Roto Zip REV01 User guide

REV01

Owner’s Manual
Guide de l’utilisateur
Manual del ususario

Roto Zip Tool Corporation

1861 Ludden Drive, Cross Plains, Wisconsin 53528 • Phone [phone]

TOLL-FREE 1-877- Rotozip (1-877-768-6947) U.S. & CANADA

FAX: [phone] WEB SITE: www.rotozip.com

Customer Service Hours: 8:00am - 4:30pm (CST)

IMPORTANT: Read Before Using

IMPORTANT : À lire avant d’utiliser

IMPORTANTE: Lea este manual antes de usar su herramienta

Parlez-vous francais? Voir page 17 ¿Habla español? Ver página 32

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Read and understand all instructions. Failure to follow all instructions listed
below, may result in electric shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS

-2-

Work Area

Keep your work area clean and well lit.

Cluttered benches and 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 by-standers, children, and visitors
away while operating a power tool.

Distractions can cause you to lose control.

Electrical Safety

Double Insulated tools are equipped with a
polarized plug (one blade is wider than the
other.) This plug will fit in a polarized outlet
only one way. If the plug does not fit fully in
the outlet, reverse the plug. If it still does
not fit, contact a qualified electrician to
install a polarized outlet. Do not change the
plug in any way. Double Insulation

eliminates the need for the three wire
grounded power cord and grounded power
supply system. Before plugging in the tool, be
certain the outlet voltage supplied is within 10%
of the voltage marked on the nameplate. Do
not use “AC only” rated tools with a DC power
supply.

Avoid body contact with grounded surfaces
such as pipes, radiators, ranges and
refrigerators. There is an increased risk of

electric shock if your body is grounded. If
operating the power tool in damp locations is
unavoidable, a Ground Fault Circuit Interrupter
must be used to supply the power to your tool.
Electrician’s rubber gloves and footwear will
further enhance your personal safety.

Don't 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
to carry the tools or pull the plug from an
outlet. Keep cord away from heat, oil, sharp
edges or moving parts. Replace damaged
cords immediately. Damaged cords 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. Refer to
Recommended sizes of Extension Cords
section of this manual.

Personal Safety

Stay alert, watch what you are doing and use
common sense when operating a power
tool. Do not use 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.

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. Keep handles dry,
clean and free from oil and grease.

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 wrenches 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 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,

hard hat, or hearing protection must be used for
appropriate conditions.

Tool Use and Care

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.

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 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.

!

WARNING

General Tool Safety Rules

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. Many accidents are

caused by poorly maintained tools. Develop a
periodic maintenance schedule for your tool.

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

Tool service must be performed only by
qualified repair personnel. Service or

maintenance performed by unqualified
personnel could result in a risk of injury.

When servicing a 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. Certain cleaning agents
such as gasoline, carbon tetrachloride,
ammonia, etc. may damage plastic parts.

Spiral SawTMPower Tool 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. 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.

The direction of feeding the bit into the
material is very important and it relates to
the direction of bit rotation. When viewing
the tool from the top, the bit rotates
clockwise. Feed direction of cutting must be

counter-clockwise. NOTE: inside and outside

cuts will require different feed direction, refer to
section on feeding the router. 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.

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.

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.

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:

• Lead from lead-based paints.

• Crystalline silica from bricks and cement

and other masonry products.

• Arsenic and chromium from chemically-

treated 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.

-5--4-

Functional Description and Specifications

NOTE: For tool specifications refer to nameplate on your tool.

REV01

RECESSED HIGH
INTENSITY LED LIGHTS

VARIABLE SPEED
CONTROL PANEL
(with LED speed indicator)

DEPTH GUIDE
BRACKET

INTAKE
AIR VENTS

BASE PLATE
LOCKING SCREW

3 POSITION ON/OFF
BUMP-OFF SLIDE SWITCH

SHAFT LOCK
BUTTON

COLLET NUT

ADJUSTABLE
BASE PLATE

COLLET AND ZIP BIT
STORAGE AREA

WRENCH AND
STORAGE AREA

REMOVABLE
TRIGGER HANDLE

ADJUSTABLE AIR
DIVERTER SWITCH

CAM LOCK LEVER TO
REMOVE HANDLE

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.

Reverse Angle

CAM LOCK
LEVER

TRIGGER SWITCH

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

No load speed Rotational speed, at no load

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

orbits etc. per minute

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

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

Symbols

0

This symbol designates that
this tool is listed to U.S. and
Canadian standards by
Underwriters Laboratories.

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.

STEP 1: INSTALLING ZIP® BITS

The Zip Bits are held by a collet system. At the
time your tool was assembled, the 1/8" collet (used
for 1/8" Zip Bits) was installed for your convenience.
The 1/4" collet (used for 1/4" Zip Bits) is located in
the Zip Bit package with your tool.

Only use Roto Zip Tool Corporation Zip Bits
with your Spiral Saw power tool.

Identify the different parts of your Zip Bits.

The Zip Bit flutes are sharp and
should be handled with caution.

To insert a Zip Bit into the tool, first remove the
standard equipment wrench and locate the
shaft lock button. Depress and hold down the
shaft lock button with one hand and at the same
time loosen the collet nut with the other hand by
turning it counter clockwise with the wrench for
a couple rotations. Remove the old Zip Bit (if
there is one), insert shank of Zip Bit into the
collet so that 1/16" to 1/8" of smooth shank
remains visible above the collet.

Do not allow the flutes/cutting

edges of the Zip Bit to fall into
the collet, and do not tighten the collet around the
flutes; doing so will result in decreased Zip Bit life.

After properly placing the Zip Bit into the collet,
depress the shaft lock button and simultaneously
tighten the collet nut in a clockwise direction, first
by hand, and then with the wrench until Zip Bit is
held securely.

Collet and Zip Bit storage compartment

area located in the handle

Changing the Collet

As stated above, the 1/8" collet is used with 1/8"
diameter Zip Bits and the 1/4" collet is used with
1/4" diameter Zip Bits. To interchange collets,
first remove the Zip Bit. Continue to loosen and
unscrew the collet nut until you can remove it
from the tool. Remove the collet and replace it
with another. (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 Zip Bit as instructed in step 1 above.

DURING STORAGE of your

tool when there is no Zip Bit
in the collet, DO NOT tighten the collet nut
down onto an empty collet. Doing so will make
the collet hole smaller, preventing you from
inserting Zip Bits into it in the future.

-7-

-6-

Operating Instructions

!

WARNING

SYSTEM COMPLETE

SYSTEM SEPERATED

COLLET

NUT

COLLET

!

CAUTION

!

CAUTION

!

WARNING

STEP 2: ADJUSTING THE AIR

DIVERTER

Always make sure tool is OFF ("0" position)
before making any adjustments to the air
diverter vents.

The exhaust air diverter vent redirects cooling
air toward the base plate to help remove debris
that may gather in the base plate while cutting.

To open the diverter vent so air pushes towards
the cutting surface, slide the air diverter lever
toward the handle. To close the vent, slide the
lever away from the handle.

STEP 3: ADJUSTING THE DEPTH

GUIDE BEFORE MAKING A CUT

The Revolution is designed to cut materials up
to 1” thick. Use the depth guide to adjust the
depth of the cut. The depth guide assembly
consists of the depth guide & locking lever, and
the adjustable base plate & locking screw.

Locate the base plate and its locking screw.
Using the end of the standard wrench, loosen
(counter clockwise) the screw enough to enable
the base plate to slide up or down to the desired
depth of cut. For best performance, set the base
plate so the Zip Bit protrudes approximately 1/8"
beyond the material being cut. For example, to
cut a piece of 1/2" thick plywood, set the base
plate so the Zip Bit protrudes 5/8" below the
base plate, as shown here. Re-tighten the screw
in a clockwise direction.

Removing Depth Guide Assembly From Tool

and Reinstalling

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 reattach
the assembly, fully replace the guide onto the
tool collar and lock the clamp lever.

Removing and Replacing the Handle

Turn the tool OFF
and unplug it.
Firmly grasp the
tool. Slide open
the cam lock lever
to the unlock
position. Gently
lift-up the rear end
of the handle and
the cam lock pin will
disengage from the
tool. Continue to gently lift-up the handle and
the 2 latches at the front of the handle will also
disengaged. Remove handle from tool.You can
only operate the tool in the "2" ON position
while the handle is disengaged from the tool.

To replace the handle, reverse the steps above.
Gently engage the 2 front latches into the tool,
slide the cam lock pin into the open hole. Gently
pull handle to check that both ends are secured
before using.

Step 2

Step 3

Step 1

-8-

STEP 4: LOCATE THE

BUMP-OFF SLIDE SWITCH

Never leave tool unattended in
either the "1" or "2" ON positions.

The tool is powered by a three position
bump-off slide switch located on the rear, side
of the tool.

Position "0" is the OFF position
Position "1" turns the tool ON and activates

the trigger switch on the handle.
When the power switch is slid upward to the

first - or "1" - position, the tool is "live" and is
activated by depressing the trigger switch on
the removable handle. To turn the tool OFF
release the trigger switch and push the slide
switch to the "0" position.

Never leave the tool

unattended in the "1" ON
position. It is considered a live tool and is
activated by the trigger switch.

Position "2" turns the tool ON with a
continuous running action.

When the power switch is slid upward to the
second - or "2" - position, the tool runs
continuously. To turn the tool OFF, push the
slide switch down to the "0" position.

Note: When the auxiliary handle is removed, the
tool can only be turned ON in the "2" position.

STEP 5. LOCATE THE VARIABLE

SPEED INDICATOR

The Revolution Spiral Saw power tool features
a variable speed range of 15, 20, 25 and
30,000 RPMs.

* The default rating is 30,000 RPMs. Meaning, if
you turn the tool OFF and then back ON again,
the tool automatically starts at 30,000 RPMs.

* While the tool is ON (either in the "1" or "2"
position) you can move between speeds by
pressing the VARIABLE SPEED button.

* An illuminated red LED light on the touch pad
indicates the variable speed chosen.

* For the best results, when using the Spiral
Saw power tool and Zip® Bits, we recommend
only using the 30,000 and 25,000 RPM. You
will not obtain a quality cut if you lower the

RPM to 20,000 or 15,000.

!

WARNING

-9-

Step 4

Step 5

Hold the tool with both hands
while starting, since torque of

the motor can cause the tool to twist.

Make A Few Practice Cuts

After assembling the Zip Bit into the tool and
adjusting your depth guide, as described
above, 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 6:

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

STEP 7:

Hold the Spiral Saw power tool firmly and turn
the tool ON.

Hold the tool with both hands while starting,
since torque from the motor can cause the tool
to twist.

STEP 8:

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

STEP 9:

Slowly bring it to a 90° angle to begin the cut.
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.

STEP 10:

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

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

Step 9

!

CAUTION

Step 8

!

CAUTION

-11-

Step 5

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 6

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 7

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 8

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

-10-

Step 1

Make certain that the electrical wires are pushed
back or to the far side of the box so that the Zip Bit
does not cut the wires when inserted through the
drywall. Your hammer handle is an excellent tool
for this.

Step 2

Before fastening the sheet you must make a mark
somewhat near the center of the opening in the
box on the side of the drywall facing you. A
drywall hammer (hatchet end) works well for this.

Step 3

Do not nail or fasten screws closer then 12"
from the box, or the drywall may bulge or blister
from the excess pressure.

Step 4

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.

ILLUSTRATED INSTRUCTIONS FOR PERFECT OUTLET

OPENINGS IN DRYWALL (SCS01 model shown)

The following procedure will illustrate cutting out a standard 2 1/8" X 3 3/4" electrical box.

SCHEMATIC FOR REV01 MODEL

-13-

-12-

Step 9

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

Step 10

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.

-15-

1 100326 HOUSING - FRONT SUBASSEMBLY
2 100352 SHAFT LOCK SUBASSEMBLY
3 100342 SPRING, SHAFT LOCK
4 100308 RETAINING RING, SHAFT LOCK
5 100310 HOUSING - BACK SUBASSEMBLY
6 100314 PCB SUBASSEMBLY - HIGH END
7 100315 SWITCH CAP
8a 100316 STRAIN RELIEF (Type 1 & 2)
8b 100350 STRAIN RELIEF (Type 3)
9 100317 POWER CORD
10 100318 DIVERTOR RING
11 100380 MOTOR SUBASSEMBLY
12 100327 COVER, WIRE
13 RTM710 SCREWS
14 100328 DECAL, INFO
15 100329 DECAL, PRODUCT NAME
16 SC701 NUT, COLLET
17 100333 HANDLE - LEFT - HIGH END
18 100334 CAM LOCK SUBASSEMBLY
19 100337 STORAGE COVER
20 100338 LINKAGE SUBASSEMBLY
21 100341 TRIGGER
22 100345 SPRING, WRENCH
23 100344 HANDLE - RIGHT - HIGH END
24 100353 CLAMP
25 100354 LEVER
26 100355 LINK, CLAMP
27 100356 WASHER, SPRING
28 100307 WASHER, SLIDE
29 100357 PIN, PIVOT
30 100359 BASE
31 100362 SCREW, THUMB
32 100363 NUT, PLATE
33 RTM125 COLLET, 1/8"
34 RTM250 COLLET, 1/4"
35 100346 WRENCH
36 100313 MEMBRANE PANEL

Ref. Part No. Description
No.

-14-

Maintenance

Service

Preventive maintenance

performed by unauthorized
personnel may result in misplacing of
internal wires and components which could
cause serious hazard. Roto Zip Tool

Corporation is the only authorized repair center
for their tools. Contact the Customer Service
department, toll free in the U.S. and Canada, at
1-877-768-6947, or 1-608-798-0139 Ext. 520,
Monday through Friday between 8am-4:30pm
CST, for further instructions.

Cleaning

To avoid accidents always

disconnect the tool from
the power supply before cleaning or
performing any maintenance.

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

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.

!

WARNING

!

WARNING

!

CAUTION

Recommended Sizes of Extension Cords

If an extension cord is

necessary, a cord with
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 3-wire
extension cords that have 3-prong plugs and
receptacles

.

RECOMMENDED SIZES OF EXTENSION CORDS

120 VOLT ALTERNATING CURRENT TOOLS

NOTE: The smaller the gauge number, the heavier

the cord.

!

WARNING

Tool’s

Ampere

Rating

Cord Size in A.W.G.

Wire Sizes in mm

2

3-6
6-8

8-10
10-12
12-16

18 16 16 14 .75 .75 1.5 2.5
18 16 14 12 .75 1.0 2.5 4.0
18 16 14 12 .75 1.0 2.5 4.0
16 16 14 12 1.0 2.5 4.0 —
14 12 — — — — — —

25 50 100 150 15 30 60 120

Cord Length in Feet

Cord Length in Meters

Accessories

Use only Roto Zip Tool Corporation’s recommended accessories with this tool.
Accessories that may be suitable for one tool, may become hazardous when

used on another tool.

!

WARNING

ZBSC5
RZ125
RZ250
GP10
ZB10

ZBWD8

FBR250

Zip®Bits

Roto Zip Tool Corporation's patented line of versatile
Zip Bits and accessories provide you with the
flexibility to quickly move from one material to
another and one job to another, without the hassle of
changing tools.