Revo Low Profile 35 User manual

REVO - LOW PROFILE 35 DRILL
ORIGINAL INSTRUCTIONS
G&J Hall Ltd, Burgess Road, Sheffield, S9 3WD, England
Tel: [phone] Fax: [phone]
Email: [email protected] Web: www.revo-
tools.co.uk
www.revo-tools.co.uk
Machine shown
REVO Low Profile 35
WARNING !
When using electric power tools
basic safety precautions should
always be used to reduce the risk
of fire, electric shock and personal
injury.

2
Annular cutter
(Not included)
Pilot pin
(Not included)
Motor switch Magnet switch
LED Work Light
Crank Lever
Standard Accessories
* Wrench M8
* Hex. Key M2.5
* Hex. Key M4
* Safety Chain
Power 1100W
Voltage See machine nameplate
No Load / Full Load min-1 650 / 390
Max. Capacity Dia. X Depth of cut 35mm x 30mm (1-3/8" x 1-3/16")
Magnetic Adhesion 15,000 N
Overload Protection With
Dimensions 285 x 101 x 200mm
Net weight 10kgs (22.4Lbs)
Quick-release
tool holder
Good balance for Carrying

3
WARNING! Read and understand all instruction before operating any drilling system. Failure to follow all
instructions listed below may result in electrical shock, damage to drilling system and even personal
injury.
GENERAL SAFETY INSTRUCTIONS
Work area
Keep your working area clean and well lit. Cluttered benches and work stations or dark work areas can
cause accidents. Always ensure work stations are clean and well lit.
Do not operate power tools in an explosive atmosphere, such as in the presence of flammable liquids,
gases or extreme dust. Power tools create sparks that may ignite gases or flammable liquids. Dust may
enter the ventilation system causing clogging and causing overheating.
Keep bystanders, children and visitors away from moving parts of the power tool. Any distractions can
cause you to loose control of the power tool and an injury could take place.
Electrical Safety
Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all
codes and ordinances. Never remove the ground prong or modify the dance plug in any way. Do not use
any adaptor plugs. Check with a qualified electrician if you are in doubt as to whether the outlet is
properly grounded. If tools should electrically malfunction or break down, grounding provides a low
resistance path to carry electricity away from the user.
Never carry a tool by the cord or hose and “yanking” the cord or the hose to disconnect it from the
receptacle. Always carry the power tools properly and store in dry and dust free place.
Keep cords and hoses away from heat, oil and sharp edges. Damaged cords increase the risk of electric
shock.
Don’t expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of
electric shock.
When operating a power tool outside, use an outdoor extension cord marked .W-A. or. W.. These cords
are rated for outdoor use and reduce the risk of electric shock.
Personal Safety
Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use
the tool while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while
operating power tools may result in serious personal injury.

4
Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and
gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.
Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with your finger on the
switch or plugging in tools that have the switch on invites accidents.
Remove adjusting keys or switches before turning the tool on. A wrench or a key that is left attached to a
rotating part of the tool may result in personal injury.
Do not overreach. Keep a proper footing and balance at all times. Proper footing and balance enables
better control of the tool in unexpected situations.
Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hardhat, or hearing
protection must be used for appropriate conditions.
Tool use and care
Use clamps or other practical way to secure and support the work piece to a stable platform. Holding the
work by hand or against your body is unstable and may lead to loss of control.
Do not force tool. Use the correct tool for your application. The correct tool will do the job better and
safer at the rate for which it is designed.
Do not use tool if the switch does not turn it on or off. Any tool that cannot be controlled with the switch is
dangerous and must be repaired.
Disconnect the plug from the power source before making any adjustments, changing accessories, or
storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally.
Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of
untrained users.
Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools, with sharp cutting
edges are less likely to bind and are easier to control.
Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may
affect the tools operation. If damaged, have the tool serviced before using. Poorly maintained tools
cause many accidents.
Use only accessories that are recommended by the manufacturer for your model.
Accessories that may be suitable for one tool may become hazardous when used on another tool.
Service
Only qualified repair personnel must perform tool service. Service or maintenance performed by
unqualified personnel could result in a risk of injury.
When servicing tool, use only identical replacement parts. Follow instructions in the Maintenance section
of this manual. Use of unauthorized parts or failure to follow Maintenance Instructions may create a risk of
electric shock or injury.

5
Symbols used in this manual
IMPORTANT: Some of the following symbols may be used on your tool. Please study them and learn their
meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.
Terminology used in the manual
1. Warning: This term means that there is a risk of physical harm or death to the operator or people
nearby.
2. Caution: This term means that there is a risk of damage to the machine, cutting tool or other
equipment.
3. Note: These terms offer useful information relating to the operation of the machine or its maintenance.
Symbol Name Designation/Explanation
V Volt Voltage (potential)
A Amperes Current
Hz Hertz Frequency (cycles per second)
W Watt Power
kg Kilograms Weight
min Minutes Time
s Seconds Time
ϕDiameter Size of drill bits
No No load speed Rotational speed, at no load
min-1 Revolutions per minute Revolutions, strokes, surface speed per minute.
0 Off position Zero speed, zero torque…
1, 2, 3, … Selector settings Speed setting,higher number means greater speed
~ Alternating current Type or a characteristic or current
Class ll construction Double Insulated, construction tool
Warning symbol Alerts user to warning messages

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SPECIFIC SAFETY RULES AND REGULATIONS
Always use safety chain. Mounting can release.
The magnet’s adhesion depends on the thickness of the work piece. Always ensure that the work piece is
a minimum of 12mm (7/16 in.) thick. If it is not, then use a piece of steel plate at least 12mm thick and
larger than the magnet below the work piece to supplement the magnetic adhesion.
Metal chips and other debris will seriously hamper magnetic adhesion. Always ensure that the magnet is
clean.
Other units used on the same receptacle will cause uneven voltage that could lead to the magnet
releasing. Always use the tool alone on the receptacle.
It is hazardous to use the drill upside-down. Do not exceed 90 degrees from horizontal.
Avoid the magnet releasing. Ensure that the magnet has properly adhered to the work piece before
beginning drilling.
Avoid operating annular cutters without coolant. Always lubricate the cutter and add as needed during
the cut. Always lubricate the cutter and add as needed during the cut.
Do not operate with dull or damaged cutting tools. This may overload the motor.
Protect the motor. Never allow cutting fluid, water, or other contaminants enter the motor.
Metal chips are often very sharp and hot. Never touch them with bare hands. Clean up with a magnetic
chip collector and a chip hook or other appropriate tool.
CAUTION: NEVER position machine on a work piece between the electrode and the ground of any arc
type welder. Damage to the machine will result, as the welder will ground through the machine’s ground
cable.
WARNING: NEVER attempt to use machine with incorrect current or abnormally low voltage. Check
machine nameplate to ensure that correct voltage and Hz are used.
USING THE SAFETY STRAP
The safety strap must always be used.
Loop the strap through the slot above the magnet and around the workpiece. Push on the spring buckle
and thread the loose end of the strap through the loop and pull tight. Push on the spring buckle to
release strap.

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MOUNTING ANNULAR CUTTERS
CAUTION: Never use a cutting tool that is larger than the maximum rated capacity of the machine.
1. To insert an annular cutter, first insert the pilot pin into the cutter.
2. Whenever mounting or removing cutters, always unplug the machine.
3. Lower the arbor.
4. Push up on the quick-release collar. Insert the cutter with pilot pin and turn until the flat meets the
locking pin. When the flat meets the locking pin, the collar will snap down. Double check to ensure
that it is fully locked.
5. To remove, lower the arbor, push up on the quick-release collar and remove the cutter.
OPERATION-GENERAL
WARNING: Always ensure that the magnet is adhered properly to the work piece before beginning
drilling.
NOTE: If mounting to a curved surface beam, mount the machine parallel to the curve in the work piece.
WARNING: Avoid operating at more than 90 degrees from horizontal. When drilling at such an angle take
precautions to prevent cutting coolant from entering the motor. Paste-type stick lubricant should be used.
1. First fit tool into arbor and line up with intended center of cut. Then switch magnet on.
2. Press green motor on button to start motor. Use the crank handle to feed to work. Always use very
light pressure when beginning the cut and just as the tool is breaking through.
Quick-release collar
Arbor

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The crank handle offers tremendous leverage; so do not use too much force. Allow the cutting tool to
determine the pace. With experience, the operator will be able to determine the best pace to feed to
the work. There should be some degree of audible slowing of the motor but not bogging in the cut.
Correct cutting speed with a properly sharp annular cutter will produce long unbroken chips, which
produce a “bird’s” nest. shaped bundle of chips around the cut.
NOTE: Always ensure that the cutting tool is sharp. A dull cutter typically will have finer and/or choppy
shavings.
WARNING: ALWAYS clear chips when there is too much build-up. Excessive chip build-up could result in a
jammed cutter or other hazardous situation.
WARNING: The slug ejects at end of cut and is very hot. Always provide a method of catching the slug,
where the ejected slug may cause injury to people below.
CAUTION: Never attempt to cut half-circles or to stitch drill (drill overlapping holes) with a TCT cutter. This
may destroy the cutter.
REVERSING OR CHANGING THE POSITION OF THE CRANK LEVER
The Crank Lever is quick-release and adjustable to suit different operating conditions.
If it is required to mount the crank lever on the opposite side or to change its position, push the Release
Button in the center of the Crank Hub and remove. Press the Button and mount on the opposite side or in
the desired position.
Crank Lever
Release Button

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THE OPTIONAL LED WORK LIGHT
Models equipped with the optional LED WORK LIGHT have a light which is always on whenever the
machine is plugged in. This can be useful when working in dark work spaces.
CAUTION: Never attempt to re enter a half-finished cut if the magnet has been turned off and the
machine shifted in the interim. This may destroy the cutter.
MAINTENANCE
1. Keep the machine clean and free of chips.
2. Check for loose fittings and tighten as needed.
3. Ensure that the ventilation slots are clear so that motor can be cooled normally. Blow low-pressure
compressed air through the ventilation slots with the motor running to keep motor clean.
THE ARBOR SHAFT
Keep the arbor shaft free of dirt and lightly grease as needed. If the mechanism is noisy, it may be dirty or
have a chip lodged in it. Clean and re-grease as needed.
LED Work Light

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THE CARBON BRUSHES
The carbon brushes are a normal wearing part and must be replaced when they reach their wear limit.
Caution: Always replace the brushes as a pair.
To replace:
1. Remove the 4 screws and remove the motor tail cover.
2. Using pliers rotate the brush spring out of the way and slide the old carbon brush out of the brush
holder.
3. Unscrew the screw to remove the brush lead. The old carbon brush may now be lifted away.
4. Install a new brush. Installation is the reverse of removal.
5. Replace the motor tail cover.
CARBON BRUSHES
Due to the brush design, if the machine comes to a stop without any reason, the brushes have to be
checked. The brush design stops the machine before the carbon brushes are finished and protects the
motor.

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Wiring

12
Exploded View
09 08 04 03 02
06 05 07
11 10 12 13 14 15
01
NO.01~109V3.0
16 17 18 19
46
22 21 23
25 26 27 24
24
20
59
60 19
49 48
50
51
55
61
33
24
32
29
30
31
34
35
36
39
38
37
40
94
41
43
67
66
68
70
58 57
69
68 65
19
71
44
72
73
74
62 63
58
68
75
77
47
46
45
76
47
76
28
81
82
84
83
110V
230V
85
86
85
86
88
87
80
92
85
86
93
100
98 99
100
101
110V
230V
102
88
87
102
103
86
86
79
78
106 105 104
107
108
109

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13
ITEM PARTS NAME PART No. QTY ITEM PARTS NAME PART No. QTY
1 INTERNAL CIRCLIP R-19 22X01 1 57 SOCKET CAP SCREW M6 x 30 22X57 2
2 ARBOR WASHER Ø10 x Ø18.5 X 0.8 22X02 1 58 SPRING WASHER M6 22X58 3
3 COOLANT SEAL Ø10.2 x Ø12 x 15 22X03 1 59 LED LAMP 22X59 1
4 SPRING Ø1.2 x Ø10 x Ø12.4 x 7T X 54L 22X04 1 60 FLAT HEAD SCREW M4 x 6 22X60 1
5 LOCK PIN 22X05 1 61 MAGNET BASE 164 x 80 x 48 22X61 1
6 SET SCREW M3 x 4 22X06 1 62 SCREW M4 x 16 22X62 2
7 LOCK PIN SPRING 22X07 1 63 CABLE CLIP 22X63 1
8 CHECK BALL Ø8 22X08 1 65 POWER SUPPLY CABLE - 110v (EU) 18Y181 1
9 SPINDLE 22X09 1 65B POWER SUPPLY CABLE - 230v (UK) 18X503 1
10 RING Ø40 x Ø44 X 9 22X10 1 65C POWER SUPPLY CABLE - 230v (EU) 18X503/EU 1
11 COLLAR PIN 22X11 1 65D POWER SUPPLY CABLE - 110v (US) 18X503/A 1
12 QUICK-RELEASE COLLAR 22X12 1 65E POWER SUPPLY CABLE - 230v (AU) 18X503/AU 1
13 SPRING Ø2 x Ø39 x Ø43 X 3T x 30L 22X13 1 66 MOTOR NVR SWITCH 110V 18X406 1
14 SPRING SEAT RING Ø35.1 x Ø44.5 x 2 22X14 1 66B MOTOR NVR SWITCH 230V 18X407 1
15 EXTERNAL CIRCLIP S-35 22X15 1 67 MAGNET SWITCH 18X510 1
16 INTERNAL CIRCLIP R-47 22X16 1 68 SCREW M4 x 8 22X68 8
17 BEARING 6005 ZZ 22X17 1 69 SWITCH BRACKET 22X69 1
18 SPINDLE GUIDE 22X18 1 70 MOUNTING PLATE 22X70 1
19 EXTERNAL CIRCLIP S-25 22X19 3 71 OVERLOAD UNIT - 110V 22X71 1
20 GEAR CASE 22X20 1 71B OVERLOAD UNIT - 230V 22X71B 1
21 BUSHING Ø18 x Ø23 x 4 22X21 1 72 SCREW M5 x 10 22X72 1
22 QUILL GEAR M1.25 x 47T 22X22 1 73 SOCKET CAP SCREW M6 x 16 22X73 1
23 BUSHING Ø30 x Ø36 x 12 22X23 1 74 SCREW M4 x 16 22X74 1
24 BALL BEARING 608 ZZ 22X24 3 75 SUN WASHER M5 22X75 1
25 BEVEL GEAR M1.0 x 46T 22X25 1 76 WASHER Ø30 x Ø38.5 22X76 2
26 PARALLEL KEY 4 x 4 x 7 22X26 1 77 SEAL 5CM 22X77 1
27 INTERMEDIATE GEAR M1.25 x 9T 22X27 1 78 RUBBER BELT 22X78A 1
28 SCREW M5 x 25 22X28 2 79 SCREW M5 x 10 22X79 1
29 SCREW M5 x 30 22X29 2 80 SCREW M5 x 12 22X80 1
30 GEAR COVER 22X30 1 81 FLAT WASHER Ø10.1 x Ø14 x 1 22X81 1
31 SCREW M5 x 25 22X31 4 82 SAFETY BELT 22X82 1
32 BEARING 6001-DU 22X32 1 83 WIRE LEAD BLACK 18CM 22X83 2
33 ARMATURE 110V 22X33 1 84 WIRE LEAD YELLOW 18CM 22X84 2
33B ARMATURE 230V 22X33B 1 85 WIRE CONNECTOR 22X85 6
34 SCREW M5 x 60 22X34 2 86 POST WRAP 22X86 6
35 STATOR 110V 22X35 1 87 CONNECTOR 22X87 1
35B STATOR 230V 22X35B 1 88 BELT 22X88 1
36 MOTOR HOUSING 22X36 1 93 E-CLIP E-3 22X93 1
37 CARBON BRUSH 7 x 11 x 17 22X37 2 98 BRACKET TOP 22X98 1
38 BRUSH HOLDER 7 x 11 22X38 2 99 BRACKET BOTTOM 22X99 1
39 NUT M4 x 8 22X39 2 100 SCREW M4 x 16 22X97 2
40 BRUSH SPRING 22X40 2 101 NUT M5 22X101 1
41 SCREW M4 x 10 22X41 2 102 WIRE CONNECTOR 22X102 2
43 MOTOR TAIL COVER 22X43 1 103 SCREW M4 x 8 22X103 1
44 SCREW M4 x 25 22X44 2 104 CHIP GUARD 22X104 1
45 CRANK SPINDLE 22X45 1 105 FLAT WASHER Ø6 x Ø13 x 1 22X105 2
46 CRANK BUSHING Ø28 x Ø32 x 12 22X46 2 106 SCREW M6 x 10 22X106 2
47 THRUST WASHER Ø25.5 x Ø40 x 2 22X47 2 107 PLUNGER 22X107 1
48 BALL SEAT 22X48 1
49 CHECK BALL Ø5 22X49 1
50 CRANK HUB 22X50 1
51 SPRING Ø0.6 x Ø4.1 x Ø5.3 x 4T x 8.5L 22X51 1
55 CRANK LEVER 22X55 1 - BLOW MOULDED CARRYING CASE 22X100 1
PARTS LIST
108 FAN SHROUD 22x108 1
109 EARTHING MARKING 22x109 1

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Low Profile 35 - Revised 280612
CE Declaration of Conformity
On our sole responsibility we declare that this product, the REVO Tools Low Profile 35
Drill, meets the basic requirements with the following standards and directives:-
DIN EN 61029 (VDE 0740 Teil 500):12 2003
DIN EN 55014-1: 2007-06
2006/95/EC - Low Voltage Directive
2004/108/EC - EMC Directive
2006/42/EC - Machinery Directive
Signed............................................. Date....28.06.12
(P.D.Edwards - Managing Director)
G&J Hall Ltd.
Burgess Road
SHEFFIELD
S9 3WD
England
United Kingdom
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.gjhall.co.uk
WARRANTY REGISTRATION
Thank you for purchasing your REVO-TOOLS magnetic based drilling machine.
To ensure any warranty claim can be processed promptly, please register your
machine, now, on-line at :-
http://www.revo-tools.co.uk
Click on the button on the left “REVO WARRANTY REGISTRATION”