Xcalibre MAGNUM Maintenance and service guide

MAGNUM
MAG 5, 10, 15, 24
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
Safety and operating instructions
Handheld core drills
FR
Prescriptions de sécurité et instructions pour
l’opérateur
Trépan hydraulique
DE
Sicherheits- und Betriebsanleitung
Hydraulischer Kernbohrer
ES
Instrucciones de seguridad y de funcionamiento
Perforadora hidráulica de muestras
PT
Instruções de segurança e operação
Caroteadora
IT
Istruzioni per la sicurezza e per l'uso
Carotatrice idraulica
NL
Veiligheidsvoorschriften en bedieningshandleiding
Hydraulische kernboor
GR
Οδηγίες ασφάλειας και χειρισμού
Υδραυλικό σωληνοειδές τρυπάνι
FI
Turvallisuusohjeet ja käyttöohje
Hydraulinen kairauskone
DK
Sikkerhedsinstruktioner og betjeningsvejledning
Hydraulisk kernebor
SE
Säkerhetsinstruktion och instruktionsbok
Hydraulisk kärnborrmaskin

Contents
MAG 5, 10, 15, 24
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
3
Introduction...................................................................................................................................................... 5
About the Safety and operating instructions ............................................................................................... 5
Safety instructions .......................................................................................................................................... 6
Safety signal words......................................................................................................................................... 6
Personal precautions and qualifications......................................................................................................... 6
Personal protective equipment .................................................................................................................... 6
Drugs, alcohol or medication ....................................................................................................................... 6
Installation, precautions.................................................................................................................................. 6
Operation, precautions ................................................................................................................................... 6
Maintenance, precautions............................................................................................................................. 10
Storage, precautions..................................................................................................................................... 10
Overview......................................................................................................................................................... 11
Design and function...................................................................................................................................... 11
Main parts ..................................................................................................................................................... 11
Labels ........................................................................................................................................................... 12
Serial number plate.................................................................................................................................... 12
Safety label ................................................................................................................................................ 12
Data label................................................................................................................................................... 12
Installation...................................................................................................................................................... 12
Hoses............................................................................................................................................................ 12
Quick-release couplings ............................................................................................................................... 12
Hydraulic oil .................................................................................................................................................. 13
Pressure adjustment..................................................................................................................................... 13
Water flushing............................................................................................................................................... 13
Drill bit........................................................................................................................................................... 14
Choosing drill bit ........................................................................................................................................ 14
Fitting and removing the drill bit................................................................................................................. 14
Operation........................................................................................................................................................ 14
Preparations before starting ......................................................................................................................... 14
Check the drilling equipment ..................................................................................................................... 14
Start and stop................................................................................................................................................ 14
Operating...................................................................................................................................................... 14
Before drilling............................................................................................................................................. 14
Starting a cut.............................................................................................................................................. 14
Drilling........................................................................................................................................................ 15
When taking a break..................................................................................................................................... 15
Maintenance................................................................................................................................................... 15
Every day...................................................................................................................................................... 15
Periodic maintenance ................................................................................................................................... 15
Storage............................................................................................................................................................ 15
Disposal.......................................................................................................................................................... 15
Technical data................................................................................................................................................ 16
Troubleshooting............................................................................................................................................ 16
Machine data ................................................................................................................................................ 16
Noise and vibration data............................................................................................................................... 17
Vibration declaration statement .................................................................................................................... 17
EC Declaration of Conformity ...................................................................................................................... 18
EC Declaration of Conformity (EC Directive 2006/42/EC)............................................................................ 18

MAG 5, 10, 15, 24
Safety and operating instructions
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
5
Introduction
Thank you for choosing a product from Xcalibre Equipment.
Since 1987, we have been committed to finding new and better ways of fulfilling our customers' needs.
We design and manufacture high quality, hydraulically powered diamond coring trailers, diamond drilling rigs,
drill stands, hand held diamond core drills and power packs for civil, marine and all types of construction
industries.
Our key emphasis on the performance of coring drilling equipment is:
oFunctionality
oReliability
oEfficiency
oUtmost drilling performance
oSafety
Through the years, we have developed innovative and ergonomic product designs that have helped
customers, in more than 26 countries worldwide, improve and rationalize their daily work. Our experts are
highly trained professionals with extensive product knowledge and application experience.
For more information please visit: www.xcalibre-equipment.com
Xcalibre Equipment Ltd
Merlin House
Channel Way
Coventry CV6 6RH
United Kingdom
About the Safety and operating instructions
The aim of the instructions is to provide you with knowledge of how to use the core drill in an efficient, safe
way. The instructions also give you advice and tell you how to perform regular maintenance on the core drill.
Before using the core drill for the first time you must read these instructions carefully and understand all of
them.

Safety and operating instructions
MAG 5, 10, 15, 24
6
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
Safety instructions
To reduce the risk of serious injury or death to
yourself or others, read and understand the Safety
and operating instruction before installing,
operating, repairing, maintaining, or changing
accessories on the machine.
Post this Safety and operating instruction at work
locations, provide copies to employees, and make
sure that everyone reads the Safety and operating
instruction before operating or servicing the
machine.
In addition, the operator or the operator's employer
must assess the specific risks that may be present
as a result of each use of the machine.
Safety signal words
The safety signal words Danger, Warning and
Caution have the following meanings:
DANGER Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
WARNING Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
CAUTION Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Personal precautions and
qualifications
Only qualified and trained persons may operate or
maintain the machine. They must be physically
able to handle the bulk, weight, and power of the
tool. Always use your common sense and good
judgement.
Personal protective equipment
Always use approved protective equipment.
Operators and all other persons in the working
area must wear protective equipment, including at
a minimum:
•Protective helmet
•Hearing protection
•Impact resistant eye protection with side
protection
•Respiratory protection when appropriate
•Protective gloves
•Proper protective boots
•Appropriate work overall or similar clothing (not
loose-fitting) that covers your arms and legs.
Drugs, alcohol or medication
▲WARNING Drugs, alcohol or medication
Drugs, alcohol or medication may impair your
judgment and powers of concentration. Poor
reactions and incorrect assessments can lead to
severe accidents or death.
►Never use the machine when you are tired or
under the influence of drugs, alcohol or
medication.
►No person who is under the influence of drugs,
alcohol or medication may operate the machine.
Installation, precautions
▲WARNING Moving or slipping insertion
tool
An incorrect dimension of the inserted tool’s shank
can result in that the inserted tool is lost or is
slipping out during operation. Risk of severe injury
or crushed hands and fingers.
►Check that the insertion tool has the shank
length and dimensions that the machine is
intended for.
►Never use an insertion tool without a collar.
▲CAUTION Moving parts
Risk for crushed hands and fingers.
►Never check bores or passages with hands or
fingers.
Operation, precautions
▲DANGER Explosion hazard
If a warm insertion tool comes into contact with
explosives, an explosion could occur. During
operation with certain materials as well as use of
certain materials in machine parts, sparks and
ignition can occur. Explosions will lead to severe
injuries or death.
►Never operate the machine in any explosive
environment.
►Never use the machine near flammable
materials, fumes or dust.
►Make sure that there are no undetected sources
of gas or explosives.
►Never drill in an old hole.

MAG 5, 10, 15, 24
Safety and operating instructions
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
7
▲WARNING Unexpected movements
The inserted tool is exposed to heavy strains when
the machine is used. The inserted tool may break
due to fatigue after a certain amount of use. If the
inserted tool breaks or gets stuck, there may be
sudden and unexpected movement that can cause
injuries. Furthermore, losing your balance or
slipping may cause injury.
►Make sure that you always keep a stable
position with your feet as far apart as your
shoulder width, and keeping a balanced body
weight.
►Always inspect the equipment prior to use.
Never use the equipment if you suspect that it is
damaged.
►Make sure that the handles are clean and free of
grease and oil.
►Keep your feet away from the inserted tool.
►Stand firmly and always hold on to the machine
with both hands.
►Never drill in an old hole.
►Never start the machine when it is lying on the
ground.
►Never ‘ride’ on the machine with one leg over
the handle.
►Never strike or abuse the equipment.
►Check regularly for wear on the insertion tool,
and check whether there are any signs of
damage or visible cracks.
►Pay attention and look at what you are doing.
▲WARNING Stalling hazard
If the insertion tool gets caught during operation,
the whole machine will start to rotate if you lose
your grip on it. This unexpected rotation of the
entire machine may cause serious injury or death.
►Stand firmly and always hold onto the machine
with both hands.
►Make sure that the handle or handles are clean
and free from grease and oil.
►Never drill in an old hole.
▲WARNING Trapping hazard
There is risk of neck ware, hair, gloves and clothes
getting dragged into or caught by a rotating
insertion tool or accessories. This may cause
choking, scalping, lacerations or death. To reduce
the risk:
►Never grab or touch a rotating drill steel.
►Avoid wearing clothing, neck ware or gloves that
may get caught.
►Cover long hair with a hair net.
▲WARNING Dust and fume hazard
Dusts and/or fumes generated or dispersed when
using the machine may cause serious and
permanent respiratory disease, illness, or other
bodily injury (for example, silicosis or other
irreversible lung disease that can be fatal, cancer,
birth defects, and/or skin inflammation).
Some dusts and fumes created by drilling,
breaking, hammering, sawing, grinding and other
construction activities contain substances known to
the State of California and other authorities to
cause respiratory disease, cancer, birth defects, or
other reproductive harm. Some examples of such
substances are:
•Crystalline silica, cement, and other masonry
products
•Arsenic and chromium from chemically-treated
rubber
•Lead from lead-based paints
Dust and fumes in the air can be invisible to the
naked eye, so do not rely on eye sight to
determine if there is dust or fumes in the air.
To reduce the risk of exposure to dust and fumes,
do all of the following:
►Perform site-specific risk assessment. The risk
assessment should include dust and fumes
created by the use of the machine and the
potential for disturbing existing dust.
►Use proper engineering controls to minimize the
amount of dust and fumes in the air and to
minimize build-up on equipment, surfaces,
clothing, and body parts. Examples of controls
include: exhaust ventilation and dust collection
systems, water sprays, and wet drilling. Control
dusts and fumes at the source where possible.
Make sure that controls are properly installed,
maintained and correctly used.
►Wear, maintain and correctly use respiratory
protection as instructed by your employer and
as required by occupational health and safety
regulations. The respiratory protection must be
effective for the type of substance at issue (and
if applicable, approved by relevant governmental
authority).
►Work in a well ventilated area.
►If the machine has an exhaust, direct the
exhaust so as to reduce disturbance of dust in a
dust filled environment.
►Operate and maintain the machine as
recommended in the operating and safety
instructions.
►Select, maintain and replace consumables/
inserted tools/ other accessory as
recommended in the operating and safety
instructions. Incorrect selection or lack of
maintenance of consumables/ inserted tools/
other accessories may cause an unnecessary
increase in dust or fumes.

Safety and operating instructions
MAG 5, 10, 15, 24
8
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
►Wear washable or disposable protective clothes
at the worksite, and shower and change into
clean clothes before leaving the worksite to
reduce exposure of dust and fumes to yourself,
other persons, cars, homes, and other areas.
►Avoid eating, drinking, and using tobacco
products in areas where there is dust or fumes.
►Wash your hands and face thoroughly as soon
as possible upon leaving the exposure area, and
always before eating, drinking, using tobacco
products, or making contact with other persons.
►Comply with all applicable laws and regulations,
including occupational health and safety
regulations.
►Participate in air monitoring, medical
examination programs, and health and safety
training programs provided by your employer or
trade organizations and in accordance with
occupational health and safety regulations and
recommendations. Consult with physicians
experienced with relevant occupational
medicine.
►Work with your employer and trade organization
to reduce dust and fume exposure at the
worksite and to reduce the risks. Effective health
and safety programs, policies and procedures
for protecting workers and others against
harmful exposure to dust and fumes should be
established and implemented based on advice
from health and safety experts. Consult with
experts.
▲WARNING Projectiles
Failure of the work piece, of accessories, or even
of the machine itself may generate high velocity
projectiles. During operating, splinters or other
particles from the working material may become
projectiles and cause personal injury by striking the
operator or other persons. To reduce these risk:
►Use approved personal protective equipment
and safety helmet, including impact resistant
eye protection with side protection.
►Make sure that no unauthorised persons
trespass into the working zone.
►Keep the workplace free from foreign objects.
►Ensure that the work piece is securely fixed.
▲WARNING Splinters hazard
Using the insertion tool as a hand struck tool can
result in splinters hitting the operator and can
cause personal injury.
►Never use an insertion tool as a hand struck
tool. They are specifically designed and heat-
treated to be used only in a machine.
▲WARNING Slipping, tripping and falling
hazards
There is a risk of slipping or tripping or falling, for
example tripping on the hoses or on other objects.
Slipping or tripping or falling can cause injury. To
reduce this risk:
►Always make sure that no hose or other object
is in your way or in any other person's way.
►Always make sure you are in a stable position
with your feet as far apart as your shoulders
width and keeping a balanced body weight.
▲WARNING Motion hazards
When using the machine to perform work-related
activities, you may experience discomfort in the
hands, arms, shoulders, neck, or other parts of the
body.
►Adopt a comfortable posture whilst maintaining
secure footing and avoiding awkward off-
balanced postures.
►Changing posture during extended tasks may
help avoid discomfort and fatigue.
►In case of persistent or recurring symptoms,
consult a qualified health professional.
▲WARNING Hydraulic oil
Spilled hydraulic oil can cause burns, accidents
due to slippery conditions and will also harm the
environment.
►Take care of all spilled oil and handle it
according to your safety and environmental
regulations.
►Never dismount the hydraulic machine when the
hydraulic oil is hot.
►Never run any hydraulic lines for attachment of
the hydraulic machine through the drivers cab.
▲WARNING Hydraulic oil at high pressure
Thin jets of hydraulic oil under high pressure can
penetrate the skin and cause permanent damage.
►Immediately consult a doctor if hydraulic oil has
penetrated the skin.
►Never use your fingers to check for hydraulic
fluid leaks.
►Keep your face away from any possible leaks.

MAG 5, 10, 15, 24
Safety and operating instructions
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
9
▲WARNING Vibration hazards
Normal and proper use of the machine exposes
the operator to vibration. Regular and frequent
exposure to vibration may cause, contribute to, or
aggravate injury or disorders to the operator’s
fingers, hands, wrists, arms, shoulders and/or
nerves and blood supply or other body parts,
including debilitating and/or permanent injuries or
disorders that may develop gradually over periods
of weeks, months, or years. Such injuries or
disorders may include damage to the blood
circulatory system, damage to the nervous system,
damage to joints, and possibly damage to other
body structures.
If numbness, persistent recurring discomfort,
burning sensation, stiffness, throbbing, tingling,
pain, clumsiness, weakened grip, whitening of the
skin, or other symptoms occur at any time, when
operating the machine or when not operating the
machine, stop operating the machine, tell your
employer and seek medical attention. Continued
use of the machine after the occurrence of any
such symptom may increase the risk of symptoms
becoming more severe and/or permanent.
Operate and maintain the machine as
recommended in these instructions, to prevent an
unnecessary increase in vibration.
The following may help to reduce exposure to
vibration for the operator:
►Let the tool do the job. Use a minimum hand
grip consistent with proper control and safe
operation.
►If the machine has vibration absorbing handles,
keep them in a central position, avoid pressing
the handles into the end stops.
►When the percussion mechanism is activated,
the only body contact with the machine you
should have are your hands on the handle or
handles. Avoid any other contact, for example
supporting any part of the body against the
machine or leaning onto the machine trying to
increase the feed force. It is also important not
to keep the start and stop device engaged while
extracting the tool from the broken work surface.
►Make sure that the inserted tool is well-
maintained (including sharpness, if a cutting
tool), not worn out, and of the proper size.
Insertion tools that are not well-maintained, or
that are worn out, or that are not of the proper
size result in longer time to complete a task (and
a longer period of exposure to vibration) and
may result in or contribute to higher levels of
vibration exposure.
►Immediately stop working if the machine
suddenly starts to vibrate strongly. Before
resuming the work, find and remove the cause
of the increased vibrations.
►Never grab, hold or touch the inserted tool when
using the machine.
►Participate in health surveillance or monitoring,
medical exams and training programs offered by
your employer and when required by law.
►When working in cold conditions wear warm
clothing and keep hands warm and dry.
See the ‘Noise and vibration declaration statement’
for the machine, including the declared vibration
values. This information can be found at the end of
these Safety and operating instructions.
▲WARNING Electrical hazard
The machine is not electrically insulated. If the
machine comes into contact with electricity, serious
injuries or death may result.
►Never operate the machine near any electric
wire or other source of electricity.
►Make sure that there are no concealed wires or
other sources of electricity in the working area.
▲WARNING Concealed object hazard
During operating, concealed wires and pipes
constitute a danger that can result in serious injury.
►Check the composition of the material before
operating.
►Watch out for concealed cables and pipes for
example electricity, telephone, water, gas and
sewage lines etc.
►If the inserted tool seems to have hit a
concealed object, switch off the machine
immediately.
►Make sure that there is no danger before
continuing.
▲WARNING Operating pressure
If the maximum operating pressure for the
hydraulic machine is exceeded, it can result in
material damage and personal injury.
►Always run the hydraulic machine with the
correct operating pressure, see ‘Technical data’.
►Only readjust the pressure relief valve (torque
control) on the machine according to procedure
and values described under maintenance. Note
that higher settings might lead to a higher
torque, which could harm the machine and
result in serious injury or death.
▲WARNING Involuntary start
Involuntary start of the machine may cause injury.
►Keep your hands away from the start and stop
device until you are ready to start the machine.
►Learn how the machine is switched off in the
event of an emergency.

Safety and operating instructions
MAG 5, 10, 15, 24
10
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
►Release the start and stop device immediately in
all cases of power supply interruption.
►Whenever fitting or removing the insertion tool,
switch off the air supply, bleed the machine by
pressing the start and stop device and
disconnect the machine from the power source.
▲WARNING Whipping hydraulic hose
Hydraulic hoses under pressure can whip
uncontrollably if screws loosen or are loosened.
A whipping hydraulic hose can cause severe
injuries.
►Depressurise the hydraulic system before
loosening the connection of a hydraulic hose.
►Tighten the nuts on the connections of the
hydraulic hoses to the required torque.
►Check that the hydraulic hose and the
connections are not damaged.
▲WARNING Noise hazard
High noise levels can cause permanent and
disabling hearing loss and other problems such as
tinnitus (ringing, buzzing, whistling, or humming in
the ears). To reduce risks and prevent an
unnecessary increase in noise levels:
►Risk assessment of these hazards and
implementation of appropriate controls is
essential.
►Operate and maintain the machine as
recommended in these instructions.
►Select, maintain and replace the insertion tool
as recommended in these instructions.
►If the machine has a silencer, check that it is in
place and in good working condition.
►Always use hearing protection.
►Use damping material to prevent work pieces
from 'ringing'.
Maintenance, precautions
▲WARNING Machine modification
Any machine modification may result in bodily
injuries to yourself or others.
►Never modify the machine. Modified machines
are not covered by warranty or product liability.
►Always use original parts, insertion tools and
accessories approved by Xcalibre Equipment.
►Change damaged parts immediately.
►Replace worn components in good time.
▲WARNING Hot insertion tool
The tip of the insertion tool can become hot and
sharp when used. Touching it can lead to burns
and cuts.
►Never touch a hot or sharp insertion tool.
►Wait until the insertion tool has cooled down
before carrying out maintenance work.
▲WARNING Insertion tool hazards
Accidental engagement of the start and stop
device during maintenance or installation can
cause serious injuries, when the power source is
connected.
►Never inspect, clean, install, or remove the
insertion tool while the power source is
connected.
Storage, precautions
►Keep the machine and tools in a safe place, out
of the reach of children and locked up.

MAG 5, 10, 15, 24
Safety and operating instructions
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
11
Overview
To reduce the risk of serious injury or death to
yourself or others, read the Safety instructions
section found on the previous pages of this manual
before operating the machine.
Design and function
MAG 5, MAG 10, MAG 15 and MAG 24 are sturdy
and reliable core drills designed for working
together with Xcalibre Equipment power packs or
other high quality power packs. The core drills are
small and flexible machines with a high
performance compared to the weight.
The core drills are designed for water flushed
diamond drilling but can also be used for dry
drilling applications, which will not harm the seals.
With prolonged use in dry drilling applications, the
housing and shaft may become extremely warm. If
this occurs, remove the drill bit and run water
through the housing and shaft for one minute to
dissipate the built up heat.
The core drills can be used in drilling rigs. The
bearing housing is designed with a 60 mm
cylindrical surface that fits into industry standard
drilling rig mounting collars.
The directly driven hydraulic power design
provides consistent rotation and torque when
drilling in concrete, brickwork, or blocks for
example.
The core drills can without any problems be used
for underwater drilling in both salt and freshwater.
They are designed for all kind of construction jobs.
No other use is permitted.
Never use the core drill as a rotation movement
supplier for other equipment.
To choose the correct insertion tool, see the spare
part list or the accessories catalogue.
The core drills are delivered with: 1.5 m 3/8 inch
tail-hoses with 1/2 inch 'Flat-Face' quick-release
couplings.
Main parts
A. Handle
B. Trigger
C. Adaptor
D. Breast plate
E. Pressure relief valve
F. Handle ring
G. Front handle
H. Hydraulic hose
I. Water hose
J. Water valve
K. Water connection
L. Front bearing housing 60 mm diameter
M. Trigger lock button
C
A
B
D
E
F
G
H
I
J
K
L
M

Safety and operating instructions
MAG 5, 10, 15, 24
12
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
Labels
The machine is fitted with labels containing
important information about personal safety and
machine maintenance. The labels shall be in such
condition that they are easy to read. New labels
can be ordered from the spare parts list.
Serial number plate
A. Serial number
B. The CE symbol means that the machine is
EC-approved. See the EC declaration
which is delivered with the machine for
more information.
Safety label
Data label
A. Maximum permitted hydraulic oil flow
B. Machine weight with adaptor and hoses
C. Machine type
D. RPM at permitted hydraulic oil flow
Installation
Hoses
For connection on the machine, the hydraulic hose
must be approved for a working pressure of at
least 160 bar (2300 psi) and have a 1/2 inch inner
diameter. To resist exterior wear and tear, we
recommend using a 2-layer hydraulic hose. The
machine connection marked P (pump) is the oil
inlet, and the connection marked T (tank) is the oil
outlet. Always connect both hoses and make sure
that all hose connections are tight. Never carry the
machine by the hose.
Quick-release couplings
The original Xcalibre Equipment hydraulic hoses
are fitted with Flat-Face quick-release couplings
that are strong and easy to clean. The quick-
release couplings are fitted so that the male
connection supplies oil and the female connection
receives oil.
NOTICE Wipe all couplings clean before
connecting. Ensure that couplings are clean and
correctly engaged before operation. Failure to do
so may result in damage to the quick couplings
and cause overheating and cause foreign matter to
enter the hydraulic system.
B
A
D
C
B
A

MAG 5, 10, 15, 24
Safety and operating instructions
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
13
Hydraulic oil
In order to protect the environment, Xcalibre
Equipment recommends the use of biologically
degradable hydraulic oil. No other fluids should be
used.
•Viscosity (preferred) 20-40 cSt.
•Viscosity (permitted) 15-100 cSt.
•Viscosity index Min. 100.
Standard mineral or synthetic oil can be used.
Make sure to only use clean oil and filling
equipment.
When the machine is used continuously, the oil
temperature will stabilise at a level which is called
the working temperature. This will, depending on
the type of work and the cooling capacity of the
hydraulic system, be between 20-40°C (68-104°F)
above the ambient temperature. At working
temperature, the oil viscosity must lie within the
preferred limits. The viscosity index indicates the
connection between viscosity and temperature. A
high viscosity is therefore preferred, because the
oil can then be used within a wider temperature
range. The machine shall not be used, if oil
viscosity fails to remain within the permitted area,
or if the working temperature of the oil does not fall
between 20°C (68°F) and 70°C (158°F).
Pressure adjustment
The maximum pressure of the power source is
important. The pressure created in case of an
incorrectly or unfitted return line coupling would
cause overloading which could harm the machine
and result in bodily injuries. The maximum
pressure of the power source is 160 bar (limited by
safety valve adjustment).
▲WARNING Operating pressure
If the maximum operating pressure for the
hydraulic machine is exceeded, it can result in
material damage and personal injury.
►Always run the hydraulic machine with the
correct operating pressure, see 'Technical data'.
►Only readjust the pressure relief valve (torque
control) on the machine according to procedure
and values described under maintenance. Note
that higher settings might lead to a higher
torque, which could harm the machine and
result in serious injury or death.
Water flushing
For diamond bit core drilling, water flushing is
required. Mount the water swivel and water hose
on the core drill as follows.
The water can be supplied directly from a source,
or a separate water kit can be used. A separate
water kit with pressure tank is available, see the
spare parts list.

Safety and operating instructions
MAG 5, 10, 15, 24
14
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
Drill bit
Choosing drill bit
A correct drill bit is a condition for good operation.
To avoid unnecessary machine damage, it is
important to choose drill bits with a high quality.
Fitting and removing the drill bit
Smaller diameter drill bits are fitted directly into the
machine drive shaft (1/2 inch BSP). For larger
diameter drill bits, use an 1/2 inch BSP male x
1.1/4 inch UNC male drive adaptor, which is
included with the machine.
To prevent an accidental start:
1) Switch off the power supply and
disconnect the machine from the power
source.
2) Screw the drill bit into the machine.
3) Lock the spindle using a spanner and
tighten the drill bit.
4) Bleed the machine by pressing the start
and stop device.
NOTICE Never cool a hot insertion tool in water; it
can result in brittleness and early failure.
Operation
▲WARNING Involuntary start
Involuntary start of the machine may cause injury.
►Keep your hands away from the start and stop
device until you are ready to start the machine.
►Learn how the machine is switched off in the
event of an emergency.
►Stop the machine immediately in all cases of
power supply interruption.
NOTICE Never exceed the maximum flow for the
machine, as this might lead to failure of the drill bit
and damage to the machine.
Preparations before starting
Check the drilling equipment
oCheck that all of the drilling equipment is in a
good condition.
oInspect the hoses generally for signs of damage.
oCheck that the drill bit is in a good condition and
has the correct diameter for the size of the core
drill.
oClean all safety labels. Replace any that are
missing or cannot be read.
oEnsure that the hydraulic couplings are clean
and fully serviceable.
oEnsure that the fittings are tight and leak-proof.
oAlways use the core drill with a front handle
mounted, to absorb the reaction torque.
oScrew the drill bit into the nose end drive of the
shaft and tighten by means of a spanner.
oCheck that the core drill is not blocked and that
water flows through without obstruction.
oEnsure that the power source to be used is
compatible with the machine model, see the
‘Technical data’.
oXcalibre Equipment recommends using an oil
flow divider, if the flow from the power source
can exceed the maximum allowed oil flow.
Start and stop
oStart the machine by pressing the trigger while
firmly holding the handle. By gradually applying
pressure on the trigger, the speed may be
reduced to obtain a soft start.
oStop the machine by releasing the trigger. The
trigger returns automatically to the stop position.
When the work is done, stop the power source.
Disconnect the hoses and fit the protective caps
to the quick-release couplings.
Operating
Before drilling
1. Connect the hydraulic hoses.
2. Connect the water hose to the water tap.
3. Screw the handle lightly into the handle
ring and place the handle in a position that
is comfortable for the operator.
4. Lock the handle ring in this position by
tightening the handle to grip the bearing
housing. Ensure that the handle remains
locked throughout the drilling operation.
5. Start the power source.
6. Activate the water supply.
Starting a cut
oStand steady and make sure that your feet and
hands are at a safe distance from the drill bit.
oTo start the drilling it is advisable to either turn
the core drill to one side in order to obtain an
initial groove and then slowly return to horizontal
or vertical position as soon as the drill bit has
engaged in the material to be drilled, or provide
a guide to stop the drill bit skidding across the
surface of the material to be drilled.

MAG 5, 10, 15, 24
Safety and operating instructions
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
15
Drilling
oSpirit levels are provided in the handle of the
drill to facilitate accurate horizontal & vertical
drilling.
oWhen the drill has started to cut, increased axial
pressure should be applied to the drill using the
breast plate (D) to obtain greater horizontal or
vertical pressure and the trigger (B) held fully in
for maximum rotational speed.
oFor optimum results do not push so hard that
the core bit slows down.
oShould the core drill jam in the hole, release the
trigger (B) and also any axial pressure on the
drill, re-apply trigger pressure and when the drill
is rotating once more re-apply axial pressure.
The normal cause of jamming is the operator
pushing the drill off line.
oTo mount the drill in a drill rig use the 60 mm
(2.5") diameter on the front of the bearing
housing (K) which is sized to the industry
standard drilling rig mounting collar.
oThe trigger (B) is fitted with a lock button (M),
which should only be used when the drill is
mounted in a drilling rig. To engage the lock
mechanism, pull the trigger fully back press the
button into the groove on the trigger and while
keeping the button depressed allow the trigger
to move forward until the spring engages in the
groove to lock the trigger. The trigger may be
released by pulling fully back to release the
spring & then releasing as normal.
When taking a break
oDuring all breaks you must place the machine in
such a way that there is no risk for it to be
unintentionally started. Make sure to place the
machine on the ground, so that it can not fall.
oIn the event of a longer break or when leaving
the workplace: Switch off the power supply and
then bleed the machine by activating the start
and stop device.
Maintenance
Regular maintenance is a basic requirement for the
continued safe and efficient use of the machine.
Follow the maintenance instructions carefully.
oBefore starting maintenance on the machine,
clean it in order to avoid exposure to hazard
substances. See ‘Dust and fume hazards’
oUse only authorised parts. Any damage or
malfunction caused by the use of unauthorised
parts is not covered by warranty or product
liability.
oWhen cleaning mechanical parts with solvent,
comply with appropriate health and safety
regulations and ensure there is satisfactory
ventilation.
oFor major service to the machine, contact your
nearest authorised workshop.
oAfter each service, check that the machine's
vibration level is normal. If not, contact your
nearest authorised workshop.
Every day
oClean and inspect the machine and its functions
each day before the work commences.
oConduct a general inspection for leaks and
damage.
oCheck the function of the trigger. Make sure that
it returns to its stop position when it is released.
Periodic maintenance
After each operating period of approximately 100
working hours or three times a year the machine
must be dismantled and all parts be cleaned and
checked. This work must be performed by
authorized staff, trained for this task.
Storage
oCheck that the machine is properly cleaned
before storage.
oStore the machine in a dry place.
oKeep the machine and tools in a safe place, out
of the reach of children and locked up.
Disposal
A used machine must be treated and disposed of
in such a way that the greatest possible portion of
the material can be recycled and any negative
influence on the environment is kept as low as
possible, and in respect to local restrictions.

Safety and operating instructions
MAG 5, 10, 15, 24
16
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
Technical data
Troubleshooting
Problem
Cause
Solution
Core drill will not operate
Core drill not connected properly
Check the performance and connection of
the power source. Make sure that the
return line coupling is completely fitted with
no clearance
Oil flow and/or pressure too low
Check the power source and ensure that
the flow and pressure are according to the
technical specifications
Core drill runs at low speed
Oil flow and/or pressure too low
As above
Contaminated hydraulic system
Clean system
Internal leakage
Carefully check the O-ring seals in the
trigger valve bushing and replace damaged
ones
Core drill runs without pushing the trigger
Un-tightened trigger valve bushing
Tighten trigger valve bushing properly
O-ring failure
Replace the O-ring at the bottom of the
trigger valve bushing hole
Check valve spring broken
Replace spring
Trigger lever stuck
Flow too high
Check the power source and ensure that
the flow and pressure are according to the
technical specifications - and that the
connections are correct
Improper pressure/return line connection
As above
Back pressure too high
As above
Impurities
Check trigger valve/reversing valve for
seizing
Trigger lever cannot be released
Trigger lever blocked in locked position
Readjust the flat spring through the two
screws on the motor housing
System overheats
Flow too high
Reduce the flow from the power source. If
necessary, use a flow divider to control the
flow
Insufficient cooling
Use a power source with higher cooling
capacity or add an additional oil cooler in
the return line
Machine data
Type: MAG 5, 10, 15, 24
Weight without hoses and drill bit
8 kg (17.6 lb)
Length x Width x Height
420 mm (16.5 inch) x 90 mm (3.5 inch) x 200 mm (7.9 inch)
Maximum power output
3 kW (4 hp)
Oil flow range
20 l/min (5.3 US gal/min)
Oil pressure
Minimum 70 bar (1000 psi). Maximum pressure is controlled within the unit itself
Maximum pressure relief valve setting
160 bar (2300 psi)
EHTMA category
C
Maximum back pressure in return line
14 bar (200 psi) (measured at core drill)
Oil working temperature
30-70°C (86-158°F)
Required cooling capacity
Approx. 2 kW
Type performance at 20 l/min (5.3 US gal/min):
Recommended Drill bit diameter in:
Type
rpm
Asphalt
Concrete
MAG 5
600
127-162mm (5.0-6.4 inch)
70-127mm (2.75-5.0 inch)
MAG 10
1000
90-127mm (3.5-5.0 inch)
40-70mm (1.6-2.75 inch)
MAG 15
1500
45-90 mm (1.75-3.5 inch)
25-50 mm (1.0-2.0 inch)
MAG 24
2400
12-45 mm (0.5-1.75 inch)
12-25 mm (0.5-1.0 inch)

MAG 5, 10, 15, 24
Safety and operating instructions
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
17
Noise and vibration data
Noise
Vibration
Sound pressure
Sound power
Three axes values
Declared values
Declared values
ISO 11203
2000/14/EC
ISO 20643
Type (Ø 102 mm, 20 l/min)
Lp
r=1m dB(A) rel
20μPa
Lw
Guaranteed dB(A)
rel 1pW
A
m/s2value
B
m/s2spreads
MAG 5
<70
-
3.10
0.81
MAG 10
<70
-
2.90
0.79
MAG 15
<70
-
2.70
0.76
MAG 24
<70
-
2.30
0.71
Vibration declaration statement
Vibration value Aand uncertainty Bdetermined according to ISO 20643. See table ‘Noise and vibration data’
for the values of A, B, etc.
These declared values were obtained by laboratory type testing in accordance with the stated directive or
standards and are suitable for comparison with the declared values of other tools tested in accordance with
the same directive or standards. These declared values are not suitable for use in risk assessments and
values measured in individual work places may be higher. The actual exposure values and risk of harm
experienced by an individual user are unique and depend upon the way the user works, in what material the
machine is used, as well as upon the exposure time and the physical condition of the user, and the condition
of the machine.
We, Xcalibre Equipment Ltd, cannot be held liable for the consequences of using the declared values,
instead of values reflecting the actual exposure, in an individual risk assessment in a work place situation
over which we have no control.
This tool may cause hand-arm vibration syndrome if its use is not adequately managed. An EU guide to
managing hand-arm vibration can be found at http://www.humanvibration.com/EU/VIBGUIDE.htm
We recommend a programme of health surveillance to detect early symptoms which may relate to vibration
exposure, so that management procedures can be modified to help prevent future impairment.

Safety and operating instructions
MAG 5, 10, 15, 24
18
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
EC Declaration of Conformity
EC Declaration of Conformity (EC Directive 2006/42/EC)
We, Xcalibre Equipment Ltd, hereby declare that the machines listed below conform to the provisions of EC
Directive 2006/42/EC (Machinery Directive), and the harmonised standards mentioned below.
Hydraulic core drill
Pmax
MAG 5
150 bar
MAG 10
150 bar
MAG 15
150 bar
MAG 24
150 bar
Following harmonised standards were applied:
oISO/FDIS 11148-3:2009
Technical Documentation authorised representative:
Christian Molbech
Xcalibre Equipment Ltd
Merlin House
Channel Way
Coventry CV6 6RH
United Kingdom
Managing director:
Christian Molbech
Manufacturer:
Xcalibre Equipment Ltd
Merlin House
Channel Way
Coventry CV6 6RH
United Kingdom
Place and date:
Coventry, 2010-05-25

MAG 5, 10, 15, 24
Safety and operating instructions
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25
Original instructions
19

www.xcalibre.com
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers, and
drawings.
© 2010 Xcalibre Equipment Limited | 67020101 | 2010-05-25