RotoZip DR1 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
DR1
Call Toll Free for
Consumer Information
& Service Locations
Pour obtenir des informations
et les adresses de nos centres
de service après-vente,
appelez ce 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 Version Version française Versión en español
See page 2 Voir page 13 Ver la página 24
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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. While the tool may appear to
work, the electrical components of the AC
rated tool are likely to fail and create a hazard
to the operator.
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.
Keep handles dry, clean and free from oil
and grease. Slippery hands cannot safely
control the power tool.
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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.
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.
Risk of injury to user, power cord must only be
serviced by a Rotozip/Bosch Factory Service
Center or Authorized Rotozip/Bosch Service
Station.
SAVE THESE INSTRUCTIONS
Drywall Router Safety Rules
Hold tool by insulated gripping surfaces
when performing an operation where the
cutting tool 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.
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.
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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. The spinning
bit can grab the surface and pull the tool out of
your control.
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
!
grinding, drilling, and other construction
activities contains chemicals known to
cause cancer, birth defects or other
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.
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.
Some dust created by
power sanding, sawing,
TWIST-TO-LOCK CONNECTOR INSTRUCTIONS FOR MODEL DR01-1100TL ONLY
The Model DR01-1100TL is equipped with a
“Twist-To-Lock” male connector as shown. Use
only a 3-wire extension cord which has a mating
“Twist-To-Lock” female connector on one end
and a 3-prong grounding plug on the other end.
(See Electrical Safety section on page 2 for
grounding information.)
20 AMP, 125 VOLT “TWIST-TO-LOCK”
NEMA L5-20P
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0
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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
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 to
Canadian Standards by
Underwriters Laboratories.
This symbol
designates
that
this tool
complies
to NOM
Mexican
Standards.
This symbol designates
that this tool is listed by
the Canadian Standards
Association.
This symbol designates that
this tool is listed by
Underwriters Laboratories,
and listed to Canadian
Standards by Underwriters
Laboratories.
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Functional Description and Specifications
WARNING
!
measures reduce the risk of starting the tool accidentally.
Disconnect the plug from the power source before making any
assembly, adjustments or changing accessories. Such preventive safety
Drywall Router
FIG. 1
WRENCH STORAGE
COMPARTMENT
BUMP SWITCH
(ON/OF)
BRUSH DOOR
SCREW
CORD
INTAKE
AIR VENTS
SUPPORT STRAP
EXHAUST
AIR VENTS
SHAFT LOCK
DEPTH GUIDE
COLLET NUT
NOTE: For tool specifications refer to nameplate on your tool.
THUMBSCREW
DEPTH GUIDE
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Assembly
WARNING
!
Disconnect the plug from
the power source 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, INSTALLING, AND
ADJUSTING THE DEPTH GUIDE
In order to remove the depth guide from the
tool, turn the thumb screw counter-clockwise
until you can remove it from the tool. The
depth guide should then pull freely from the tool.
To reattach the depth guide, line up the slot in
the depth guide with the threaded hole in the
metal housing and re-install the thumb screw
by rotating it clockwise until tight. Be careful
not to cross-thread the thumb screw.
The depth guide allows you to control the
depth of cut. Loosen the thumb screw by
CHANGING THE COLLET
WARNING
!
The bit flutes are sharp and
should be handled with
caution.
The 1/8" collet is used with 1/8" diameter
bits, the 1/4" collet is used with 1/4" diameter
bits and the 5/32" collet is used with 5/32"
diameter bits.
To change collets, loosen the collet nut with
the included wrench and 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. 3).
turning it counter-clockwise until the depth
guide can slide freely on the metal housing.
For bits with a guide point (Drywall XBITS
Guidepoint
®
and Window & Door Zip®bits)
™,
make sure that the entire guide point tip will
extend 1/8” beyond the material thickness
(Fig. 2). For standard point drywall Zip
®
bits,
make sure that the fluted end of the bit
extends 1/8” beyond the material thickness.
1/8"
FIG. 2
THUMB SCREW
(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 Bits (Fig. 4).
SHAFT
LOCK
COLLET
OUTPUT SHAFT
FIG. 3
COLLET
NUT
The bits are held by a collet system. Use either
INSTALLING BITS
the 1/8", 1/4" or 5/32" collet depending on the
size of the bit shank.
Depress and hold the shaft-lock in and rotate
the collet nut and shaft until the shaft-lock
engages and holds the shaft.
Use the included wrench to loosen the nut by
rotating it counter-clockwise (Fig 4). Remove
the old bit (if there is one) and insert the new
bit as far as possible. Re-engage the shaft
lock and tighten the nut by rotating it
clockwise by hand, then with the wrench until
the bit is held securely.
SHAFT
LOCK
COLLET NUT
1/8"
-7-
FIG. 4
1
2
0
1
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INSTALLING THE SUPPORT STRAP
With the Velcro
the strap with the Rotozip
®
facing up, thread the end of
®
logo around the
post near the cord as shown.
Thread the other end through the slot near
the front of the tool. Fold the front flap over
first (1), then fold the end with the Rotozip
logo (2) as shown. Press firmly to ensure the
strap is secured.
Operating Instructions
This tool is switched “ON” by the bump switch
located on the back of the motor housing
(Fig. 6).
TO TURN THE TOOL “ON” slide the switch
button up or “1” position.
TO TURN THE TOOL “OFF” slide the switch
button down or “0” position.
from the motor can cause the tool to twist.
BUMP SWITCH (ON/OFF)
WARNING
!
Hold the tool with both hands
while starting, since torque
FIG. 5
®
FIG. 6
BUMP
SWITCH
(ON/OFF)
(See next section for cutting electrical boxes and door/window openings)
GENERAL DRYWALL CUTTING INSTRUCTIONS
MAKE A FEW PRACTICE CUTS
After installing the Bit into the tool and
adjusting your depth guide, you should make
a few practice cuts with the tool before
attempting an actual job.
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.
FIG. 7
Step 3: While holding the tool firmly, insert
the bit into the material at a 45
Step 4: Slowly bring it to a 90
° angle (Fig. 7).
° angle to begin
the cut. The depth guide should be flush to
the material surface (Fig. 8).
Step 5: Steer the tool in a clockwise direction
with slow, steady pressure to make the cut.
-8-
FIG. 8
3
4
5
6
7
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INSTRUCTIONS FOR CREATING CUT-OUTS IN DRYWALL
FOR OUTLETS, CAN LIGHTS, WINDOWS, AND DOORS
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.
!
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 the tool by
its thermoplastic housing, and always wear
eye protection when operating this device.
WARNING
Do not attempt to use this
tool to make cut-outs
Step 1: Be certain that the box or fixture is
firmly mounted and all wires or other
obstructions around the opening are pushed
back out of the way. The 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 Drywall Router firmly with both
hands, plunge the bit through the mark you
made. Then guide the bit to the right until you
feel and hear the bit touch the inside edge of
the box (Fig. 9).
FIG. 9
Step 5: While moving slowly and continuously
along the top contour you will feel the bit come
to the next corner. Round the corner and
apply light down and inward pressure until the
bottom corner is reached (Fig. 10).
Step 6: Move the bit right and upward
maintaining light continuous pressure toward
the box (Fig. 10).
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 Drywall Router
switch to off (Fig. 10).
FIG. 10
Step 3: Pull the bit out far enough to slip it
over the edge of the box so it is now against
the outside of the box (Fig. 10).
Step 4: While keeping the 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 (Fig. 10).
Step 8: The completed box, executed quickly,
neatly, and in a fraction of the time taken by
other methods.
NOTE: These step-by-step instructions are
generalized to acquaint you with the Drywall
Router’s operation. After some practice, you
may develop a technique with which you are
more comfortable. However, you must always
begin the cut somewhat centrally, and MOVE
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THE DRYWALL ROUTER ONLY COUNTERCLOCKWISE to take advantage of the
“hugging” action of the bit along the contours
of the template. Remember to use a smooth,
continuous motion. The exception to this rule
Maintenance
Service
WARNING
!
personnel may result in misplacing of
internal wires and components which could
cause serious hazard. We recommend that
all tool service be performed by a
Rotozip/Bosch Factory Service Center or
Authorized Rotozip/Bosch Service Station.
Your Rotozip tool has been properly lubricated
and is ready to use.
After about 75-100 hours of operation, or at
every second brush change, the bearings
should be replaced at Bosch Factory Service
Center or Authorized Bosch Service Station.
Bearings which become noisy (due to heavy
load or very abrasive material cutting) should
be replaced at once to avoid overheating or
motor failure.
The brushes and commutator in your tool have
been engineered for many hours of
dependable service. To maintain peak motor
efficiency, we recommend the brushes be
examined every two to six months. Only use
genuine Rotozip replacement brushes
specially designed for your tool.
If your tool runs sporadically, loses power,
makes unusual noises, or runs at a reduced
speed, check the brushes. Continuing to use
the tool in this condition will permanently
damage the motor.
Do not attempt to operate the tool with
broken, missing, or loose brush doors. If
the brush doors or brush door screws become
lost or damaged, please contact Rotozip
Customer Service for replacement parts.
To Replace the Brushes
1. Disconnect the tool from the power supply.
2. Each door is held in place by a screw.
Using a screwdriver, loosen the screw by
Preventive maintenance
performed by unauthorized
TOOL LUBRICATION
BEARINGS
CARBON BRUSHES
applies to cutting window and door openings.
Since you are tracing around the inside of the
framing members, move the bit clockwise to
take advantage of the bits “hugging” action.
rotating it counter-clockwise (Fig. 1). Be careful
not to lose the screw.
3. Using your fingernail, pry the brush door
loose and remove it from the tool.
4. In order to remove the brush, you must pull
back the spring that is holding the brush in
place. Using needle nose pliers, carefully pull
back the end of the brush spring and place it to
the side of the brush near the hole for the
brush door screw. Once the spring has been
moved, you can remove the brush by pulling
on the brush wire connector (Fig. 11). Be
careful not to bump the brush spring or
damage the brush wire connector. Make a
note of which side of the tool the brush was
removed.
BRUSH
WIRE
BRUSH WIRE
CONNECTOR
FIG. 11
SPRING
SCREW HOLE
5. Check both brushes. The brushes in your
Drywall Router will not wear at the same rate.
If either brush is less than 3/16" (4.8mm) long
or the worn end of the brush is rough or pitted,
replace both brushes. Place the new brush in
the brush holder, making sure the brush wire is
securely connected to its terminal inside the
tool. Fold the brush wire away from the screw
hole as shown. Place the end of the spring into
its original position.
6. Replace the brush doors. Be careful not to
over-tighten the brush door screw.
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Cleaning
WARNING
!
the power supply before cleaning or
performing any maintenance. 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
To avoid accidents always
disconnect the tool from
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
not attempt to clean by inserting pointed
objects through openings.
!
CAUTION
Certain cleaning agents
and solvents damage
plastic parts. Some of these are: gasoline,
carbon tetrachloride, chlorinated cleaning
solvents, ammonia and household
detergents that contain ammonia.
RECOMMENDED SIZES OF EXTENSION CORDS
120 VOLT ALTERNATING CURRENT TOOL
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
2
Accessories & Attachments
!
WARNING
Do not use metal cutting bits, router bits, or
non-approved accessories with this product.
See list of approved accessories in manual.
Accessories that may be suitable for one
tool, may become hazardous when used on
another tool.
XB-DW2 / XB-DW10 Drywall XBITS™ with
Guidepoint (available in 2-pack or 10-pack)
Use only recommended
accessories with this tool.
Drywall XBITS™ (Ø5/32”)
!
WARNING
For drywall cutting only.
Your DR1 Drywall Router
was designed specifically for cutting drywall.
Rotozip offers products to cut a wide range
of materials. If your cutting requirements
extend to materials beyond drywall, please
contact your local Rotozip retailer, Rotozip
Customer Service, or www.Rotozip.com for
further information on our products.
®
GP10 / GP20 Guidepoint Zip
Drywall Zip
Bits (Ø1/8”)
®
Bit (available
in 10-pack or 20-pack)
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