSTRUCTION MANUAL
Depending on the size of the T-DRILL head, the forming pin span T should
be 0,020” – 0,055” (0,5 – 1,4mm) bigger than the branch pipe outer
diameter (O.D.)
1. Loosen the screws on the cover
plate by about one circle using a 3
mm hexagon wrench, that is
supplied with the T-DRILL
package.
2. To enlarge the outlet rotate the conical
cover with respect to the cover plate in
plus (+) direction. Hold the cover plate
stationary.
To make a smaller outlet rotate the
conical cover in minus (–) direction while
holding the cover plate stationary.
One
notc
h on the cover-plate equals to 0.01” or
0,25 mm on the forming pin span.
3. Tighten the two screws on the cover
plate and check the adjustment either by
measurement across the pins or by forming
a trial outlet.
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