Evolution EVO42 User guide

www.evolutionsteel.com
Guard omitted for illustrative purposes only.
EVO42
42mm MAGNETIC DRILLING SYSTEM
Original
Instruction
Manual
Read instructions before operating this tool.

www.evolutionsteel.com
3
Original
Instruction
Manual
Read instructions before operating this tool.
GB
TABLE OF CONTENTS GB
EC - Declaration of Conformity p3
Important Information p4
12 Month Limited Warranty p4
General Safety Rules p4
Health Advice p5
Specific Safety Rules p6
Additional Safety Advice p6
Labels & Symbols p7
Specifications p7
Assembly p8
Getting Started p9
Operating Instructions p10
Operating Advice p10
Maintenance p11
Environmental Protection p11
Service Parts Diagram p12
Original Instructions
This instruction manual was originally written
in English.
EC - DECLARATION OF CONFORMITY GB
We, manufacturer and importer
Evolution Power Tools Ltd.
Venture One
Sheffield
S20 3FR
Declare that the product
Part numbers: EVO42
Evolution: EVO42
42mm Magnetic Drilling System
Complies with the essential requirements of the
following European Directives:
2006/42/EC – Machine Directive
2006/95/EC – Low Voltage Directive
2004/108/EC – EMC Directive
2002/95/EC – Restriction of the use of Certain
Hazardous Substances in Electrical and Electric
Equipment
The following standards have been applied:
EN55014-1 : 2006
EN55014-2 : 1997+A1+A2
EN61000-3-2 : 2000
EN61000-3-3 : 1995+A1+A2
EN61029-2-9 : 2002
EN60825-1 : 1994+A1+A2
EN61029-1:2009
EN ISO 12100-2/A1:2009
ISO 12100-2:2003
All documentation is held on file at the above
address and is available, on request for review.
Authorised Signatory
Date: 21/10/2011
Mr Matthew J Gavins
Managing Director

EVO42
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IMPORTANT INFORMATION GB
Please read these operating and safety instructions
carefully and completely. For your own safety, before
using this equipment check that the voltage is correct
and that all handles and parts are firmly secured.
If you are uncertain about any aspect of using this
equipment, please contact our Technical Helpline.
Technical Helpline UK: 0870 609 2297
Congratulations on your purchase of an
Evolution Power Tools machine.
Please complete your product registration
online to validate your machine’s warranty
period and ensure prompt service if needed.
We sincerely thank you for selecting a product
from Evolution Power Tools.
12 MONTH LIMITED WARRANTY GB
Evolution power tools reserves the right to
make improvements and modifications to
design without prior notice.
Evolution Power Tools will, within twelve (12)
months from the original date of purchase, repair
or replace any goods found to be defective in
materials or workmanship. This warranty is void
if the machine being returned has been used to
cut materials beyond the recommendations in the
Instruction Manual or if the machine has been
damaged by accident, neglect, or improper service.
This warranty does not apply to machines and / or
components which have been altered, changed, or
modified in any way, or subjected to use beyond
recommended capacities and specifications.
Electrical components are subject to respective
manufacturers’ warranties. All goods returned
defective shall be returned prepaid freight to
Evolution Power Tools. Evolution Power Tools
reserves the right to optionally repair or replace
it with the same or equivalent item. There is
no warranty – written or verbal – for drill bits or
cutters. In no event shall Evolution Power Tools
be liable for loss or damage resulting directly or
indirectly from the use of our merchandise or from
any other cause.
Evolution Power Tools is not liable for any costs
incurred on such goods or consequential damages.
No officer, employee or agent of Evolution Power
Tools is authorised to make oral representations of
fitness or to waive any of the foregoing terms of
sale and none shall be binding on Evolution Power
Tools. Questions relating to this limited warranty
should be directed to the company’s head office or
call the appropriate Helpline number.
IMPORTANT SAFETY INSTRUCTIONS
To reduce the risk of electric shock, this equipment
is fitted with an approved cord and plug for its
intended country of use. Do not change the cord or
plug in any way.
GENERAL SAFETY RULES GB
WARNING: When using electric tools, basic safety
precautions should always be followed to reduce
the risk of fire, electric shock and personal injury.
Please read all of these instructions before
attempting to operate this machine. Save this
manual for future reference.
1. Keep work area clear. Cluttered work areas invite
accidents.
2. Consider work area environment. Do not expose
tools to rain. Do not use tools in damp or wet
locations. Keep work area well lit. Do not use tools
in the presence of flammable liquids or gases.
3. Guard against electric shock. Avoid body contact
with earthed or grounded surfaces (e.g. pipes,
radiators, ranges, refrigerators).
4. Keep other people away. Do not let others,
especially children, come close to the work, and
touch the tool or the extension lead. Keep them
away from the work area.

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5. Store idle tools. When not in use, tools should
be stored in a dry locked-up place, out of reach of
children.
6. Do not force the tool. It will do the job better and
safer at the rate for which it was intended.
7. Use the right tool. Do not force small tools to
do the job of a heavy duty tool. Do not use tools
for purposes not intended; for example do not use
circular saws to cut tree limbs or logs.
8. Dress properly. Do not wear loose clothing or
jewellery, they can be caught in moving parts.
Non-skid footwear is recommended when working
outdoors. Wear protective hair covering to contain
long hair.
9. Use protective equipment. Use safety glasses. Use
face or dust mask if working operations create dust.
10. Connect dust extraction equipment. If the tool
is provided for the connection of dust extraction
and collection equipment, ensure these are
connected and properly used.
11. Do not abuse the cord. Never yank the cord to
disconnect it from the socket. Keep the cord away
from heat, oil and sharp edges.
12. Secure work. Where possible, use clamps or
a vice to hold the work. It’s much safer than using
your hand.
13. Don’t over reach. Keep proper footing and
balance at all times.
14. Maintain tools with care. Keep cutting tools
sharp and clean for better and safer performance.
Follow instructions for lubricating and changing
accessories. Inspect tool cords periodically and,
if damaged, have them repaired by an authorised
service facility. Inspect extension cord periodically
and replace immediately if damaged. Keep handles
dry, clean and free from oil and grease.
15. Disconnect tools. When not in use, before any
servicing and when changing accessories such
as blades, bits, cutters, disconnect tool from the
power source
16. Remove adjusting keys and spanners. Form
the habit of checking to see the keys and adjusting
spanners are removed from the tool before turning it on.
17. Avoid unintentional starting. Ensure switch is in
“off” position when plugging in.
18. Use outdoor extension leads. When the tool is
used outdoors, use only extension cords intended
for outdoor use and so marked.
19. Stay alert. Watch what you are doing, use
common sense and do not operate the tool when
you are tired.
20. Check damaged parts. Before further use of
tool, it should be carefully checked to determine
that it will operate properly and perform the
intended function. Check for alignment of moving
parts, mountings and any other components that
may affect its operation. A guard or other part that
is damaged should be properly repaired or replaced
by an authorised service centre unless otherwise
indicated in this instruction manual. Have defective
switches replaced by an authorised service centre.
Do not use the tool if the switch does not turn it
on and off.
21. WARNING. The use of any accessory or
attachment other than one recommended in this
instruction manual may present a risk of personal injury.
22. Have your tool repaired by a qualified person.
This electric tool complies with relevant safety
rules. Repairs should only be carried out by
qualified persons using original spare parts.
Otherwise this may result in considerable danger
to the user.
HEALTH ADVICE GB
WARNING: When drilling, sanding, sawing or
grinding, dust particles will be produced. In some
instances, depending on the materials you are
working with, this dust can be particularly harmful
to you (e.g. lead from old gloss paint).You are
advised to consider the risks associated with the
materials you are working with and to reduce the
risk of exposure.
You should:
• Work in a well-ventilated area.
• Work with approved safety equipment, such as
dust masks that are specially designed to filter
microscopic particles.

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EVO42
SPECIFIC SAFETY RULES GB
A) Keep guards in place and in working order.
B) Remove adjusting keys and wrenches. Form the
habit of checking to see that keys and adjusting
wrenches are removed from the machine before
turning it on.
C) Keep work area clean. Cluttered areas and
benches invite accidents.
D) Don’t use in dangerous environment. Don’t use
power tools in damp or wet locations, or expose
them to rain. Keep work area well lit.
E) Keep children away. All visitors should be kept a
safe distance from the work area.
F) Don’t force the tool. It will do the job better and
safer if used at the rate for which it was designed.
G) Use proper extension cord. Make sure your
extension cord is in good condition. When using an
extension cord, be sure to use one heavy enough
to carry the current your machine will draw. An
undersized cord will cause a drop in line voltage
resulting in loss of power and possible overheating.
H) Wear proper apparel. Do not wear loose
clothing, gloves, neckties, rings, bracelets, or
other jewellery which may get caught in moving
parts. Nonslip footwear is recommended. Wear
protective hair covering to contain long hair.
I) Always use safety glasses. Also use face or
dust mask if cutting operation is dusty. Everyday
eyeglasses only have impact resistant lenses, they
are NOT safety glasses.
J) Secure work. Use clamps to hold work when practical.
K) Don’t overreach. Keep proper footing and
balance at all times.
L) Maintain tools with care. Keep tools sharp
and clean for best and safest performance.
Follow instructions for lubricating and changing
accessories.
M) Disconnect tools before servicing and when
changing accessories, such as blades
drill bits or cutters.
N) Reduce the risk of unintentional starting. Make
sure switch is in off position before plugging in.
O) Use recommended accessories. Only use
genuine Evolution accessories.
P) Check for 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 properly repaired or replaced.
Q) Keep hands out of the path of the saw blades,
drill bits or cutters
R) Never reach around saw blades, drill bits or cutters
S) Turn off tool and wait for saw blades, drill bits
or cutters to stop before moving the machine or
changing settings.
T) Disconnect the power before changing saw
blades, drill bits, cutters, or servicing or cleaning.
U) Never carry the tool by the power cord. Carrying
the tool by the power cord could cause damage to
the insulation or the wire connections resulting in
the possibility of electric shock or fire.
ADDITIONAL SAFETY ADVICE GB
1. Although compact, this machine is heavy. To
reduce the risk of back injury, get help whenever
you have to lift the machine.
2. To reduce the risk of back injury, hold the tool
close to your body when lifting. By bending your
knees you can lift with your legs, not your back. Lift
by using the integral lifting/carrying handle.
3. Never carry the machine by the power cord.
Carrying the tool by the power cord could cause
damage to the insulation or the wire connections
resulting in electric shock or fire.
4. Before moving the machine tighten the
secondary slide lock knob to guard against sudden
movement.
WARNING: Do not use the machines cutting head
as a ‘lifting point’.

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LABELS & SYMBOLS GB
WARNING: Do not operate machine if warning
and / or instruction labels are missing or damaged.
Contact your supplier for replacement labels.
Symbol Description
V Volts
A Amperes
Hz Hertz
min-1 Minutes
~ Alternating current
No no load speed
Wear Safety Goggles
Wear Ear Protection
Only use genuine Evolution replacement parts.
Unauthorized parts may be dangerous!
To obtain an additional copy of your manual, please
contact your supplier.
SPECIFICATIONS GB
Motor (230V ~ 50 Hz) (Watts): 1200
Maximum Cutter Diameter (mm): 42
Maximum Cutting Depth (mm): 50
RPM No Load (min-1 ): 450
Recommended Max Duty Cycle (Mins): 30
Weight (kg): 11.2
Max Dimensions
(Rack Fully Raised) (mm): 570 x 300 x 170
Magnet Dimensions (mm): 40 x 90 x 180
Magnetic Adhesion (kg): 1300 LNF
Cutter Retainer (Weldon Shank)
Internal Diameter (mm): 19
Noise and Vibration Data
Sound pressure level (LpA): 89.4dB(A)
Sound power level (LwA): 102.4dB(A)
K = 3dB(A)
Vibration Data
Ah = 0.629 m/s2
K = 1.5 m/s2
Vibration level:
The declared vibration total value has been
measured in accordance with a standard test
method and may be used for comparing one tool
with another. The declared vibration total value
may also be used in a preliminary assessment of
exposure.
WARNING: The vibration emission during actual
use of the power tool can differ from the declared
total value depending on the ways in which the tool
is used. The need to identify safety measures and
to protect the operator are based on an estimation
of exposure in the actual conditions of use (taking
account of all parts of the operating cycle, such
as the times the tool is switched off, when it is
running idle, in addition to trigger time).
ADDITIONAL ACCESSORIES
In addition to the standard accessories supplied
with this machine, other accessories are available
from your supplier.
These include the following items:
HTA 47 Chuch Adaptor
HTA153 Chuck & Key 13mm
HTA 030 Countersink Bit 0-30mm
HTxxS Short 25mm Cutters
12mm - 42mm
HTxxL Long 50mm Cutters
12mm - 42mm

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EVO42
ASSEMBLY GB
Your Evolution Power Tools saw is shipped
complete. Remove all contents from the box and
inspect to ensure no damage was incurred during
shipping, and that the items listed below are
included.
ITEMS SUPPLIED
Description Quantity
Instruction Manual 1
Coolant System 1
Guard 1
Hex Key 2mm 1
Hex Key 3mm 1
Hex Key 4mm 1
Hex Key 5mm 1
Handles 3
Wing Screws 2
Spring Washers 2
Safety Strap 1
Carry Case 1
1. Insert the three handles into the spindle boss
and screw them tightly in place. (Fig. 1)
2. Attach the guard using the Wing Screws/Socket
Headed Screws and washers provided. (Fig. 2)
3. Attach the coolant tank and coolant pipe to the
Left Hand side of the machine. The coolant pipe is
a push fit onto the quick fit connector on Left Hand
side gearbox casing. The coolant tank should be
fastened to the machine using the ø 6 mm socket
headed screw inserted into the threaded hole
located at the top Left Hand side of the machines
carriage. (Fig. 3)
Note: For some operations it may be convenient
to remove the coolant tank and supply pipe, and to
use alternative coolant application methods.
FIG 1
FIG 2
FIG 3

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GETTING STARTED GB
WARNING: Always Disconnect The Machine
From Power Source Before Making
Adjustments. Refer to the “Service Parts
Diagram”.
INSTALLING OR REMOVING A CUTTER
WARNING: Only use genuine Evolution cutters
which are designed for this machine. Select the
correct cutter for the material to be cut.
Note: It is recommended that the operator
considers wearing protective gloves when handling
the cutter during installation or when changing the
machines cutter.
TO INSERT A CUTTER
1. Insert the relevant pilot pin into the cutter. The
‘point’ of the pilot pin should face towards the
cutting edge of the cutter.
2. Slide the cutter into the arbor and align the two
flats on the cutters shank with the two locking
screws. (Fig. 4)
3. Tighten the locking screws securely with the
supplied hex wrench.
Caution: Ensure that both locking screws are on
a machined flat on the cutters shank and not just
against the rounded shank.
To remove the cutter, reverse the procedure.
FIG 4
INSTALLING THE CHUCK ADAPTOR
The optional chuck adaptor (part HTA 47) can be
fitted into the EVO42 machines arbor, and then the
machine can be fitted with a standard 3 jawed self
centering chuck. This enables the EVO42 to take
standard parallel twist drills up to ø13mm.
Fit the adapter in the same way as fitting a cutter
into the arbor, but omit the pilot pin.
Note: To use the machine with standard twist
drills will mean that the secondary slide facility of
the machine must be utilised. This will allow the
machine to be adjusted to take account of the
longer reach of the standard chuck and twist drills.
The locking lever for the secondary slide has a left
hand thread and is found on the lower Left Hand
side of the gearbox housing. (Fig. 5)
OPERATING INSTRUCTIONS GB
Magnetic Drill Safety
Note: It is recommended that only operators who
have been fully trained in the use of this machine,
and have read and understood the machines
operating manual are allowed to use this machine.
Magnetic Adhesion
The drills magnetic adhesion depends upon the
thickness and condition of the workpiece. Rust
and multi-layer paint buildup can affect magnetic
adhesion. Whenever possible loose rust and paint,
FIG 5

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EVO42
etc, should be removed from the work area before
the machine is positioned. 10 mm is the optimum
material thickness for safe operation. Keep the
magnet clean of metal chips and other dirt and
debris. These can also seriously reduce magnetic
adhesion. The operator should ensure that the
magnet has adhered to the workpiece firmly before
switching on the drill. Always use the supplied
safety strap.
Note: The Magnet has an automatic 2 stage power
feature. When the magnet is first switched on it
will operate at approximately 50% adhesion power,
allowing the operator to make final adjustments to
the machines position. When the motor is started
the magnet will switch to full magnetic adhesion
power.
Supply
The drill should be operated from its own electrical
outlet with a Residual Current Device (RCD)
fitted. If other units share a common supply (such
as an on-site generator) operator care should
be exercised to ensure that the supply to the
magnetic drilling system is never compromised.
Coolant
Before each use always check the coolant feed and
level is sufficient.
Note: The coolant feed can be checked with
the machine in position, but the motor must be
switched off and the cutter stationary and cold.
Never operate without cutting coolant or paste.
Ensure that the coolant feed tap is on and coolant
feeds properly by pushing the pilot pin. If it feeds
too quickly or slowly, adjust the tap accordingly.
Keep the tap closed when not in use.
Adjusting Gibs (Dovetail Slides) Free Play
Periodically check, lubricate and adjust as
necessary.
1. Using the supplied 3mm Hex Key slightly loosen
the 3 cap screws. (Fig. 6A shows 1 of the cap
screws).
2. Using the 2 mm Hex Key supplied turn the 3
adjusting screws (Fig. 6B shows 1 of the adjusting
screws), evenly whilst operating the crank handle
to move the slide up and down.
There should be so no free play, yet no binding
anywhere throughout the range of travel.
3. Re-tighten the 3 cap screws when adjustment
is complete.
OPERATING ADVICE GB
Note: Do not operate this machine wearing gloves.
Ensure that the machine is connected to a suitable
power supply and any trailing cables do not pose a
safety risk to the operator or other workers on site.
Always attach the safety strap if at all possible.
1. Position the machine using the pilot pin as an aid
to locating the center of the cut.
2. Switch on the magnet using the red switch
located at the back of the machine.
Note: The machines motor will not operate until
the machines magnet has been switched on.
3. Check that the cutter is still in the correct
position and the machine is securely held onto the
workpiece.
4. With the motor head in the raised position,
switch on the motor using the switch on the top of
FIG 6
A
B

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the machine and allow to run up to full speed.
5. Turn the crank handle to begin cutting. Use light
pressure at first to keep the cutter from
wandering, and then gradually increase until normal
pressure is being applied. Do not force the tool –
let the speed of the cutter do the work. Cutting
performance will not improve by applying more
pressure on the tool, and cutter and motor life will
be reduced.
6. Regulate the flow of cutting coolant as required
with the coolant feed tap. Use less pressure as the
cutter exits through the material. Always provide
a method of catching the slug, where the ejected
slug may cause injury.
Caution: The slug ejected at the end of a cut can
be very hot.
Overload Protection
This machine is fitted with an overload protection
device, which prevents damage to the machine
should the motor be overloaded. Overload could be
caused by using a blunt, damaged or an oversized
cutter or by using excessive feed-in pressure.
If the overload protection device trips the machines
motor will stop, but maximum magnetic adhesion
will be maintained holding the machine in position.
Before attempting to restart the machine
investigate the cause of the overload situation.
To restart the machine operate the motor switch
on the top of the machine, switching it first to
the ‘OFF’ position before returning it to the ‘ON’
position. The motor will restart.
If the overload protection device persistently
operates and causes such as those mentioned
above have been eliminated, have the machine
checked and serviced by a qualified person.
MAINTENANCE GB
Note: Any maintenance must be carried out with
the machine switched off and disconnected from
the mains/battery power supply.
Check that all safety features and guards are
operating correctly on a regular basis. Only use
this machine if all guards/safety features are fully
operational.
All motor bearings in this machine are lubricated for
life. No further lubrication is required.
Use a clean, slightly damp cloth to clean the plastic
parts of the machine. Do not use solvents or
similar products which could damage the plastic
parts.
WARNING: Do not attempt to clean by inserting
pointed objects through openings in the machines
casings etc. The machines air vents should be
cleaned using compressed dry air.
Excessive sparking may indicate the presence of
dirt in the motor or worn out carbon brushes.
If this is suspected have the machine serviced and
the brushes replaced by a qualified person.
ENVIRONMENTAL PROTECTION GB
Waste electrical products should not be disposed
of with household waste. Please recycle where
facilities exist. Check with your Local Authority or
retailer for recycling advice.

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EVO42

UK 25.10.11