Magnum 657 High Velocity Drill Rig MAG65701 Owners Manual & Operating Instructions GENERAL SAFETY RULES for ALL POWER TOOLS Work Area • KEEP WORK AREA CLEAN

Magnum 657 High Velocity Drill Rig MAG65701 Owners Manual & Operating Instructions GENERAL SAFETY RULES FOR ALL POWER TOOLS Work Area • KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. • AVOID DANGEROUS ENVIRONMENT. Don’t use power tools in damp or wet locations. Do not expose power tools to rain. Keep work area well lit. • AVOID GASEOUS AREAS. Do not operate portable electric tools in explosive atmospheres in presence of flammable liquids or gases. Motors in these tools normally spark, and the sparks might ignite fumes. • KEEP CHILDREN AWAY. Do not let visitors contact tool or extension cord. All visitors should be kept away from work areas. Personal Safety • GUARD AGAINST ELECTRIC SHOCK. Prevent body contact with grounded surfaces such as pipes, radiators, ranges and refrigerator enclosures. Rubber gloves and non-skid footwear are recommended when working outdoors, where damp or wet ground may be encountered. A Ground Fault Circuit Interrupter protected power line must be used for these conditions. • DRESS PROPERLY. Do not wear loose clothing or jewelry. They can be caught in moving parts. Wear protective hair covering to contain long hair. • USE SAFETY EQUIPMENT. WEAR SAFETY GOGGLES or glasses with side shields. Wear hearing protection during extended use of power tools and dust mask for dusty operations. • STAY ALERT. USE COMMON SENSE. Watch what you are doing. Do not operate tool when you are tired or under influence of drugs. • REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on. • AVOID ACCIDENTAL STARTING. Don’t carry plugged in tool with finger on switch. Be sure the switch is OFF before being plugged in. • DON’T OVERREACH. Keep proper footing and balance at all times. • BEFORE CONNECTING THE TOOL to a power supply (receptacle, outlet, etc.) be sure the voltage supplied is the same as that specified on the tool’s nameplate. A power supply with voltage greater than that specified for the tool can result in serious injury to the user - as well as damage to the tool. If in doubt, DO NOT PLUG IN THE TOOL. Using a power supply with voltage less than the nameplate rating is harmful to the motor. NOTE: “Volts AC” designated tools are for Alternating Current 50-60 Hz only. “Volts DC” designated tools are for Direct Current. Do not use AC designated tools with DC power supply. Do not use electronic speed controlled tools with DC power supply. TOOL USE AND CARE • DON’T FORCE TOOL. It will do the job better and safer at the rate for which it was designed. • USE RIGHT TOOL. Don’t force small tool or attachment to do the job of a heavy-duty tool. Don’t use tool for purpose not intended - for example; don’t use a circular saw for cutting tree limbs or logs. • SECURE WORK. Use clamps or a vise to hold work. It’s safer than using your hand and it frees both hands to operate the tool. • DON’T ABUSE CORD. Never carry tool by cord or yank it to disconnect from receptacle. Keep cord from heat, oil, and sharp edges. Always keep cord away from the spinning blade, bits or any other moving part while the tool is in use. • OUTDOOR USE EXTENSION CORDS. When tool is used outdoors, use only extension cords suitable for use outdoors and marked with suffix W-A (for UL), or W (for CSA). • DISCONNECT TOOLS. When not in use, before servicing, or when changing blades, bits, cutters, etc. • STORE IDLE TOOLS. When not in use, tools should be stored in dry, high or locked up place - out of the reach of children. • DO NOT ALTER OR MUSUSE TOOL. These tools are precision built. Any alterations or modifications not specified is misuse and may result in a dangerous condition. • THE USE OF ANY ACCESSORIES not specified in this manual may create a hazard. • MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricat- ing and changing accessories. Inspect tool cords periodically and if damaged, have repaired by authorized service facility. Inspect extension cords periodically and replace if damaged. Keep handles dry, clean and free from oil and grease. • CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of 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 promptly and properly repaired or replaced. Have defective switches replaced. Do not use tool if switch does not turn it on or off. • ALL REPAIRS, ELECTRICAL OR MECHANICAL, should be attempted only by trained repairmen.

...continued on next page

800.654.0637 • Fax 859.885.1731 [email protected] • www.lockmasters.com

MAG65701INSTPDF 2101 John C.Watts Dr., Nicholasville, KY 40356 Copyright © 2011 Lockmasters Inc. 10/11 Magnum 657 High Velocity Drill Rig MAG65701 continued from previous page... 1. Barrel and Quill 2. Tower 3. Hole Saw Base Plate 1 4. Bolt Hook 5. X-Lock Drill Template 6. s&G Group 1 HR Drill Template 2 7. 8-32 x 3/4” Socket Head Screw (2) 5 6 4 8. 1/2” High Speed Drill Bit 9. chuck Key 3 7 10. 8-32 x 1/2” Socket Head Screw (2) 11. Hex Wrench 10 13 8 9 11 12 14 12. Template Drilling Base 13. #14 x 1” Hex Head Self Drilling Screw (2)

15 16 14. Magnetic Nut Driver 15. Right Hand Magnetic Template 16. Left Hand Magnetic Template

Photo 1 Photo 2 Photo 3 1. Prepare the area of penetration (Remove dial, dial ring, center punch any hole if needed). (Photo 1) 2. Mount the Pattern Drill Template. (Photo 2) The Drill Templates provided with the Magnum High Velocity has been designed for, but not limited to, target specific drill points for the Kaba Mas X07, X08 and X09 locks as well as the Sargent and Greenleaf 8400 and 8500 series locks. See the instruction sheet provided with each template for specific drill points on each lock. 3. Align the selected Drill Template with the dial ring screw holes located on the container. Make sure to orient the arrow on the template the direction the bolt of the combination lock is pointing. 4. Use the (2) 8-32 x 1/2” socket head cap screws to fasten the Drill Template to the door and tighten securely. Photo 4 5. Attach the High Velocity Template Drilling Base over the targeted hole and secure the base to the template using (2) 8/32 x 3/4” socket head cap screw and tighten securely. (Make sure the screw securing the drill bushing is positioned away from the spindle to prevent interference) (Photo 3) 6. Remove the Barrel and Quill from the Tower by depressing the spring loaded coupling ring and pull the barrel completely out of the Tower. 7. Attach the Tower to the to the High Velocity Template Drilling Base by pulling the 2 quick release couplings and pushing them over the stationary couplings attached to the Template Drilling Base. (Photos 4 & 5) 8. Insert your initial drill bit into the drill chuck located on the barrel and Quill assembly. Tighten securely. Photo 5 ...continued on next page

800.654.0637 • Fax 859.885.1731 [email protected] • www.lockmasters.com

Photo 6 Photo 7 Photo 8 9. Insert the Quill into the Tower. (Photo 6) (Note: We recommend starting your hole with a high speed steel or cobalt drill to drill through the milder steel outer skin. This will act as a pilot hole). 10. Insert the Hex drive shaft into your drill motor and then insert the shaft into the Hex drive socket located at the end of the quill. Depress the trigger on the drill to spin the drill bit then slowly begin feeding the drill bit into the container using the handles located on the Quill.* (Photos 7 & 8) 11. Once the hard plate has been reached, switch drill bits to carbide or diamond tip by depressing the coupling ring to remove the Quill from the Tower. It will also be necessary to remove the guide bushing from the drill template. The bushing is designed to keep the high speed drill bit from “walking” as pressure is applied and to drill a pilot hole. Most carbide and diamond drill are slightly oversized and do not fit into the drill bushing. Photo 9 (Photos 9, 10 & 11) 12. You can chuck a carbide or diamatip drill bit into the Barrel and begin cutting the hard plate. Keep in mind the Magnum High Velocity rig will only accept 4” drill bits. 13. Insert Quill into Tower. (Photo 12) 14. Insert the Hex drive shaft into your drill motor and then insert the shaft into the Hex drive socket located at the end of the Quill. Depress the trigger on the drill to spin the drill bit then slowly begin feeding the drill bit into the container using the handles located on the quill.* *One revolution of the red hand is 1/16” of an inch penetration. Overall barrel travel is 2” Photo 10 Remotely mounting the Magnum High Velocity The Magnum High Velocity was designed to be mounted out side the dial ring without using a pattern drill template. This will allow the drill rig to be mounted to the side or top of a container. 1. Locate the two 3/16” holes on the drilling High Velocity Template Drilling Base. 2. Mark the position of these holes after the drilling base has been centered over your desired drill point. 3. Us the self-drilling, self-tapping screw to pre-drill the mounting holes. 4. Once the holes have been drilled and tapped secure the Hole Saw Base Plate to the container using the self-drilling self-tapping screws. Photo 11 5. Attach the Tower to the High Velocity Hole Saw Base Plate by pulling the 2 quick release couplings and pushing them over the stationary couplings attached to the Drilling Base. 6. Insert the Quill into the Tower and begin drilling. Installation and operation for cutting the locking bolts on red label GSA file cabinets. NOTE: These instructions are for the approved opening of the Hamilton Mosler-Diebold GSA Red Label file cabinets by cutting the locking bolts. The High Velocity Drill Rig should not be used for opening vault doors, map and plan containers, GSA black label or non-GSA approved containers. Before attempting to use this method please read the instructions completely and understand them. Once the bolts of the drawer have been cut, the drawer will need to be replaced. Replacement drawers are available through Lockmasters. Photo 12 ...continued on next page

800.654.0637 • Fax 859.885.1731 [email protected] • www.lockmasters.com

Photo 13 Photo 14 Photo 15

For Hamilton Legal Size: Top of drawer head and down 5-3/16”. Edge of drawer inward 5-1/2” for hole saw location. Edge of drawer inward 3-1/4” for Bolt Hook location. For Diebold-Mosler Legal Size Left Hand: Top of drawer head and down 5 7/16”. Edge of drawer inward 5-7/16” for hole saw location. Edge of drawer inward 3-3/16” for Bolt Hook location. For Diebold-Mosler Legal Size Right Hand: Top of drawer head and down 5-7/16”. Edge of drawer inward 6-5/16” for hole saw location. Photo 16 Edge of drawer inward 4-1/16” for Bolt Hook location. 1. Align the magnetic template with the correct side of the container. The templates are labeled at the top and side for both Hamilton and Mosler-Diebold. Make sure you are aware of the size of the container i.e. letter or legal size. (Photo 13) NOTE: If the templates are not available you can measure from the top of the drawer down and from the side of the drawer inward. 2. Center punch the appropriate marks for the hole saw, the base plate holes (2) and the hole for the hook bolt. (Photo 14) 3. Drill the holes for the Bolt Hook (one for each side) using the 1/2” bit supplied with the kit. You only need to drill through the outer skin. (Photo 15) NOTE: For this type of opening a low speed (400-500 r.p.m.) high torque (approximately 7 Photo 17 amp) drill motor is recommended. 4. After drilling the 1/2” bolt hook holes, chuck the bolt driver supplied with the kit into your drill. Then, using the (2) self-drill/self tapping screws supplied with the kit drill the holes, which will hold the Base Plate in place. These can be pre-drilled or hold the base plate into position over the center punched holes, then start the screw in the top hole first and then secure the bottom screw (make sure the Hole Saw Base Plate is straight on the face of the drawer). (Photos 16 & 17) NOTE: Special care must be taken when driving this type of screw. Once the screw starts to tap into the hole on the front of the container, release power from the drill motor or you might strip or break the head off of the screw or even bind the drill causing injury to yourself. 5. A Bolt Hook is supplied with the Magnum High Velocity Kit. The Bolt Hook is designed to secure the bolt being drilled and to prevent the bolt from pinching or binding the hole saw Photo 18 while drilling. This is one of the most important components in the kit. 6. Insert the Bolt Hook into the 1/2” hole with the handle pointing down and the end of the hook at the hole. The handle will need to be aligned so that the tip of the hook can be inserted into the hole. Once inserted, rotate the hook up and around and loop the bolt. Once the bolt is hooked tighten the two plastic handles against the front of the drawer. Make sure both are tight to prevent the Bolt Hook from loosening up while drilling. (Photo 18, 19 & 20) ...continued on next page

800.654.0637 • Fax 859.885.1731 [email protected] • www.lockmasters.com

Photo 22

Photo 19 Photo 20 Photo 21

7. Attach the Tower to the to the Magnum High Velocity Hole Saw Base Plate by pulling the 2 quick release couplings and pushing them over the stationary couplings attached to the Base Plate. (Photo 21) 8. Depress the quick disconnect coupling ring on the frame and insert the quill into the Tower without the hole saw attached. (Photo 22) Photo 23 9. Once the chuck on the Quill has cleared the coupling, insert the Bi-metal High Speed Hole Saw into the chuck and tighten securely. (Photo 23) 10. Insert the Hex Drive Shaft into your drill motor and tighten, then insert the Hex Drive Shaft into the Hex Drive Socket located at the end of the Quill. Depress the trigger on the drill to spin the hole saw then slowly begin feeding the hole saw into the container using the handles located on the Quill. Cut the outer skin of the container only. ( Photos 24 & 25) 11. Once the hole is through the outer skin, replace the High Speed Hole Saw with a Carbide Tipped Hole Saw. The width of the teeth on the carbide saw are a little wider and might catch on the outside of the container, continue to feed the saw into the hole until you Photo 24 have cleared the outside hole. Before you start cutting the bolts check the Bolt Hook and make sure it’s still tight. 12. Begin feeding the carbide saw until it engages the bolt, the saw may vibrate and chatter until it begins cutting a groove in the bolt. When drilling into the bolts try not to exceed 450 RPM’s with steady pressure. Once you start cutting a bolt try not to stop, the bolts are work hardened and if you allow it to cool it will only get harder to cut. On average it will take appox.5 -15 minutes to cut a single bolt. ( Photo 26 & 27) 13. Once the bolt has been cut you’ll want to remove the hole saw from the container as soon as possible to prevent it from becoming stuck inside the container. The cutting action creates Photo 25 excessive heat, which expands the metal saw. It can also damage the hole saw, be sure to inspect the saw for warps and cracks. If you see evidence of this do not use the saw to cut the next bolt. You should always have a supply of both types of hole saws. NOTE: if you can gauge the depth of cut it is possible to stop a 1/16th of an inch short of severing the bolt. Back out the saw and break out the bolt with a hammer and chisel. This will extend the life of the carbide saw. 14. Set up for the other side of the container and drill that bolt as well. Once both bolts are cut, the handle of the container can be used to open the drawer.

...continued on next page Photo 26

Photo 27

800.654.0637 • Fax 859.885.1731 [email protected] • www.lockmasters.com

HELPFUL HINTS ON HARDPLATES AND BARRIER MATERIALS “Hardplate” is a generic term used to describe barrier materials in safes and vaults. Its purpose is to protect the lock(s), relock device(s) and/or boltwork against attempted penetration by drilling, torching, etc. Most safes have hardplate only in the door. High- Security safes have this type of material on all sides, and so are said to provide “six-sided” protection. Case Hardened Tool Steel is commonly used as a barrier material in lower-grade safes. It is hardened on the surface only, and once this is penetrated should drill easily. Depending on how hard it is, it may be drilled with cobalt or carbide-tipped bits. Stainless Steel is non-magnetic and has a slight yellowish tint. It is tough, but not hard. It may be drilled with a cobalt bit, without needing a drill rig. Manganese Steel will “work harden” as it is drilled. That is, the heat of drilling will leave the material harder than it was before. Slow speed (rpms) should be used, and once drilling is begun, it should be continued nonstop until the hole is through. Flame Sprayed Carbide hardplate consists of small carbide chips flame sprayed onto steel plate. This can be drilled with carbide tipped bits, but it will dull them. A drill rig, medium to heavy pressure and low rpms, and possibly more than one bit, are required. Relsomite is a hard surfacing material bonded to a base metal. It can be drilled with a carbide-tipped drill bit and a fixed drill rig. Use 1000 rpm or less, and steady medium to heavy pressure. If one bit wears out before penetrating, punch the hole sharply with a pointed punch, attempting to crack the surface. Continue drilling with another carbide-tipped bit. Kymloy is made by bonding together tungsten carbide fragments and steel powder. It can be drilled with a drill rig and carbide-tipped drill bit. Carbide Welded hardplate is made by welding a carbide material onto a steel plate. When this is used in a safe, the carbide side will be what the drill hits first. A fixed drill rig, carbide-tipped bits, and low rpm drilling, combined with lots of punching, will succeed. Alternating bits with different tip angles is often helpful. This may be drilled quicker and more easily with a diamond-tipped core drill, after a carbide-tipped bit is used to smooth the surface. Use a fixed drill rig, slow speed (no more than 500 rpm) and light pressure. After the carbide chip portion has been drilled, use a hole saw of the same diameter to remove the core which has been cut or simply break off the core. Half an hour or more may be necessary to penetrate the hardplate. Carbide Matrix hardplates, such as Shwayder’s “Maxalloy” (also known as “Relsom”) are made by sprinkling carbide chips in a mild steel pan of copper wash. These can be identified by the copper color of the material, and by the way it gouges drill bits. This cannot be penetrated by drilling alone, even if carbide-tipped bits are used. Punching will be necessary to break up and dislodge the carbide chips, and the drilling and punching are alternated and continued until the hole is completed. A diamond-tipped core drill may also be used. Carbide Rods are sometimes used in the door or in the safe, inserted side by side in parallel holes. Punching will fracture these, and alternating drilling and punching will penetrate them. Ceramics are usually white. They are very hard but also very brittle, and may be penetrated by alternating punching and drilling. Punching will fracture and crush ceramics. The pieces may be blown or probed from the hole. Composite materials are used on many high security safes. These will have hardened nuggets of various types bonded within aluminum, steel or some other substance. Drilling composites requires close attention to the progress of the hole and condition of the tip of the bit, to learn what material is being encountered. Punching may be necessary to break or dislodge hardened inclusions. Ball Bearings may be used as a barrier material. Sometimes the ball bearings are bound in an epoxy-like layer. This material pro- tects against radiological (X-Ray) attack as well as drilling. It can be drilled, using slow forward speed and prying out ball bearings as they become loose. An envelope of loose ball bearings has been used to deter drilling. The ball bearings may be removed with a mag- net, or held out of the way with glue. LaGard made a hardplate which sandwiches a layer of ball bearings between two dimpled pieces of Zamac. This hardplate may be drilled using a drill rig, moderate to heavy pressure and a carbide-tipped drill bit. Rough-Surface materials present certain difficulties because the bit does not contact the surface evenly. This would be the case with a welded-surface or open-faced carbide matrix hardplate. It is essential that a pocket be formed in the material in order to drill it. Often this may be done by using an already-dull bit to wear off the rough surface of the hardplate. Offset surfaces must sometimes be overcome. The offset is intended to push a drill off course or break the bit. When in doubt about the material being drilled, look in the hole to detect such surfaces. Drilling with slow feed is the best way to deal with these. Angled materials, called deflectors, may be built into the safe to discourage drilling. Use a sharp carbide-tipped bit and light pressure to form a pocket in the material. Once the pocket is formed, drill as usual. There may be more than one of these, so check with a scope after penetrating each one. Torch-Resistant materials are sometimes found in higher-rated safes. A layer of copper or aluminum will dissipate heat rapidly, preventing a torch from melting the material. Sometimes a layer of rubber will be used, and attempts to penetrate it by torching will release smoke. This will be noticeable and would be detected by a smoke alarm. The smoke would also make breathing difficult for the technician.

800.654.0637 • Fax 859.885.1731 [email protected] • www.lockmasters.com