Bosch RZ18V User Manual

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IMPORTANT: IMPORTANT : IMPORTANTE:

Read Before Using Lire avant usage Leer antes de usar

Operating/Safety Instructions
Consignes de fonctionnement/sécurité

Instrucciones de funcionamiento y seguridad

RZ18V

Call Toll Free

for Consumer Information

& Service Locations

Pour renseignement des

consommateurs et centres

de service, appelez au

numéro gratuit :

Llame gratis para
obtener información
para el consumidor y

ubicaciones de servicio

1-877-ROTOZIP (1-877-768-6947) www.rotozip.com

For English Parlez-vous français? ¿Habla español?
See page 2 Voir page 22 Ver página 42

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General Safety Rules

WARNING

!

all of the warnings listed below refers to your mains-operated (corded) power tool or battery­operated (cordless) power tool.

Read all instructions. Failure to follow all instructions listed below may
result in electric shock, fire and/or serious injury. The term “power tool” in

SAVE THESE INSTRUCTIONS

Work area safety

Keep work area clean and well lit.

Cluttered or dark areas invite accidents.

Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power

tools create sparks which may ignite the dust
or fumes.

Keep children and bystanders away while
operating a power tool. Distractions can

cause you to lose control.

Electrical safety

Power tool plugs must match the outlet.
Never modify the plug in any way. Do not
use any adapter plugs with earthed
(grounded) power tools. Unmodified plugs

and matching outlets will reduce risk of
electric shock.

Avoid body contact with earthed or
grounded surfaces such as pipes,
radiators, ranges and refrigerators. There

is an increased risk of electric shock if your
body is earthed or grounded.

Do not expose power tools to rain or wet
conditions. Water entering a power tool will

increase the risk of electric shock.

Do not abuse the cord. Never use the cord
for carrying, pulling or unplugging the
power tool. Keep cord away from heat, oil,
sharp edges or moving parts. Damaged or

entangled cords increase the risk of electric
shock.

When operating a power tool outdoors,
use an extension cord suitable for
outdoor use. Use of a cord suitable for

outdoor use reduces the risk of electric
shock.

Do not use AC only rated tools with a DC
power supply.

work, the electrical components of the AC
rated tool are likely to fail and create a
hazard to the operator.

While the tool may appear to

If operating the power tool in damp
locations is unavoidable a Ground Fault
Circuit Interrupter (GFCI) must be used to
supply the power to your tool. GFCI and

personal protection devices like electrician’s
rubber gloves and footwear will further
enhance your personal safety.

Personal safety

Stay alert, watch what you are doing and
use common sense when operating a
power tool. Do not use a power tool while
you are tired or under the influence of
drugs, alcohol or medication. A moment of

inattention while operating power tools may
result in serious personal injury.

Use safety equipment. Always wear eye
protection. Safety equipment such as dust

mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate
conditions will reduce personal injuries.

Avoid accidental starting. Ensure the
switch is in the off-position before
plugging in. Carrying power tools with your

finger on the switch or plugging in power
tools that have the switch on invites
accidents.

Remove any adjusting key or wrench
before turning the power tool on. A wrench

or a key left attached to a rotating part of the
power tool may result in personal injury.

Do not overreach. Keep proper footing
and balance at all times. This enables

better control of the power tool in unexpected
situations.

Dress properly. Do not wear loose
clothing or jewelry. Keep your hair,
clothing and gloves away from moving
parts. Loose clothes, jewelry or long hair can

be caught in moving parts.

If devices are provided for the connection
of dust extraction and collection facilities,
ensure these are connected and properly
used. Use of these devices can reduce dust-

related hazards.

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Keep handles dry, clean and free from oil
and grease. Slippery hands cannot safely

control the power tool.

Power tool use and care

Do not force the power tool. Use the
correct power tool for your application.

The correct power tool will do the job better
and safer at the rate for which it was
designed.

Do not use the power tool if the switch
does not turn it on and off. Any power tool

that cannot be controlled with the switch is
dangerous and must be repaired.

Disconnect the plug from the power
source and/or the battery pack from the
power tool before making any
adjustments, changing accessories, or
storing power tools. Such preventive safety

measures reduce the risk of starting the
power tool accidentally.

Store idle power tools out of the reach of
children and do not allow persons
unfamiliar with the power tool or these
instructions to operate the power tool.

Power tools are dangerous in the hands of
untrained users.

Maintain power tools. Check for
misalignment or binding of moving parts,
breakage of parts and any other condition
that may affect the power tools operation.
If damaged, have the power tool repaired
before use. Many accidents are caused by

poorly maintained power tools.

Keep cutting tools sharp and clean.

Properly maintained cutting tools with sharp
cutting edges are less likely to bind and are
easier to control.

Use the power tool, accessories and tool
bits etc., in accordance with these
instructions and in the manner intended
for the particular type of power tool,
taking into account the working
conditions and the work to be performed.

Use of the power tool for operations different
from those intended could result in a
hazardous situation.

Use clamps or other practical way to
secure and support the workpiece to a
stable platform. Holding the work by hand

or against your body is unstable and may
lead to loss of control.

Battery tool use and care

Ensure the switch is in the off position
before inserting battery pack.

battery pack into power tools that have the
switch on invites accidents.

Recharge only with the charger specified
by the manufacturer. A charger that is

suitable for one type of battery pack may
create a risk of fire when used with another
battery pack.

Use battery tools only with specifically
designated battery packs. Use of any other

battery packs may create a risk of injury and
fire.

When battery pack is not in use, keep it
away from other metal objects like paper
clips, coins, keys, nails, screws, or other
small metal objects that can make a
connection from one terminal to another.

Shorting the battery terminals together may
cause burns or a fire.

Under abusive conditions, liquid may be
ejected from the battery, avoid contact. If
contact accidentally occurs, flush with
water. If liquid contacts eyes, additionally
seek medical help. Liquid ejected from the

battery may cause irritation or burns.

Inserting the

Service

Have your power tool serviced by a
qualified repair person using only identical
replacement parts. This will ensure that the

safety of the power tool is maintained.

Develop a periodic maintenance schedule
for your tool. When cleaning a tool be
careful not to disassemble any portion of
the tool since internal wires may be
misplaced or pinched or safety guard
return springs may be improperly
mounted. Certain cleaning agents such as

gasoline, carbon tetrachloride, ammonia, etc.
may damage plastic parts.

SAVE THESE INSTRUCTIONS

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Spiral Saw™ Safety Rules

Hold tool by insulated gripping surfaces
when performing an operation where the
cutting tool may contact hidden wiring.

Contact with a "live" wire will make exposed
metal parts of the tool "live" and shock the
operator.

Use clamps or other practical way to
secure and support the workpiece to a
stable platform. Holding the work by hand

or against your body is unstable and may
lead to loss of control.

If cutting into existing walls or other blind
areas where electrical wiring may exist is
unavoidable, disconnect all fuses or circuit
breakers feeding this worksite.

Always make sure the work surface is free
from nails and other foreign objects.

Cutting into a nail can cause the bit and the
tool to jump and damage the bit.

Never hold the workpiece in one hand and
the tool in the other hand when in use.
Never place hands near or below cutting
surface. Clamping the material and guiding

the tool with both hands is safer.

Never lay workpiece on top of hard
surfaces, like concrete, stone, etc...

Protruding cutting bit may cause tool to jump.

Always wear safety goggles and dust
mask. Use only in well ventilated area.

Using personal safety devices and working in
safe environment reduces risk of injury.

After changing the bits or making any
adjustments, make sure the collet nut and
any other adjustment devices are
securely tightened. Loose adjustment

device can unexpectedly shift, causing loss
of control, loose rotating components will be
violently thrown.

Never start the tool when the bit is
engaged in the material.

The bit cutting
edge may grab the material causing loss of
control of the cutter.

Always hold the tool with two hands
during start-up

. The reaction torque of the

motor can cause the tool to twist.

When routing or cutting, the direction of
feed with the bit’s cutting edge into the
material is very important. Always feed
the bit into the material in the same
direction as the cutting edge is exiting
from the material. When viewing the tool

from the top, the bit rotates clockwise. If the
tool is between the workpiece and your body,
then feed the tool to your right. If the
workpiece is between the tool and your body,
then feed the tool to your left. Feeding the
tool in the wrong direction causes the cutting
edge of the bit to climb out of the work and
pull the tool in the direction of this feed.

START

HERE

WORK

BIT

DIRECTION OF

FEED

Never use dull or damaged bits. Sharp
bits must be handled with care. Damaged

bits can snap during use. Dull bits require
more force to push the tool, possibly causing
the bit to break.

Never touch the bit during or immediately
after the use. After use the bit is too hot to

be touched by bare hands.

Never lay the tool down until the motor
has come to a complete standstill.

spinning bit can grab the surface and pull the
tool out of your control.

Never use bits that have a cutting
diameter greater than the opening in the
base.

Do not use the tool for drilling purposes.

This tool is not intended to be used with drill
bits.

Always use the tool with the depth guide
securely attached and positioned flat
against material being cut. The guide

securely positioned on the material improves
the stability and control of your tool.

WARNING

!

Some dust created by

power sanding, sawing,
grinding, drilling, and other construction
activities contains chemicals known to
cause cancer, birth defects or other
reproductive harm. Some examples of
these chemicals are:

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The

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• Lead from lead-based paints,

• Crystalline silica from bricks and cement
and other masonry products, and

• Arsenic and chromium from chemically­treated lumber.

Zipmate Abrasive Cut-Off Attachment Safety Rules

Always use wheel guard, and the tool’s
auxiliary handle with this abrasive cut off
tool. The guard must always be securely
attached to the tool and positioned for
maximum safety, so the least amount of
wheel is exposed on the operators side of
the tool. A guard protects operator from

broken wheel fragments. The support ribs
and auxiliary handle provide additional
guarding, stability and control in cut off
applications. The body of your Rotozip tool
or your Zipmate attachment can also be
used as a handle.

Always be certain that the wheel guard,
and tool’s auxiliary handle are
reassembled and securely fastened to the
tool when changing the point of operation
from fire forward to fire reverse or after
changing the wheels. A tool missing an

essential safety component is dangerous to
operate.

Hold tool by insulated gripping surfaces
when performing an operation where the
abrasive wheels may contact hidden
wiring or its own cord. Contact with a “live”

wire will make exposed metal parts of the
tool “live” and shock the operator.

Wear proper apparel while using an
abrasive cut off tool. Face shield or at least

safety goggles, dust mask, leather gloves
and shop apron capable of stopping small
wheel or workpiece fragments.

This attachment is not intended to be
used with Wet Diamond Wheels. Using

water or other liquid coolants with this tool
may result in electrocution or shock. Use of
Dry Diamond Wheels is acceptable.

Use only Type 1 abrasive cut off wheels
with the correct size arbor hole. Never
use damaged or incorrect wheel flanges
or round nut. Other types of wheels are not

intended to apply load on periphery and may
shatter. Wheels with arbor holes that do not
match the mounting hardware of the tool will

Your risk from these exposures varies,
depending on how often you do this type of
work. To reduce your exposure to these
chemicals: work in a well ventilated area, and
work with approved safety equipment, such
as those dust masks that are specially
designed to filter out microscopic particles.

run eccentrically, vibrate excessively and will
cause loss of control.

Do not grind on the side of Type 1
abrasive cut off wheels. Side forces

applied to these wheels may cause them to
shatter.

Do not use this attachment with
“Woodcarving” blade or standard wood
cutting toothed blades. These blades are

not intended for this tool and can create loss
of control during use.

Abrasive Cut Off Wheels must have a
maximum safe operating speed greater
than the “no load RPM” marked on the
attachment. Wheels running over the rated

speed can fly apart and cause injury.

Before each use inspect the cut off wheel
for chips and cracks. Do not use a wheel
that may be damaged. Install a new wheel
if tool was dropped. When installing a
new wheel carefully handle individual cut
off wheels to avoid chipping or cracking.
Run the tool at no load for one minute,
holding the tool in the direction away
from people. Wheels with flaws will
normally break apart during this time.

Fragments from a wheel that bursts during
operation will fly away at great velocity
possibly striking you or bystanders.

Do not use a cut off wheel that is larger
than the maximum recommended size for
your tool, or worn down damaged wheels
from larger abrasive cut off tools. Wheels

intended for larger tools are not suitable for
the higher speed of a smaller tool, these
wheels may easily burst and the fragments
strike you or bystanders.

Keep your body positioned to either side
of the wheel, but not in line with the
wheel. It is important to support the tool

properly and to position your body such as to
minimize body exposure from the possible
wheel binding and the recoil of the tool.

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Keep hands away from cutting area and
wheel. Keep your second hand on
auxiliary handle or the attachment. Hold
the tool firmly to prevent loss of control.
NEVER place your hand behind the wheel
since the tool may recoil over your hand.
Do not attempt to remove cut material
when wheel is moving. If both hands are

holding the tool, they cannot be cut by the
wheel

Do not “jam” the abrasive wheel into the
work, apply excessive pressure or
attempt to use large depths of cut while
using this tool. Let the rotating wheel do the

work, Abrasive Cut Off Tools are intended to
“cut” the material in a series of shallow depth
of cuts. See the instructions for depth of cut
later in this manual.

Avoid bouncing and snagging the wheel,
especially when working corners, sharp
edges etc. This can cause loss of control

and tool’s recoil.

Do not run the tool while carrying it at
your side. Accidental contact with the

spinning wheel could result in serious
personal injury.

Never lay the tool down until the motor
has come to a complete standstill. The

spinning wheel can grab the surface and pull
the tool out of your control.

Do not use the Zipmate near flammable
materials. Sparks from the wheel could

ignite these materials.

Never cut or attempt to cut magnesium
with this attachment. The dust generated

when cutting magnesium is highly flammable
and may be explosive under certain
conditions.

Regularly clean the tool’s air vents by
compressed air. Excessive accumulation of

powdered metal inside the motor housing
may cause electrical failures.

Causes and Operator

Recoil is a sudden reaction to a pinched,
bound or misaligned rotating wheel. The
wheel may stall and cause an uncontrolled
tool to back out of the kerf toward the
operator when the tool is in the “fire forward”
position, if the tool is set in the “reverse fire”
position the tool may tend to
the operator. The rotation direction arrow
located on the back side of the guard can be
used to identify the “fire forward” and

Prevention of Recoil:

walk away from

“reverse fire” positions. The attachment is in
the fire forward position when the directional
arrow points toward the operator, and it is in
the reverse fire position when the arrow is
pointing away from the operator.

If an abrasive wheel or diamond wheel
becomes twisted or misaligned in the cut, the
side of the wheel that is entering into the
material can dig into the top surface of the
material causing the wheel to climb out or
recoil out of the kerf either toward or away
from the operator, depending on the fire
forward or reverse fire orientation.

Abrasive wheels may also shatter under
these conditions causing pieces or fragments
to strike or impale the operator and
bystanders. Recoil or shattered wheels are
the result of tool misuse and/or incorrect
operating procedures or conditions and can
be avoided by taking proper precautions as
given below:

Maintain a firm grip with both hands on
the tool handles and position your body
and arm to allow you to resist recoil
forces. Recoil forces can be controlled by

the operator, if proper precautions are taken.

When wheel is binding, or when
interrupting a cut for any reason, slowly
ease the wheel out of the material while
maintaining a firm grip on the tool and
auxiliary handle with both hands.

Investigate and take corrective action to
eliminate the cause of wheel binding.

When restarting a tool in a workpiece,
center the wheel in the kerf and check
that the sides of the wheel are not
engaged into the material. If wheel is

binding, it may walk up or recoil from the
workpiece as the tool is restarted.

Support large panels to minimize the risk
of wheel pinching and recoil. Large panels

tend to sag under their own weight. Supports
must be placed under the panel on both
sides, near the line of cut and near the edge
of the panel.

Use extra caution when making a “Pocket
Cut” into existing walls or other blind
areas. The protruding wheel may cut objects

that can cause recoil.

WARNING

!

grinding, drilling, and other construction
activities contains chemicals known to
cause cancer, birth defects or other

Some dust created by
power sanding, sawing,

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reproductive harm. Some examples of
these chemicals are:

• Lead from lead-based paints,

• Crystalline silica from bricks and cement
and other masonry products, and

• Arsenic and chromium from chemically­treated lumber.

Battery/Charger

Before using battery charger, read all
instructions and cautionary markings on
(1) battery charger, (2) battery pack, and
(3) product using battery.

Use only the charger which accompanied
your product or direct replacement as
listed in the catalog or this manual. Do not

substitute any other charger. Use only Bosch
approved chargers with your product. See
Functional Description and Specifications.

Do not disassemble charger or operate
the charger if it has received a sharp blow,
been dropped or otherwise damaged in
any way. Replace damaged cord or plugs
immediately. Incorrect reassembly or

damage may result in electric shock or fire.

Do not recharge battery in damp or wet
environment. Do not expose charger to
rain or snow. If battery case is cracked or
otherwise damaged, do not insert into
charger. Battery short or fire may result.

Charge only Bosch approved rechargeable
batteries. See Functional Description and

Specifications. Other types of batteries may
burst causing personal injury and damage.

Charge battery pack in temperatures
above +40 degrees F (4 degrees C) and
below +105 degrees F (41 degrees C).
Store tool and battery pack in locations

Your risk from these exposures varies,
depending on how often you do this type of
work. To reduce your exposure to these
chemicals: work in a well ventilated area, and
work with approved safety equipment, such
as those dust masks that are specially
designed to filter out microscopic particles.

where temperatures will not exceed 120
degrees F (49 degrees C). This is important

to prevent serious damage to the battery
cells.

Battery leakage may occur under extreme
usage or temperature conditions. Avoid
contact with skin and eyes. The battery

liquid is caustic and could cause chemical
burns to tissues. If liquid comes in contact
with skin, wash quickly with soap and water,
then with lemon juice or vinegar. If the liquid
contacts your eyes, flush them with water for
a minimum of 10 minutes and seek medical
attention.

Place charger on flat non-flammable
surfaces and away from flammable
materials when re-charging battery pack.

The charger and battery pack heat during
charging. Carpeting and other heat insulating
surfaces block proper air circulation which
may cause overheating of the charger and
battery pack. If smoke or melting of the case
are observed unplug the charger immediately
and do not use the battery pack or charger.

Use of an attachment not recom­mended or sold by Bosch may result in a
risk of fire, electric shock or injury to
persons.

Battery Care

WARNING

!

away from metal objects. For example, to
protect terminals from shorting DO NOT
place batteries in a tool box or pocket with
nails, screws, keys, etc. Fire or injury may
result.

When batteries are not in
tool or charger, keep them

WARNING

!

tool or charger, always place protective
cap onto end of battery pack. Protective

cap, guards against terminal shorting.

DO NOT PUT BATTERIES INTO FIRE OR
EXPOSE TO HIGH HEAT. They may

explode.

To prevent fire or injury
when batteries are not in

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Battery Disposal

WARNING

!

remove any component projecting from
the battery terminals. Fire or injury may

result. Prior to disposal, protect exposed
terminals with heavy insulating tape to
prevent shorting.

NICKEL-CADMIUM BATTERIES

If equipped with a nickel-cadmium battery, the
battery must be collected, recycled or
disposed of in an environmentally sound
manner.

Do not attempt to disas­semble the battery or

“The EPA certified RBRC
Battery Recycling Seal on the
nickel-cadmium (Ni-Cd)
battery indicates Robert
Bosch Tool Corporation is
voluntarily participating in an

industry program to collect and recycle these
batteries at the end of their useful life, when
taken out of service in the United States or
Canada. The RBRC program provides a
convenient alterative to placing used Ni-Cd
batteries into the trash or the municipal
waste stream, which may be illegal in your
area.

Please call 1-800-8-BATTERY for information
on Ni-Cd battery recycling and disposal
bans/restrictions in your area, or return your
batteries to a Skil/Bosch/Dremel Service
Center for recycling. Robert Bosch Tool
Corporation’s involvement in this program is
part of our commitment to preserving our
environment and conserving our natural
resources.”

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Symbols

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.

Symbol Name Designation/Explanation

V Volts Voltage (potential)
A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watt Power
kg Kilograms Weight

min Minutes Time

s Seconds Time

Diameter Size of drill bits, grinding wheels, etc.

n

0

.../min Revolutions or reciprocation per minute Revolutions, strokes, surface speed,

0 Off position Zero speed, zero torque...

1, 2, 3, ... Selector settings Speed, torque or position settings.

I, II, III, Higher number means greater speed

0

No load speed Rotational speed, at no load

orbits etc. per minute

Infinitely variable selector with off Speed is increasing from 0 setting
Arrow Action in the direction of arrow
Alternating current Type or a characteristic of current
Direct current Type or a characteristic of current
Alternating or direct current Type or a characteristic of current
Class II construction Designates Double Insulated

Construction tools.
Earthing terminal Grounding terminal
Warning symbol Alerts user to warning messages
Ni-Cad RBRC seal Designates Ni-Cad battery recycling

program

This symbol designates
that this tool is listed by
Underwriters Laboratories.

This symbol designates
that this tool is listed by
the Canadian Standards
Association.

This symbol designates
that this tool is listed to
Canadian Standards by
Underwriters Laboratories.

This symbol designates that
this tool is listed by
Underwriters Laboratories,
and listed to Canadian
Standards by Underwriters
Laboratories.

-9-

This symbol

designates
that
this tool
complies
to NOM
Mexican
Standards.

RZ 2610925600 9-05 9/1/05 11:04 AM Page 10

Functional Description and Specifications

WARNING

!

Disconnect battery pack from tool or place the switch in the locked or
off position before making any assembly, adjustments or changing

accessories. Such preventive safety measures reduce the risk of starting the tool

accidentally.

Cordless Spiral Saw™

FIG. 1

BATTERY

RELEASE TABS

BUMP-OFF SLIDE

"ON/OFF" SWITCH

INTAKE

AIR VENTS

EXHAUST

AIR VENTS

BATTERY PACK

BIT / COLLET

STORAGE

LOCK PIN

BIT / COLLET

STORAGE

REMOVABLE

HARD

AUXILIARY

CONTROL

HANDLE

WRENCH STORAGE

RZVAC1

VACUUM ADAPTER

(Not included, available as

accessory)

DEPTH GUIDE

LOCKING

KNOB

COLLAR

DEPTH GUIDE

LOCKING

SCREW

SHAFT LOCK

COLLET NUT

DEPTH GUIDE

BRACKET

LOCK LEVER

DEPTH

GUIDE

Tool Charger

Model number RZ18V BC003, 4, 6, BC016, BC130 & BC230
Voltage rating 18 V Voltage rating 120 V 60 Hz
No load speed n

30,000/min Battery pack BAT025, BAT026

0

BAT180 & BAT181

BC006 charger requires 12 V DC input

NOTE: ONLY USE CHARGERS LISTED ABOVE

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Assembly

WARNING

!

switch in the locked or off position before
making any assembly, adjustments or
changing accessories. Such preventive

safety measures reduce the risk of starting
the tool accidentally. Make certain that the
collet nut is securely tightened before turning
the tool on.

REMOVING AND INSTALLING THE

The depth guide assembly consists of the
depth guide, locking screw and bracket.

In order to remove the depth guide from the
tool, release the locking lever and pull the
entire assembly straight off of the tool. To

The bits are held by a collet system. Use either
the 1/8" (.125"), 1/4" (.250") or 5/32" (.156")
collet depending on the size of the bit shank.

caution.
Depress and hold the shaft-lock in and rotate

the collet nut and shaft until the shaft-lock
engages and holds the shaft.

a braking devise to stop the tool from
rotating.

Use the standard equipment wrench to
loosen nut (counter-clockwise) (Fig. 2).

DEPTH GUIDE ASSEMBLY

INSTALLING BITS (Standard models)

!

WARNING

!

CAUTION

Disconnect battery pack
from tool or place the

The bit flutes are sharp and
should be handled with

To prevent damage to tool.

Never use the shaft lock as

1/8"

FIG. 2

reattach the assembly, fully replace the guide
onto the tool collar and lock the clamp lever
(Fig. 1).

REMOVING AND INSTALLING THE

RZVAC1 VACUUM ADAPTER

(Not included, available as accessory)

The vacuum adapter is sized to accept 1-1/4"
vacuum hoses.

The vacuum adapter assembly consists of the
vacuum adapter, locking knob and bracket.

In order to remove the vacuum adapter
assembly from the tool, release the locking
lever and pull the entire assembly straight off
of the tool. To reattach the assembly, fully
replace the vacuum adapter assembly onto the
tool collar and lock the clamp lever (Fig. 1).

(clockwise) by hand and then with the
wrench until bit is held securely.

INSTALLING BITS (Keyless models)

(Not included, available as accessory)

The bits are held by a keyless collet system
designed specifically for spiral saw bits with
1/8" (.125"), 1/4" (.250") or 5/32" (.156") shanks.

Depress and hold the shaft-lock in and rotate
the keyless chuck and shaft until the shaft­lock engages and holds the shaft.

Rotate the keyless chuck (counter-clockwise)
(Fig. 3). Remove the old bit (if there is one)
insert the new bit as far in as possible, but
not so far that the bit flutes engage the jaws
of the chuck (leave approximately 1/8" of
shank exposed) Re-engage the shaft-lock
and securely tighten the keyless chuck
(clockwise) by hand.

Note: When using 1/4" & 5/32" bits it may be
necessary to use a wrench on the front of the
keyless chuck to securely tighten the bit.

FIG. 3

1/8"

SHAFT

LOCK

Remove the old bit (if there is one) insert the
new bit as far in as possible, but not so far
that the bit flutes engage the collet (leave
approximately 1/8" of shank exposed)
Re-engage the shaft-lock and tighten the nut

COLLET

NUT

-11-

SHAFT

LOCK

KEYLESS

CHUCK

RZ 2610925600 9-05 9/1/05 11:04 AM Page 12

The 1/8" collet is used with 1/8" diameter Zip

CHANGING THE COLLET

bits, the 1/4" collet is used with 1/4" diameter
Zip bits and the 5/32" collet is used with
5/32" diameter Zip bits. To change collets,
first remove the bit. Continue to loosen and
unscrew the collet nut until you can remove it
from the tool. Remove the collet and replace
it with the other (Fig. 4). (Each collet is
double-ended, and either end is acceptable
to use.) By hand, re-tighten the collet nut
around the collet in a clockwise direction.
You are now ready to insert a new bit as
instructed in Installing Zip Bits (Fig. 2 or 3).

REMOVING AND INSTALLING THE HARD

AUXILIARY CONTROL HANDLE

Turn the tool OFF and remove battery pack.
Firmly grasp the tool. Depress and hold lock
pin from either side of the handle. While
depressing the lock pin, depress release
button so lock pin is engaged, then remove
handle (Fig. 5).

With the lock pin engage, gently engage the
two (2) front latches on handle into the tool and
push handle until it snaps securely into place.

Your handle is equipped with a bit and collet
storage area. To open door, pull tab on door
downward away from tool. To close door, lift

FIG. 4

COLLET

COLLET

NUT

OUTPUT SHAFT

door upward toward the tool. Be sure door is
closed to prevent bits from falling out.

LOCK

PIN

BIT / COLLET

STORAGE

FIG. 5

RELEASE

BUTTON

TAB

DOOR

Operating Instructions

BUMP-OFF SLIDE "ON/OFF" SWITCH

This tool is switched "ON" by the slide switch
located on the front of the motor housing (Fig. 6).

TO TURN THE TOOL "ON" slide the switch
button out to "I" position.

TO TURN THE TOOL "OFF" slide the switch
button in to "0" position.

!

WARNING

torque from the motor can cause the tool to
twist.

Hold the tool with both
hands while starting, since

FIG. 6

BUMP-OFF

SLIDE "ON/OFF"

SWITCH

-12-

0

1

RZ 2610925600 9-05 9/1/05 11:04 AM Page 13

DEPTH GUIDE ADJUSTMENT

Use the depth guide to adjust the depth of
cut. Using the end of the standard wrench,
loosen (counter clockwise) the screw enough
to enable the depth guide to slide up or down
to the desired depth of cut (about 1/8"
greater than material thickness) and
retighten the locking screw (clockwise)
(Fig. 7).

RELEASING AND INSERTING BATTERY PACK

Release battery pack from tool by pressing on
both sides of the battery release tabs and pull
downwards. Before inserting battery pack,
remove protective cap from battery pack. To

CHARGING BATTERY PACK (30 MINUTE SINGLE BAY-BC130)

INDICATORS, SYMBOLS AND MEANING

If the indicator lights are “OFF”, the charger
is not receiving power from power supply
outlet.

If the green indicator light is
“ON”, the charger is plugged in

but the battery pack is not
inserted, or the battery pack is fully charged
and is being trickle charged.

If the green indicator light is
“BLINKING”, the battery pack is

being fast-charged. Fast­charging will automatically stop when the
battery pack is fully charged.

FIG. 7

DEPTH GUIDE

LOCKING

SCREW

1/8"

insert battery, align battery and slide battery
pack into tool until it locks into position. Do
not force.

If the red indicator light is “ON”,
the battery pack is too hot or

cold for fast-charging. The
charger will switch to trickle charge, until a
suitable temperature is reached, at which
time the charger will switch automatically to
fast-charging.

If the red indicator light is
“BLINKING”, the battery pack

cannot accept a charge or the
contacts of the charger or battery pack are
contaminated. Clean the contacts of the
charger or battery pack only as directed in
these operating instructions or those supplied
with your tool or battery pack.

Plug charger cord into your standard power
outlet. Before inserting battery pack, remove
protective cap, then insert battery pack into
charger (Fig. 8).

The charger’s green indicator light will begin to
“BLINK”. This indicates that the battery is
receiving a fast charge. Fast-charging will
automatically stop when the battery pack is
fully charged.

When the indicator light stops “BLINKING”
(and becomes a steady green light) fast
charging is complete.

The battery pack may be used even though
the light may still be blinking. The light may

require more time to stop blinking depending
on temperature. When you begin the
charging process of the battery pack, a
steady red light could also mean the battery
pack is too hot or too cold.

The purpose of the green light is to indicate
that the battery pack is fast-charging. It does
not indicate the exact point of full charge.
The light will stop blinking in less time if the
battery pack was not completely discharged.

When charging several batteries in
sequence, the charge time may slightly
increase.

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RZ 2610925600 9-05 9/1/05 11:04 AM Page 14

When the battery pack is fully charged,
unplug the charger (unless you're charging
another battery pack) and slip the battery
pack back into the tool.

BATTERY

PACK

CHARGER

RED LIGHT

GREEN LIGHT

To prevent fire or injury when batteries are
not in tool or charger, always place protective
cap onto end of battery pack.

FIG. 8

PROTECTIVE

CAP

IMPORTANT CHARGING NOTES

1. The battery pack accepts only about 80%
of its maximum capacity with its first few
charge cycles. However, after the first few
charge cycles, the battery will charge to full
capacity.

2. The charger was designed to fast charge
the battery only when the battery
temperature is between 40˚F (4˚C) and
105˚F (41˚C).

3. A substantial drop in operating time per
charge may mean that the battery pack is
nearing the end of its life and should be
replaced.

4. If you anticipate long periods (i.e. a month
or more) of non-use of your tool, it is best to
run your tool down until it is fully discharged
before storing your battery pack. After a long
period of storage, the capacity at first recharge
will be lower. Normal capacity will be restored
in two or three charge/discharge cycles.

Remember to unplug charger during storage
period.

5. If battery does not charge properly:
a. Check for voltage at outlet by plugging

in some other electrical device.

b. Check to see if outlet is connected to a

light switch which turns power “off” when
lights are turned off.

c. Check battery pack terminals for dirt.

Clean with cotton swab and alcohol if
necessary.

d. If you still do not get proper charging,

take or send tool, battery pack and charger
to your local Bosch Service Center. See
“Tools, Electric” in the Yellow Pages for
names and addresses.

Note: Use of chargers or battery packs not
sold by Bosch will void the warranty.

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RZ 2610925600 9-05 9/1/05 11:04 AM Page 15

MAKE A FEW PRACTICE CUTS

After installing the Zip Bit into the tool and
adjusting your depth guide, you should make
a few practice cuts with the tool before
attempting an actual job.

A few exercises will give you the necessary
practice to make clean, professional cuts.

Step 1

Make certain that the collet nut is securely
tightened before turning the tool on.

Step 2

Hold the tool firmly and turn the tool ON.

IMPORTANT USER TIP

Step 3

While holding the tool firmly, insert the Zip Bit
into the material at a 45° angle (Fig. 9).

Step 4

Slowly bring it to a 90° angle to begin the cut
(Fig. 10). The base guide should be flush to
the material surface. For all materials
(EXCEPT cutting around outlet boxes in
drywall), steer the tool in a clockwise
direction with slow, steady pressure to make
the cut.

FIG. 9

Step 5

After completing your cut, turn off the tool
and carefully remove it from the material.

Do not attempt to use this tool to make cut­outs around any fixture or opening which has
live electrical wires, or any wall which may
have live electrical wiring behind it, as the Zip
Bit could conduct current to the tool, creating
an electrocution hazard for the operator. Shut
off breakers or remove fuses to disconnect
the circuit. Always hold the tool by its
thermoplastic housing, and always wear eye
protection when operating a Spiral Saw
power tool.

NOTE: Because of the rotating cutting action
of the Zip Bit, there will be a slight pull when
cutting. The slower you cut, the more control
you have. Excessive pressure or fast cutting
will cause excessive heat and may shorten
the life of the Zip Bit.

NOTE: When cutting on a vertical surface,
avoid ending your cut at the bottom of the
hole. If possible, start and end your cut at
the top so the scrap part will not drop onto
the rotating Zip Bit. Turn the tool off and
remove it from the material.

FIG. 10

MAKING DRYWALL CUT OUTS

After assembling the bit into the tool as
described earlier, it will be necessary to
review the instructions provided below and
make some practice cut-outs with this tool
before attempting an actual job. The best
method is to take some scrap pieces and nail
or screw them in place over wall studs which
have an electrical box or other feature in
place. A few such exercises will give you the
necessary practice to make clean,

professional cutouts around whatever is
behind the drywall you are installing.

WARNING

!

around any fixture or opening which has
live electrical wires, or on any wall which
may have live electrical wiring behind it,
as the bit could conduct current to the
tool, creating an electrocution hazard for
the operator. Shut off breakers or remove

fuses to disconnect the circuit. Always hold

Do not attempt to use this
tool to make cut-outs

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RZ 2610925600 9-05 9/1/05 11:04 AM Page 16

the tool by its thermoplastic housing, and
always wear eye protection when operating
this device.

Step 1: Be certain that the box or fixture
which requires a cut-out is firmly mounted
and all wires or other obstructions around the
opening are pushed back out of the way. The
drywall cut-out bit uses the outer edge of the
box or fixture as a guide, so it is important
that there is nothing in the way which can
prevent it from guiding completely around the
opening. For the purposes of this instruction
manual, the procedure discussed will be to
make a cut-out around a standard 2 1/8" x 3
3/4" electrical box.

Step 2

Slide switch to turn the tool on. While holding
the Spiral Saw power tool firmly with both
hands plunge the Zip Bit through the mark
you made. Then guide the Zip Bit to the right
until you feel and hear the Zip Bit touch the
inside edge of the box.

Step 3

Pull the Zip Bit out far enough to slip it over
the edge of the box so it is now against the
outside of the box.

Step 4

While keeping the Zip Bit in contact with the
outside of the box move the tool counter
clockwise while applying light inward and
upward pressure until you feel and hear it
come to the corner. As you round the corner
apply light pressure left and downward.

Step 5

While moving slowly and continuously along
the top contour you will feel the Zip Bit come
to the next corner. Round the corner and
apply light down and inward pressure until
the bottom corner is reached.

Step 6

Move the Zip Bit right and upward maintaining
light continuous pressure toward the box.

Step 7

Round the right bottom corner and begin
moving the bit upward while applying light
pressure left toward the box until you meet
initial upward cut. Push Spiral Saw power tool
switch to off.

Step 8

The completed box, executed quickly, neatly
and in a fraction of the time taken by other
methods.

These step-by-step instructions are
generalized to acquaint you with the Spiral
Saw power tool operation. After some
practice, you may develop a motion
technique with which you are more
comfortable. However, you must always
begin the cut somewhat centrally, and MOVE
THE SPIRAL SAW POWER TOOL ONLY
COUNTERCLOCKWISE to take advantage
of the “hugging” action of the rotating Zip Bit
along the contours of the template.
Remember to use a smooth continuous
motion.

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RZ 2610925600 9-05 9/1/05 11:04 AM Page 17

Functional Description and Specifications

!

WARNING

sufficient control of the cutting wheel in case of recoil.

WARNING

!

accessories. Such preventive safety measures reduce the risk of starting the tool
accidentally.

Zipmate attachment must be used only with an hard auxiliary control
side handle. Two handed control of solid gripping handles will provide

Disconnect battery pack from tool or place the switch in the locked or
off position before making any assembly, adjustments or changing

Zipmate®Abrasive Cut Off Attachment

WHEEL GUARD

LOCK LEVER

FIG. 1

LOCK LEVER

ADJUSTMENT

SCREW

LOCK

LEVER

WHEEL GUARD

GUARD

LOCK LEVER

ADJUSTMENT

SCREW

ABRASIVE

WHEEL

SHAFT LOCK

Recommended for use with: Rebel, Revolution,

and all RZ model Spiral Saws.

WARNING

!

Note : The speed of your tool will be reduced 2 : 1 when using your Abrasive Cut-Off attachment.

Hard auxiliary control handle must be obtained for models RZ1 and RZ25.
Call 1-877-ROTOZIP.

Assembly

WARNING

!

control over torque reaction or kick-back.

Operation of the tool without the auxiliary
handle could cause loss of control of the tool,
resulting in possible serious personal injury.

REMOVING AND INSTALLING

ABRASIVE CUT OFF ATTACHMENT

WARNING

!

switch in the locked or off position before
making any assembly, adjustments or
changing accessories. Such preventive

safety measures reduce the risk of starting
the tool accidentally. Make certain that the
collet nut is securely tightened before turning
the tool on.

Always use auxiliary
handle for maximum

Disconnect battery pack
from tool or place the

1.Insert the 1/4” collet into the collet nut.
Loosely thread the collet nut onto the output
shaft (Fig. 2).

2. Insert drive bit into the collet until it stops,
and securely tighten the collet nut with the
wrench.

3.Open locking lever and position
attachment onto the collar. Note: It may be
necessary to rotate attachment slightly and
hold both the tool and attachment shaft
locks to engage square end of drive bit into
attachment.

4. Position attachment as shown and lock the
clamp lever.

Use the allen wrench to adjust the lock lever
adjustment screw.

-17-

RZ 2610925600 9-05 9/1/05 11:04 AM Page 18

!

CAUTION

Overtightening the lock lever
adjustment screw can

permanently damage the locking mechanism.

COLLAR

OUTPUT

SHAFT

COLLET NUT

COLLET

DRIVE BIT

LOCK LEVER

ADJUSTMENT

SCREW

LOCK LEVER

FIG. 2

INSTALLING ABRASIVE WHEELS

Always use the arbor nut that has same
thread size as the output shaft.

1. Install abrasive wheel onto output shaft.

2. Thread arbor nut provided onto
output shaft finger tight, depress shaft lock
and tighten wheel with the wrench provided
(Fig. 3).

WARNING

!

Do not overtighten. Cracks

in the wheel can occur if
overtightened. Use wrench provided with
tool. Other wrenches may promote
overtightening.

Test the tightness of the lever after each full
turn of the adjustment screw.

GUARD

WHEEL GUARD

LOCK LEVER

WARNING

!

Do not depress shaft lock
while the tool is running.

LOCK LEVER

ADJUSTMENT

SCREW

SHAFT LOCK

Depressing the shaft lock may cause wheel
to spin off or damage to attachment.

GUARD

ABRASIVE

WHEEL

FIG. 3

SHAFT

LOCK

OUTPUT

SHAFT

ARBOR

NUT

Operating Instructions

MAKING A CUT

1. Make sure material being cut is secured in
a vise or fixture before attempting to cut.

2. Keep your body positioned to either side of
the wheel, but not in line with wheel. It is
important to support the tool properly and to
position your body such as to minimize body
exposure from possible wheel binding and
recoil.

3. Grip the tool with both hands when cutting
and always be ready and able to manage the
cut.

4. Avoid jamming, twisting or pinching the
wheel with the workpiece or otherwise
applying excessive side pressure to the
wheel.

Keep guard covering between wheel and

5.
user.

6. Make sure the guard lock lever is in the
closed position and the guard is securely
mounted to the attachment. Use the allen
wrench to adjust the guard adjustment screw.

7. Maximum cutting depth is 11/16”.

-18-

RZ 2610925600 9-05 9/1/05 11:04 AM Page 19

CAUTION

!

permanently damage the locking
mechanism. Test the tightness of the lever
after each full turn of the adjustment screw.

WARNING

!

ensure that the inner or outer flanges never
contacts the workpiece surface.

Overtightening the guard

adjustment screw can

To prevent recoil and

damage to the tool, always

8. Generally, the harder the material being
worked on, the faster the wheel will wear.

9. When cutting thicker material, never make
the cut in one pass. Make successive passes
until you reach desired depth.

10. When using the Diamond Wheel, do not
make long, continuous cuts. Allow the blade to
cool for approximately 10 seconds for each
minute cutting.

FIG. 4

HARD AUXILIARY
CONTROL HANDLE

WHEEL

DIRECTION

DIRECTION OF CUT

APPLICATIONS

This tool is intended for cutting the following
materials.

1/8˝ maximum thick sheet steel.
Floor and wall tile.
Concrete cinder blocks and bricks.
Reinforcing rod-generally under 5/8˝ diameter.
1/8˝ concrete wire mesh.
Electrical conduit 1/8˝ wall thickness.
1/8” maximum thick structural forms such as:

channels, angles, plate and etc.
ATTENTION: If you run the tool continuously

for more than 5 minutes, it is normal for the
housing to feel warm.

FOOT

It is important to read and understand the
section in this manual called “Causes and
Operator Prevention of Recoil”.

When making a cut in sheet metal,
masonry, etc.: You may start your cut at the

end of the piece or you can plunge cut
somewhere in the body of the material.

In order to try to avoid recoil (a situation where
the wheel wants to skip out of the material) it
is recommended to make cuts in the same
direction as the rotation of the wheel (Fig. 4).

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RZ 2610925600 9-05 9/1/05 11:04 AM Page 20

Maintenance

Service

!

WARNING

maintenance performed by unauthorized
personnel may result in misplacing of
internal wires and components which
could cause serious hazard. We recom-

mend that all tool service be performed by a
Bosch Factory Service Center or Authorized
Bosch Service Station. SERVICEMEN:
Disconnect tool and/or charger from power
source before servicing.

Be alert for battery packs that are nearing
their end of life. If you notice decreased

tool performance or significantly shorter
running time between charges then it is time
to replace the battery pack. Failure to do so
can cause the tool to operate improperly or
damage the charger.

Long term battery storage should be in
the discharged state. Battery packs last

longer and re-charge better when they are
stored discharged. Remember to fully re­charge battery packs before using after
prolonged storage.

Your Bosch tool has been properly lubricated
and is ready for use.

The wrenchless chuck has been properly
lubricated and is ready to use. If the chuck's
jaws begin to stick during use, the chuck
requires lubrication. To lubricate the chuck,
first remove debris from the inside of the
chuck with compressed air. Apply a pea-

NO USER SERVICEABLE
PARTS INSIDE. Preventive

BATTERIES

TOOL LUBRICATION

CHUCK LUBRICATION

sized amount of general-purpose grease to
the sides of the jaws, and adjust the chuck
through its full range of motion to distribute
the grease.

D.C. MOTORS

The motor in your tool has been engineered
for many hours of dependable service. To
maintain peak efficiency of the motor, we
recommend it be examined every six
months. Only a genuine Bosch replacement
motor specially designed for your tool should
be used.

BEARINGS

Bearings which become noisy (due to heavy
load or very abrasive material cutting) should
be replaced at once to avoid overheating and
motor failure.

Cleaning

WARNING

!

charger from the power supply before
cleaning. The tool may be cleaned most
effectively with compressed dry air. Always
wear safety goggles when cleaning tools
with compressed air.

Ventilation openings and switch levers must be
kept clean and free of foreign matter. Do not
attempt to clean by inserting pointed objects
through opening.

CAUTION

!

parts. Some of these are: gasoline, carbon
tetrachloride, chlorinated cleaning solvents,
ammonia and household detergents that
contain ammonia.

To avoid accidents, always
disconnect the tool and/or

Certain cleaning agents and
solvents damage plastic

Extension Cords

WARNING

!

adequate size conductors that is capable
of carrying the current necessary for your
tool must be used. This will prevent

excessive voltage drop, loss of power or
overheating. Grounded tools must use 3­wire extension cords that have 3-prong plugs
and receptacles.

NOTE: The smaller the gauge number, the

heavier the cord.

If an extension cord is
necessary, a cord with

RECOMMENDED SIZES OF EXTENSION CORDS

120 VOLT ALTERNATING CURRENT TOOLS

Tool’s

Ampere

Rating

3-6
6-8

8-10
10-12
12-16

Cord Size in A.W.G.

Cord Length in Feet Cord Length in Meters

25 50 100 150 15 30 60 120

18 16 16 14 0.75 0.75 1.5 2.5
18 16 14 12 0.75 1.0 2.5 4.0
18 16 14 12 0.75 1.0 2.5 4.0
16 16 14 12 1.0 2.5 4.0 —
14 12 — — — — — —

Wire Sizes in mm

-20-

2