Victaulic TM-HCT908 Manual

OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL
HCT908 Hole Cutting Tool
WARNING
Original Instructions
WARNING
Failure to follow instructions and warnings could result in death,
serious personal injury, property damage, and/or product damage.
• Before operating or servicing any grooving tools, read all
instructions in this manual and all warning labels on the tool.
• Wear safety glasses, hardhat, foot protection, and hearing
protection while working around this tool.
• Save this operating and maintenance manual in a place
accessible to all operators of the tool.
If you need additional copies of any literature, or if you have questions concerning the safe
and proper operation of this tool, contact Victaulic, P.O. Box 31, Easton, PA 18044-0031,
Phone: 1-800-PICK-VIC, E-Mail: [e-mail].
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TM-HCT908

TABLE OF CONTENTS
Hazard Identification ................. 4
Operator Safety Instructions ............ 4
Introduction ....................... 6
Receiving The Tool ...................6
Container Contents ...................6
Returning The Tool ...................6
Power Requirements ................. 7
Power Supply Requirements ............7
Extension Cord Requirements ...........7
Tool Nomenclature................... 8
Installing the Hole Saw ............... 9
Tool Setup ........................ 9
Tool Operation......................11
Removing the Hole Saw .............. 13
Maintenance .......................14
Lubrication ........................14
Adjusting the Gib ....................14
Parts Ordering Information .............14
Accessories........................15
Troubleshooting.....................15
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TM-HCT908 / Operating and Maintenance Instructions Manual

HAZARD IDENTIFICATION
Definitions for identifying the various hazard
levels are provided below.
This safety alert symbol indicates
important safety messages. When
you see this symbol, be alert to the
possibility of personal injury.
Carefully read and fully understand the message
that follows.
DANGER
• The use of the word “DANGER” identifies
an immediate hazard with a likelihood
of death or serious personal injury if
instructions, including recommended
precautions, are not followed.
WARNING
• The use of the word “WARNING”
identifies the presence of hazards
or unsafe practices that could result
in death or serious personal injury if
instructions, including recommended
precautions, are not followed.
CAUTION
• The use of the word “CAUTION”
identifies possible hazards or unsafe
practices that could result in personal
injury and product or property damage
if instructions, including recommended
precautions, are not followed.
NOTICE
• The use of the word “NOTICE” identifies
special instructions that are important
but not related to hazards.
OPERATOR SAFETY
INSTRUCTIONS
The HCT908 tool is designed ONLY for cutting
holes in steel and stainless steel pipe and
copper tubing, and should ONLY be used for
that purpose. These instructions must be read
and understood by each operator PRIOR to
working with the grooving tool. These instructions
describe safe operation of the tool, including
set up and maintenance. Each operator must
become familiar with the tool’s operations,
applications, and limitations. Particular care
should be given to reading and understanding
the dangers, warnings, and cautions described
throughout these operating instructions.
Use of this tool requires dexterity and mechani-
cal skills, as well as sound safety habits.
Although this tool is designed and manufactured
for safe, dependable operation, it is difficult to
anticipate all combinations of circumstances
that could result in an accident. The following
instructions are recommended for safe operation
of this tool. The operator is cautioned to always
practice “safety first” during each phase of
use, including set up and maintenance. It is the
responsibility of the lessee or user of this tool
to verify that all operators read this manual and
fully understand the operation of this tool.
Store this manual in a clean, dry area where
it is always readily available. Additional copies
of this manual are available upon request
through Victaulic, or can be downloaded at
victaulic.com.
DANGER
1. Avoid using the tool in potentially
dangerous environments. Do not expose
the tool to rain, and do not use the tool in
damp or wet locations. Do not cut holes
into pressurized pipe/tubing or pipe/tubing
that is filled with fluid or compressed gas.
Keep the work area well lit.
2. Ground the tool to protect the operator
from electric shock. Verify that the tool
is connected to an internally grounded
electrical source.
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3. Disconnect the power cord from the
electrical source before servicing the
tool. Only authorized personnel should
perform maintenance on the tool. Always
disconnect the power cord from the
electrical source before servicing or
adjusting the tool.
4. Do not operate the tool in gaseous or
explosive environments. The tool motor
produces a normal spark, which could
ignite fumes.
WARNING
1. Prevent back injury. Always use proper
lifting techniques when handling tool
components.
2. Wear proper apparel. Do not wear loose
clothing, gloves, jewelry, or anything that
can become entangled in moving parts.
3. Wear protective items when working with
tools. Always wear safety glasses, hardhat,
foot protection, and hearing protection. A
face or dust mask is recommended, since
the cutting operation produces fine metal
particles.
4. Keep hands and tools away from the arbor
assembly during the cutting operation.
Ensure that adjustment keys and wrenches
are removed from the tool before operation.
5. Do not reach inside pipe/tubing ends
during tool operation. Pipe edges can
be sharp and can snag hands and shirt
sleeves.
6. Prevent accidental startups. Do not carry
the tool with the trigger depressed.
7. Do not over-reach. Maintain proper
balance at all times.
8. Do not make any modifications to the
tool. Do not remove any safety guarding
or any components that affect tool
performance.
9. Do not abuse the power cord. Never carry
the tool by the power cord or yank the cord
out of a receptacle. Keep the cord away
from heat, oil, and sharp objects.
CAUTION
1. The HCT908 tool is designed ONLY for
grooving pipe/tubing sizes, materials, and
wall thicknesses as designated.
2. Inspect the equipment. Before using
the tool, check moveable parts for
obstructions. Ensure that tool components
are installed and adjusted in accordance
with setup instructions.
3. Stay alert. Do not operate the tool if you
are drowsy from medication or fatigue.
4. Keep visitors, trainees, and observers
away from the immediate work area. All
visitors should be kept a safe distance from
the equipment at all times. When using this
tool on an elevated floor, the area below
must remain clear of other personnel.
5. Keep work area clean. Keep the work area
around the tool clear of any obstructions
that could limit movement of the operator.
Clean up any spills.
6. Secure the tool and accessories. Verify
that the tool is stable. Refer to the “Tool
Setup” section.
7. Support the work. Use clamps or a vise to
hold work securely.
8. Do not force the tool. Do not force the tool
or accessories to perform any functions
beyond the capabilities described in these
instructions. Do not overload the tool.
9. Maintain tool with care. Keep the tool clean
to ensure proper and safe performance.
Follow the instructions for lubricating tool
components and changing accessories.
10. Use only Victaulic replacement parts
and accessories. Use of any other parts
may result in a voided warranty, improper
operation, and hazardous situations. Refer
to the “Parts Ordering Information” and
“Accessories” sections.
11. Do not remove any labels from the tool.
Replace any damaged or worn labels.
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INTRODUCTION
NOTICE
• Drawings and/or pictures in this manual
may be exaggerated for clarity.
• The tool, along with this operating
and maintenance instructions manual,
contains trademarks, copyrights, and/or
patented features that are the exclusive
property of Victaulic Company.
The Victaulic HCT908 Hole Cutting Tool is
specifically designed to cut holes in carbon steel
and stainless steel pipe and copper tubing
for branch connections using Victaulic
Hole Cut Products. This tool is not designed
for use on cast iron pipe, HDPE, or PVC
plastic pipe. Never use the tool to cut anything
but the intended materials. The HCT908 is
suitable for 1 ¼ – 8 inch/42.4 – 219.1 mm pipe/
tubing sizes and can cut up to 2¾ inch/70 mm
hole sizes.
CAUTION
• This tool must be used ONLY for grooving
pipe/tubing with specifications that fall
within the designated parameters.
Failure to follow this instruction could
overload the tool, resulting in reduced tool
life, tool damage, or personal injury.
RECEIVING THE TOOL
HCT908 Hole Cutting Tools are packed
individually in sturdy containers. Upon receipt
of the tool, ensure that all necessary parts
are included. If any parts are missing, contact
Victaulic. NOTE: If the tool is rented, save the
container for return shipment.
CONTAINER CONTENTS
Qty. Description
1Drill Motor Assembly with Chuck Key
1Extra Pilot Drill with Coupon Saver
1Arbor Assembly
1Coupon Removal Tool
2Operating and Maintenance Instructions Manual
NOTE: Hole saws must be ordered separately. A
permanent carrying case is available and can be
ordered separately.
RETURNING THE TOOL
Prepare tool for shipment as received. Contact
Victaulic with questions.
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POWER REQUIREMENTS
DANGER
• To reduce the risk of
electric shock, check
the electrical source for
proper grounding.
• Before performing any
maintenance on the
tool, disconnect the
power cord from the
electrical source.
Failure to follow these instructions could
result in death or serious personal injury.
The HCT908 tool is equipped with a three-
prong plug and must be plugged into a
grounded, single-phase electrical receptacle.
Refer to Figure “A” below. If an adapter (Figure
“C”) is used to accommodate the three-prong
plug, the adapter’s wire must be attached to a
known ground. Refer to Figures “A” and “B”
and the “Power Supply Requirements” table
on this page. NEVER REMOVE THE THIRD
PRONG FROM THE DRILL MOTOR’S POWER
CORD PLUG.
POWER SUPPLY REQUIREMENTS
Volts/Amps Power Supply Requirements
120 120 VAC, 15-amp, 50/60 Cycle Power
Supply
7
NOTICE
• The tool is equipped with a UL Listed
three-conductor cord and a three-prong,
grounding-type plug to fit the proper
grounding-type receptacle. The green (or
green and yellow) conductor in the cord
is the grounding wire. Never connect the
green (or green and yellow) wire to a live
terminal.
EXTENSION CORD REQUIREMENTS
When pre-wired outlets are not available and
an extension cord must be used, it is important
to use the proper cord size (i.e. Conductor Size
American Wire Gauge). Cord size selection is
based upon tool rating (amps) and cord length
(feet). Use of a cord size (gauge) thinner than
required will cause significant voltage drop
at the power head while the tool is operating.
Voltage drops may cause damage to the power
head and can result in improper tool operation.
NOTE: It is acceptable to use a cord size that is
thicker than required.
The required cord sizes for cord lengths up to
and including 100 ft/31 m are listed in the table
below. Use of extension cords longer than 100
ft/31 m must be avoided.
Circuit
Rating
Cord Lengths
feet/meters
Volts/
Amps
25
8
50
15
100
31
120
15
12 gauge 12 gauge 10 gauge
6 530
circular mils
6 530
circular mills
10 380
circular mils
ADAPTER
GROUNDING
MEANS
GROUNDED
OUTLET BOX
METAL
SCREW
GROUNDED
OUTLET BOX
GROUNDING
PRONG IS
LONGEST OF
THE 3 PRONGS
Figure A Figure C Figure B
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TOOL NOMENCLATURE
NOTICE
• Drawings and/or pictures in this manual may be exaggerated for clarity.
• The tool, along with this operating and maintenance instructions manual, contains
trademarks, copyrights, and/or patented features that are the exclusive property of
Victaulic.
Power Cord
Trigger
Drill Motor Handle Drill Motor
Feeder Knob
Bearing
Feeder Rod
Vise
Handle
Chain
Base
Chain
Slot
Arbor
Assembly
Coupon
Removal Tool
Chuck Key
(attached to
power cord) Chuck
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TM-HCT908 / Operating and Maintenance Instructions Manual

INSTALLING THE HOLE SAW
1. Thread or push the locking ring of the arbor
assembly back as far as it will go.
2. Thread the hole saw onto the arbor assembly
enough to line up the holes in the top of the hole
saw with the drive pins on the arbor assembly. If
the pins do not line up with the holes, back off
the hole saw to line up the holes with the drive
pins.
3. Thread or push the locking ring of the arbor
assembly down until the pins engage the holes
in the top of the hole saw. Ensure that the hole
saw is flush with the arbor assembly and that
the hole saw is installed firmly onto the arbor
assembly.
TOOL SETUP
WARNING
• DO NOT connect the tool to the
electrical source until instructed
otherwise.
Accidental startup of the tool could result
in serious personal injury.
NOTICE
• When selecting the hole location, take
into account the width of the product
being installed. Ensure that the product
will not interfere with couplings or other
system components. In addition, allow
room on the pipe/tubing for mounting the
hole cutting tool.
1. Ensure that the pipe/tubing is secured before
attempting to set up the tool.
2. Locate the center of the hole to be cut on the
pipe/tubing run. Mark this center point clearly
with a punch.
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3. Raise the drill motor to its highest position by
rotating the feeder knob counterclockwise.
4. Insert the hex-shaped end of the arbor
assembly into the chuck.
5. While supporting the arbor assembly, tighten
the chuck securely with the chuck key provided.
6. Place the hole cutting tool onto the pipe/
tubing. Wrap the chain around the pipe/tubing
and insert is loosely into the chain slot on the
tool’s base. Leave the chain loose enough to
permit movement of the tool base.
7. Align the hole saw’s drill bit with the center
punch mark.
8. Using the vice handle, tighten the chain to
secure the hole cutting tool.
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Switch –
shown in
forward
position
Trigger
9. Ensure that the switch on the underside
of the drill motor’s handle is in the “forward”
position, as shown above.
10. To install the cord, align the three prongs
of the connector with the receptacle in the drill
motor’s handle. Push the connector in, then
turn the connector one quarter turn clockwise
to lock the cord in place.
DANGER
• To reduce the risk of
electric shock, check
the electrical source for
proper grounding.
Failure to follow this
instruction could result in
death or serious personal
injury.
11. Plug the cord into an appropriate
outlet or extension cord. Refer to the “Power
Requirements” section.
NOTE: All of the settings shown are based on
using Milwaukee™ 4/6 Bi-Metal Hole Saws or
Victaulic Hole Saws.
TOOL OPERATION
WARNING
• NEVER use the HCT908 Hole Cutting
Tool for applications where spark
hazards exist or where contact with
water can occur.
Failure to follow this instruction could
result in serious personal injury.
NOTICE
• To extend hole saw life, apply thread-
cutting oil to the hole during the cutting
operation.
1. Depress the trigger on the underside of
the drill motor’s handle. Feed the hole saw by
turning the feeder knob clockwise. Feed the
saw into the cut at a moderate rate to maintain
smooth cutting action. DO NOT feed the saw
too fast, since it can cause the motor to stall. If
difficulties occur during the cutting operation,
refer to the “Troubleshooting” section.
2. After completing the cut, release the trigger
completely. Retract the hole saw by turning the
feeder knob counterclockwise.
™Milwaukee is a registered trademark of Milwaukee Electric Tool
Corporation
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WARNING
• DO NOT touch coupons
with bare hands.
Coupons can be hot and
edges will be sharp.
Failure to follow this
instruction could result in
serious personal injury.
3. Unplug the tool from the electrical source.
Remove the coupon from the hole saw by using
the coupon removal tool, as shown above. DO
NOT touch coupons with bare hands. Use
caution to prevent damage to the wire that is
wound into the drill. Remove any chips from the
drill by using a brush. If the coupon falls into the
pipe/tubing, remove it immediately.
4. While supporting the tool, loosen the vise
handle.
5. While continuing to support the tool, unhook
the chain from the slot. Remove the tool from
the pipe/tubing.
6a. Ensure that a ⁄-inch/16-mm area around
the hole is clean, smooth, and free from
indentations and/or projections that could
affect gasket sealing (refer to the sketch on the
following page). Remove any burrs and sharp
or rough edges from the hole. Burrs and sharp
edges could affect product assembly, seating
of the locating collar, flow from the outlet, and
gasket sealing.
6b. The pipe/tubing around the entire
circumference, within the “A” dimension shown
in the sketch on the following page, must be
free from any dirt, scale, projections, and cutting
particles that could prevent the housing from
seating fully on the pipe/tubing.
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A
5⁄8"
16 mm
PIPE/TUBING SURFACE PREPARATION
REQUIREMENTS
Branch Size
Surface
Preparation
“A” Dimension
Nominal inches/
Actual mm inches/mm
All ½-inch/21.3-mm Outlets 3.50
88.9
All ¾-inch/26.9-mm Outlets 3.50
88.9
All 1-inch/33.7-mm Outlets 3.50
88.9
All 1 ¼-inch/42.4-mm Outlets 4.00
101.6
All 1 ½-inch/48.3-mm Outlets 4.00
101.6
All 2-inch/60.3-mm Outlets 4.50
114. 3
All 2½-inch/73.0-mm Outlets 5.00
127.0
All 76.1-mm Outlets 5.50
139.7
REMOVING THE HOLE SAW
WARNING
• Before removing the hole saw from the
arbor assembly, disconnect the power
cord from the electrical source.
Failure to follow these instructions could
result in serious personal injury.
1. Using the chuck key provided, remove the
arbor assembly from the drill.
2. Depending on the type of arbor assembly
included with the tool, pull or thread the locking
ring all the way up. Ensure that the pins in the
arbor assembly clear the hole saw completely.
Unscrew the hole saw to remove it from the
arbor assembly.
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MAINTENANCE
DANGER
• Before performing any
maintenance on the
tool, disconnect the
power cord from the
electrical source.
Failure to follow this
instruction could result in
death or serious personal
injury.
LUBRICATION
HCT908 Hole Cutting Tool components are
lubricated at the factory. However, periodic
lubrication of the following parts will maintain
proper operation of the tool.
1. Lubricate the feeder rod with light-grade oil.
2. Lubricate the bearing with light-grade oil.
ADJUSTING THE GIB
If play develops at the gib, which allows
excessive side-to-side movement of the drill
motor assembly, use the adjustment screws on
the tool to correct the problem.
1. Loosen the lock nuts, and use the adjustment
screws to take up any slack.
2. While holding the adjustment screws in place,
re-tighten the lock nuts. Check the sideways
movement of the drill motor assembly. Using the
feeder knob, run the drill motor assembly up
and down to check for excessive drag. The drill
motor assembly should have minimal sideways
motion, and minimal drag should be produced
when the feeder knob is rotated.
PARTS ORDERING
INFORMATION
When ordering parts, the following information
is required for Victaulic to process the order and
send the correct part(s). Parts can be ordered
by calling 1-800-PICK-VIC.
1. Tool Model Number
2. Tool Serial Number
3. Quantity, Item Number, Part Number, and
Description
4. Where to send the part(s) – Company
Name and Address
5. To whose attention to send the part(s) –
Person’s Name
6. Purchase Order Number
7. Billing Address
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ACCESSORIES
ARBOR ASSEMBLY FOR 1-INCH
DIAMETER HOLE SAW
1
2
3
4
Item
No. Part No. Qty. Description
Ref. R-450-900-HCT ‡ Arbor Assembly
1N-M14-000-007 1 Arbor
2N-S90-050-004 1 Nyloc Half Dog Set Screw
3R-402-900-HCT 1 Coupon-Retaining Drill Bit
4N-M18-000-011 * 1-inch/26-mm Hole Saw
‡ The arbor assembly is supplied with the tool.
* Hole saws must be ordered separately.
ARBOR ASSEMBLY FOR 1 3/16-INCH OR
LARGER DIAMETER HOLE SAWS
14 15 16 17
18 19 20
13
12
11
Item
No. Part No. Qty. Description
Ref. R-400-900-HCT ‡ Arbor Assembly
11 N-M14-000-025 1 Arbor
12 N-S90-050-010 1 Nyloc Half Dog Set Screw
13 R-402-900-HCT 1 Coupon-Retaining Drill Bit
14 N-M18-000-012 * 1 ⁄-inch/30-mm Hole Saw
15 N-M18-000-016 * 1 ¼-inch/32-mm Hole Saw
16 N-M18-000-021 * 1 ½-inch/38-mm Hole Saw
17 N-M18-000-026 * 1 ¾-inch/45-mm Hole Saw
18 N-M18-000-031 * 2-inch/51-mm Hole Saw
19 N-M18-000-037 * 2 ½-inch/64-mm Hole Saw
20 N-M18-000-040 * 2 ¾-inch/70-mm Hole Saw
‡ The arbor assembly is supplied with the tool.
* Hole saws must be ordered separately.
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
The base will not tighten onto the
pipe. The vise handle has run out of threads. Loosen the vise handle and position one link tighter on the chain slot. Re-tighten the vise handle.
The drill motor will not operate.
The tool is not plugged into the electrical source. Plug the tool into a proper voltage outlet or
extension cord.
The circuit breaker has tripped or a fuse has blown. Test/reset the jobsite breaker, or replace the fuse.
The drill motor’s trigger switch is defective. Factory service is required. Contact Victaulic.
The power cord plug is not making contact with
the receptacle.
Inspect the connection and make repairs, as
necessary.
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TROUBLESHOOTING (CONTINUED)
PROBLEM POSSIBLE CAUSE SOLUTION
The pilot drill will not cut.
The drill motor is running in reverse. Place the drill motor’s switch in the forward position.
The pilot drill is not tight in the arbor. Tighten the arbor’s set screw. Ensure that the arbor is
engaged with the ats of the pilot drill.
The pilot drill is dull. Replace the pilot drill.
The hole saw blade will not cut.
The drill motor is running in reverse. Place the drill motor’s switch in the forward position.
The hole saw blade is dull. Replace the hole saw blade.
One or more teeth have been broken o the hole
saw blade.
Replace the hole saw blade. Inspect the cut for
teeth lodged in the pipe/tubing. Remove lodged
teeth with a center punch or small chisel (wear eye
protection).
The pipe/tubing has a hard spot or a hard weld
seam.
Use a sharp hole saw blade, lubricating the cut
generously with thread-cutting oil. Cut the hole
slowly.
Chips are stuck in the cut. Remove chips from the hole saw’s teeth and the cut.
Excessive torque is required to rotate
the feeder knob.
The drill motor is running in reverse. Place the drill motor’s switch in the forward position.
There is a lack of lubrication on the feeder rod. Lubricate the feeder rod by following the instructions
in the “Maintenance”section.
The gib is too tight. Adjust the gib by following the instructions in the
“Maintenance”section.
The drill motor gets very hot.
Holes are being cut too fast. Feed the hole saw into the cut at a moderate rate.
The hole saw blade is dull. Replace the hole saw blade.
An improper extension cord is being used (cord is
either undersized or too long).
Replace the extension cord with one that is the
proper size and length. Refer to the“Power
Requirements”section.
Excessive side-to-side play is occurring
at the drill motor assembly. The gib is out of adjustment. Adjust the gib by following the instructions in the “Maintenance”section.
The pilot drill does not retain the
coupon. The coupon-retaining drill bit is damaged. Replace the coupon-retaining drill bit.
In the event of tool malfunction outside the scope of the troubleshooting section, contact Victaulic for
assistance.
UPDATED 03/2018
TM-HCT908 3022 REV C RM00908000
VICTAULIC IS A REGISTERED TRADEMARK OF VICTAULIC COMPANY AND/OR ITS AFFILIATED
ENTITIES IN THE UNITED STATES AND/OR OTHER COUNTRIES.
©2018 VICTAULIC COMPANY. ALL RIGHTS RESERVED.
OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL
HCT908 Hole Cutting Tool
TM-HCT908