RotoZip RZ2000 User Manual [en, es, fr]
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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
RZ1500
RZ2000
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 25 Ver la página 48
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General Power Tool Safety Warnings
WARNING
!
Read all safety warnings and instructions. Failure to follow the warnings
and instructions may result in electric shock, fire and/or serious injury.
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or
battery-operated (cordless) power tool.
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
us e a ny adapter pl ug s with earthe d
(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.
If operating the power tool in damp locations
is unavoidable, use a Ground Fault Circuit
Interrupter (GFCI) protected supply. Use of
an GFCI reduce the risk of electric shock.
Personal safety
Stay alert, watch what you are doing and
us e co mmon sense w hen opera ting 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 personal protective equipment. Always
wear eye protection. Protective equipment
such as dust mask, non-skid safety shoes, hard
hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
Prevent unintentional starting. Ensure the
sw itch is in th e o ff-po sitio n b efore
connecting to power source and / or battery
pa ck, picki ng u p or carrying the t ool.
Carrying power tools with your finger on the
switch or energizing 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
co ntrol of the power to ol in unexpe ct ed
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 dust collection can reduce dust-
related hazards.
Power tool use and care
Do not forc e the power to ol . 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
ca nn ot be co nt ro ll ed wi th th e swi tc h is
dangerous and must be repaired.
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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 tool’s operation. If damaged,
have the power tool repaired before use.
Ma ny acci de nt s a re caus ed by poorly
maintained power tools.
Spiral Saw 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 fu ses or circui t br eakers fe eding this
worksite.
Always make sure the work surface is free
fr om nails and othe r foreig n object s.
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 wor kp ie ce on top of ha rd
surface s, li ke co ncret e, st on e, etc...
Protruding cutting bit may cause tool to jump.
Always wear saf ety goggl es and dus t
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 makin g any
adjustments, make sure the collet nut and
any other adjus tm en t d evice s ar e
se curel y tigh tened. Lo ose ad justm ent
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,
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.
Service
Have your power tool serviced by a qualified
re pa ir person using o nl y id en ti ca l
replacement parts. This will ensure that the
safety of the power tool is maintained.
device can unexpectedly shift, causing loss
of control, loose rotating components will be
violently thrown.
Never start t he t oo l when th e bi t is
engaged in the material. The bit cutting
edge may grab the material causing loss of
control of the cutter.
Al wa ys ho ld the tool wi th tw o 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 ma te ri al in th e same
direction as the cutting edge is exiting
from the material. When viewing the tool
START
HERE
WORK
BIT
from the top, the bit rotates clockwise. If the
tool is between the workpiece and your body,
DIRECTION OF
FEED
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then feed the to ol t o yo ur rig ht . 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.
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.
Additional Safety Warnings
GFCI and personal protection devices like
electrician’s rubber gloves and footwear will
further enhance your personal safety.
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.
Keep handles dry, clean and free from oil
and grease. Slippery hands cannot safely
control the power tool.
Develop a periodic maintenance schedule
for your tool. When cleaning a tool be
careful not to disassemble any portion of
th e tool since inter nal wires may be
misplaced or pinched or safety guard return
sp rings ma y be impro perly mo unted.
Certain cleaning agents such as gasoline,
carbon tetrachloride, a mmonia, etc. may
damage plastic parts.
Risk of injury to user. The power cord must only
be serviced by a Rotozip Factory Service
Center or Autho rized Rotozip Service Station.
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.
Never use bi ts t hat ha ve a cut ti ng
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
se curel y attached and pos ition ed flat
ag ainst ma te rial b ei ng cut. The gui de
securely positioned on the material improves
WARNING
!
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 chro mium from chemicallytreated lumber.
Yo ur ri sk from these ex po su res varies,
depending on how often you do this type of
work. To reduce your exposure to th ese
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, grinding,
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Zipmate Abrasive Cut-Off Attachment Safety Rules
Always use wheel guard, and the Zipmate'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 protec ts operator f rom
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 can also be used as
a handle.
Always be certain that the wheel guard,
an d Zipmat e' s auxili ary hand le a re
reassembled and securely fastened to the
tool when changing the point of operation
from fire forward to fire reverse or after
changing the whee ls. A tool missing an
essential safety component is dangerous to
operate.
We ar prope r appa re l whil e 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
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 n ot u se t his att ac hment wit h
“Woodcarving” blade or standard wood
cutting toothed blades. These blades are not
intended for this tool and can create loss of
control during use.
Abras ive Cut Off Whe els must ha ve 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
gr eat v elocity possib ly st riking you o r
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.
Position the cord clear of the spinning
wheel. Do not wrap the cord around your
arm or wrist. If you lose control and have the
cord wrapped around your arm or wrist, it may
entrap you and cause injury.
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.
Keep hands away from cutting area and
wheel. Keep your second hand on auxiliary
handle. 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 whe el is m oving. 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 rota ting 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.
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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 vent s by
compressed air. Excessive accumulation of
powdered metal inside the motor housing may
cause electrical failures.
Causes and Operator
Prevention of Recoil:
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 walk away from the operator. The
rotation direction arrow located on the back
side of the guard can be used to identify the
“fire forward” and “reverse fire” positions. The
attachment is in the fire forward position when
th e directi on al ar row point s toward th e
operator, and it is in the reverse fire position
when the arrow is pointing away from the
operator.
If an ab ra sive wheel or di am ond 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 t he 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
to ol misuse an d/or incor re ct operati ng
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.
Re coil forces can be co nt rolled by the
operator, if proper precautions are taken.
Wh en w heel is binding , or w hen
interrupting a cut for any reason, slowly
ease the wheel out of the material while
maintaining a firm grip on the tool and
au xiliary handle with both h ands.
Investig ate and take cor rec tive actio n to
eliminate the cause of wheel binding.
When restarting a tool in a wo rkpiece,
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 exist ing walls or o the r blind
areas. The protruding wheel may cut objects
that can cause recoil.
Jigsaw Handle Attachment Safety Rules
WARNING
!
than 1/4" with the Jigsaw Handle Attachment.
WARNING
!
Jigsaw Handle Attachment, the collet nut
must be tightened using the supplied wrench.
Finger tight is not sufficient for router bits.
Do not us e any r ou ter bi t
with a cutting diameter larger
When using a 1/4" shank bit
or any rout er bit wi th the
WARNING
!
from above, DOR is CW. When viewed from
the end of the bit, DOR is CCW.
WARNING
!
tighten the depth adjust screw tightly.
Indicate direction of rotation
of the bit. When vi ewing
Before doing any work with
the Jig S aw At tachm en t,
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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
n Rated speed Manufacturers rated speed
.../min Revolutions or reciprocation 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
per minute 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
Li-ion RBRC seal Designates Li-ion battery recycling
program
Ni-Cad RBRC seal Designates Ni-Cad battery recycling
program
Read manual symbol Alerts user to read manual
Wear eye protection symbol Alerts user to wear eye protection
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Symbols (continued)
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.
This symbol designates that this tool is listed by Underwriters Laboratories.
This symbol designates that this tool is listed by Underwriters Laboratories,
to United States and Canadian Standards.
This symbol designates that this tool is listed by the Canadian Standards
Association.
This symbol designates that this tool is listed by the Canadian Standards
Association, to United States and Canadian Standards.
This symbol designates that this tool is listed by the Intertek Testing
Services, to United States and Canadian Standards.
This symbol designates that this tool complies to NOM Mexican Standards.
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Functional Description and Specifications
WARNING
!
Di sc onnect the plug fro m the pow er source bef ore maki ng any
assembly, adjustments or changing accessories. Such preventive safety
measures reduce the risk of starting the tool accidentally.
Spiral Saw™
FIG. 1
SPEED
CONTROL DIAL
(Model RZ2000 only)
UPPER
ATTACHMENT
POINT
SLIDE ON-OFF
SWITCH WITH
LOCK
INTAKE
AIR VENTS
WRENCH STORAGE
COMPARTMENT
SUPPORT STRAP
WORKLIGHT
(Model RZ2000 only)
COLLAR
COLLET
LOCK LEVER
DEPTH GUIDE
NOTE: For tool specifications refer to nameplate on your tool.
-9-
EXHAUST
AIR VENTS
COLLET NUT
DUST PORT
THUMB SCREW
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Assembly
WARNING
!
making any assembly, adjustments or
changi ng acces sories. 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.
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.
WARNING
!
caution.
Depress and hold the shaft-lock in and rotate
the collet nut and shaft until the shaft-lock
engages and holds the shaft.
!
CAUTION
braking devise to stop the tool from rotating.
Us e the st an da rd equipment wrench to
lo osen nut (counte r-clock wise) (F ig. 2).
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
Disconnect the plug from
the power source before
INSTALLING BITS
The bit flutes are sharp and
sh ou ld b e h andled with
To prevent damage to tool.
Never use the shaft lock as a
REMOVING AND INSTALLING THE
DEPTH GUIDE ASSEMBLy
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
reattach the assembly, fully replace the guide
onto the tool collar and lock the clamp lever
(Fig. 1).
approxi ma te ly 1/8" of sh an k ex po sed)
Re-engage the shaft-lock and tighten the nut
(clockw is e) by han d and the n with th e
wrench until bit is held securely.
CHANGING THE COLLET
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"
diamete r b it s. To ch an ge co llets, fir st
re move the bit. Con tinue to loosen and
unscrew the collet nut until you can remove it
from the tool. Remove the collet and replace
it with the o ther (Fig. 3). (Each col let 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. 2).
SHAFT
LOCK
1/8"
COLLET
NUT
FIG. 2
FIG. 3
COLLET
COLLET
NUT
OUTPUT SHAFT
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INSTALLING THE SUPPORT STRAP
With the wrench storage pocket facing down,
threa d the end of the st rap opp osi te the
Rotozip® logo through the post near the front
of the tool as shown. Continue to thread the
strap through the rear post near the cord. Fold
the back flap over first (1), then fold the end
with the Rotozip® logo (2) as shown in figure
4. Press firmly to ensure the strap is secured.
Operating Instructions
SLIDE ON-OFF SWITCH WITH LOCK
Th e to ol is switch ed “ON” by the switc h
bu tt on lo ca te d at the si de of th e motor
housing (Fig. 5). The switch can be locked in
the “ON” position, a convenience for long
cutting operations.
TO TURN THE TOOL “ON” without locking it,
slide the switch button forward by applying
pressure ONLY at the REAR portion of the
button. When pressure is released the switch
button will snap to “OFF” position.
TO LOCK THE SWITCH “ON”, slide the
switch button forw ard and p ress “IN” the
FRONT portion.
TO UNLOCK THE SWITCH, simply press
and release the REAR portion of the button.
Switch is spring loaded and will snap back
automatically.
FIG. 4
FIG. 5
FIG. 6
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ELECTRONIC VARIABLE
SPEED CONTROL
(Model RZ2000 only)
The electronic speed control feature allows
motor speed to be matched to cutter size and
materia l ha rd ne ss f or impro ve d fi ni sh ,
extended bit life, and higher performance.
Speed c hanges are achieved by rota ting
Control Dial UP to increase speed, DOWN to
decrease as indicated on housing (Fig. 7).
Speed may be changed while tool is on. The
reference numbers on the dial facilitate resetting control to desired speed.
DEPTH GUIDE ADJUSTMENT
Use the depth guide to adjust the depth of
cut. Loosen the thumb screw by turning it
counter-clockwise until the depth guide can
slide freely to the desired depth of cut (about
1/8” greater than material thickness) and
retighten the thumb screw (clockwise) (Fig.
8). For bits with a guide point, make sure that
the entire guide point tip will extend 1/8”
beyond the material thickness (Fig. 2). For
standard point bits, make sure that the fluted
en d o f the bit extends 1/8” beyond the
material thickness.
FIG. 7
FIG. 8
SPEED
CONTROL DIAL
1/8"
THUMB
SCREW
WORKLIGHT
(Model RZ2000 only)
Your tool is also equipped with a light that
turns on automatically when the switch is
activated, for better visibility when cutting
(Fig. 1).
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MAKE A FEW PRACTICE CUTS
Af te r i nstalling th e bit in to the tool an d
adjusting your depth guide, you should make
a few pra ct ice cu ts with t he too l 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 to your desired speed.
Step 3: While holding the tool firmly, insert the
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
(EXCE PT c utting around outle t boxes in
drywall), steer the tool in a clockwise direction
with slow, steady pressure to make the cut.
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 bit could
co nd uct cu rr en t to the tool , creati ng an
electrocution hazard for the operator. Shut off
breakers or remove fuses to disconnect the
ci rc ui t. A lw ay s h old 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 bit, there will be a slight pull when
FIG. 9
FIG. 10
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 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 bit. Turn the tool off and remove it
from the material.
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.
!
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 the tool by
its thermoplastic housing, and always wear
eye protection when operating this device.
Do not attempt to use this
to ol to ma ke cut-outs
-13-
3
4
5
6
7
RZ 2610011540 04-10:RZ 2610011540 04-10 4/7/10 8:16 AM Page 14
Step 1: Be certain that the box or fixture is
firmly mount ed an d a ll wi re s o r oth er
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 Sp ria l Saw® firmly with b oth
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. 11).
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. 12).
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. 12).
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. 12).
St ep 6: Mov e the bit ri gh t and upwar d
maintaining light continuous pressure toward
the box (Fig. 12).
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 Sprial Saw®
switch to off (Fig. 11).
Step 8: The completed box, executed quickly,
neatly, and in a fraction of the time taken by
other methods.
FIG. 11
NOTE: These step-by-step instructions are
generalized to acquaint you with the Sprial
Saw’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
TH E Spri al Saw® O NL Y COUN TE RCL OC KW IS E 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
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.
FIG. 12
USING THE VACUUM PORT
Your Spiral Saw® is designed to work with
the Rotozip model DM5 Dust Management
Kit. Visit your local Rotozip retailer or call
1-877-ROTOZIP (1-877-768-6947) for more
information.
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RZ 2610011540 04-10:RZ 2610011540 04-10 4/7/10 8:16 AM Page 15
Functional Description and Specifications
WARNING
!
sufficient control of the cutting wheel in case of recoil.
WARNING
!
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
Di sc onnect t he plug fro m the pow er source bef or e making an y
assembly, adjustments or changing accessories. Such preventive safety
Zipmate®Abrasive Cut Off
Attachment
AUXILIARY CONTROL
FIG. 1
LOCKING
COLLAR
SIDE HANDLE
GUARD
PLUG
WHEEL GUARD
LOCK LEVER
FOOT
SHAFT-LOCK
NOT INCLUDED WITH ALL KITS
Note : The speed of your tool will be reduced 2.11 : 1 when using
your Abrasive Cut-Off attachment.
-15-
WHEEL
GUARD
DEPTH
ADJUSTMENT
THUMB
SCREW
RZ 2610011540 04-10:RZ 2610011540 04-10 4/7/10 8:16 AM Page 16
Assembly
WARNING
!
making any assembly, adjustments or
changing accessories. Such preventive safety
measures reduce the risk of starting the tool
accidentally.
WARNING
!
hose is not connected. Wheel bursting may
eject wheel fragments towards user if guard
plug is not attached.
REMOVING AND INSTALLING
ABRASIVE CUT OFF ATTACHMENT
1. Depress and hold the shaft-lock in and
rotate the collet nut and shaft until the shaft
lock engages and holds the shaft.
Disconnect the plug from
the power source before
Guard plug should always
be attached when vacuum
ATTACHMENT
FIG. 2
2. Remove the collet nut by rotating it counter-
clockwise. Remove the collet from the tool
shaft.
3. Position the attachment onto the threaded
Rotozip Connect™ interface. Note: It may be
necessary to rotate attachment slightly to
engage square end of the right angle drive into
tool shaft (figure 2).
4. Position attachment in desired orientation
an d ro ta te th e lo ck ing c ol lar u nt il th e
attachment is secure. The locking collar has
been tightened sufficiently when the Zipmate
body can no longer move relative to the Spiral
Saw® (figure 3).
LOCKING
COLLAR
ROTOZIP
CONNECT™ INTERFACE
ATTACHMENT
FIG. 3
-16-
RZ 2610011540 04-10:RZ 2610011540 04-10 4/7/10 8:16 AM Page 17
INSTALLING X-WHEEL and Zip®
ABRASIVE WHEELS
1. Dep ress the cover relea se b utton and
remove the X-SHIELD cover.
2. Install abrasive wheel onto output shaft.
3. Thread arbor nut provided onto output shaft
finger tight, depress shaft lock and tighten
wheel with the wrench provided (Fig. 2).
4. Attach X-SHIELD cover . Make su re XSHIELD cover is properly snapped onto the
X-SHIELD guard.
OUTPUT
ZIPMATE™
ATACHMENT
FIG. 4
COLLAR
SHAFT
5. Keep guard covering between wheel and
user.
6. Make sure the wheel guard lock lever is in
the closed position and the XSHIELD guard
is secure ly mo un ted t o the Zipm at e
attachment. Use the allen wrench to adjust
the wheel guard adjustment screw.
7. Adjust the foot of the X-SHIELD abrasive cut
off attachment to the desired depth of cut by
loosening and tightening the wing knob.
8. Maximum cutting depth is 3/4".
X-SHIELD
ABRASIVE
WHEEL
ARBOR
NUT
COVER
WHEEL
GUARD
LOCK
LEVER
COVER
RELEASE
BUTTON
X-SHIELD™
GUARD
-17-
RZ 2610011540 04-10:RZ 2610011540 04-10 4/7/10 8:16 AM Page 18
Operating Instructions
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
wh ee l wi th the work pi ec e or otherwise
applying excessive side pressure to the wheel.
5. Keep guard covering between wheel and
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 3/4”.
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.
MAKING A CUT
Ov ertightening the g uard
adjustm en t screw ca n
To pr event re co il an d
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.
ATTENTION: If you run the tool continuously
for more than 5 minutes, it is normal for the
housing to feel warm.
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. 5).
USING THE VACUUM PORT
Your Zipmate® Abrasive Cut Off Attachment
is designed to work with the Rotozip model
DM5 Dust Management Kit. Visit your local
Ro to zip reta il er or cal l 1-877-RO TO ZIP
(1-877-768-6947) for more information.
FIG. 5
FOOT
DIRECTION OF
CUT
WHEEL DIRECTION
-18-
RZ 2610011540 04-10:RZ 2610011540 04-10 4/7/10 8:16 AM Page 19
Functional Description and Specifications
WARNING
!
measures reduce the risk of starting the tool accidentally.
Di sc onnect the plug fro m the pow er source bef ore maki ng any
assembly, adjustments or changing accessories. Such preventive safety
Jigsaw Handle
FIG. 1
NOT INCLUDED WITH ALL KITS
UPPER LOCK
LOCKING
PIN
LOCK OUT
LEVER
LEVER
HANDLE
LOWER LOCK
LEVER
VACUUM
PORT
TRIGGER
DEPTH ADJUSTMENT
THUMB SCREW
BASE PLATE
-19-
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INSTALLING AND REMOVING THE
JIGSAW HANDLE ATTACHMENT
1. Remove depth guide from the tool.
2. Open the lock lever near the base of the
attachment (figure 2.)
FIG. 2
LOWER
LOCK LEVER
3. Insert your Spiral Saw® with the switch
toward the attachment as shown in (figure 3.)
Pr ess down firmly and squee ze the too l
toward the atta chment, m aking sur e th e
lo ck in g p in en ga ge s t he correspond in g
keyway on the Spiral Saw®.
FIG. 3
LOCKING
PIN
4. Rotate t he up pe r l oc k l ever to the
“UNLOCK” position and squeeze the tool
toward the attachment. With the Spiral Saw®
po sitio ned ti ght ag ainst the attachm ent,
release the upper lock lever. Make sure both
the lower and upper lock levers are in their
“LOCK” positions (figures 4 & 5.)
UPPER LOCK
LEVER
FIG. 4
FIG. 5
Operating Instructions
DEPTH ADJUSTMENT
Loosen the depth adjustment thumb screw
(counter-clockwise) to change the depth of
cut. Slide the base plate to the desired depth
of c ut and re-tigh te n th e th um b sc re w
(clockwise) (figure 6.)
LOWER
LOCK
LEVER
To remove the jigsaw handle attachment,
reverse steps 2, 3, and 4.
FIG. 6
DEPTH ADJUSTMENT
THUMB SCREW
-20-
RZ 2610011540 04-10:RZ 2610011540 04-10 4/7/10 8:17 AM Page 21
1. You r j igsaw h andle a ttachme nt is
equipped with a trigger switch. Slide the lockout lever (figure 7) to either side with your
thumb, then squeeze the trigger.
MAKING A CUT
FIG. 7
LOCK OUT
LEVER
TRIGGER
2. While holding the tool firmly, insert the bit
into the material at a 45° angle (figure 8).
3. Slowly bring it to a 90° angle to begin the
cut. The base plate should be flush to the
material surface (figure 9).
Maintenance
Service
!
WARNING
per so n nel may result in misplacing of
inter nal wires and c omponent s wh ich
co uld cau se serious hazard. We
recommend that all tool service be performed
by a Bosch or Rotozip Factory Service Center
or Authorized Bosch Service Station. Call 1877-ROTOZIP (1-877-768-6947) if your tool
needs service.
Your Rotozip tool has been properly lubricated
and is ready to use. The lubrication applied at
the factory lasts for the life of the tool.
The brushes and commutator in your tool have
be en engine er ed for ma ny hours of
de pendable s ervice. To maint ain peak
efficiency of the motor, we recommend every
two to six months the brush es be examined.
Only genuine Rotozip replace ment brushes
specially designed for your tool should be
used.
Your Rotozip tool and attachments contain
sealed bearings designed to last the life of the
Pr eventiv e main tenance
performed by unauthorized
TOOL LUBRICATION
CARBON BRUSHES
BEARINGS
4. Release the trigger to de-activate your tool
after the cut.
tool. Bearings which become noisy (due to
heavy load or very abrasive material cutting)
sh ould be in spected at once to a void
overheating or motor failure. Contact your local
Bosch or Rotozip Factory Service Center if
your bearings become noisy.
Cleaning
!
WARNING
th e power supp ly be fo re cl eaning or
performing any main tenance. The tool may
be cleaned most effectively with compressed
dry air. Always wear safety gog gles when
cleaning tools with compressed air.
Ventilation openings and switch levers must be
kept clean and free of foreign matter. Do not
at tempt to clean by inserting pointed objects
through openings.
!
CAUTION
plastic parts. Some of these are: gasoline,
carbon tetrachlo ride, chlo rinated cleaning
solvents, ammonia and house hold detergents
that contain ammonia.
-21-
To avoid accidents always
dis connect the tool from
Ce rtain clean ing agents
an d sol ve nts da mage
FIG. 8
FIG. 9
RZ 2610011540 04-10:RZ 2610011540 04-10 4/7/10 8:17 AM Page 22
Extension Cords
!
WARNING
If an exten si on cord is
necessa ry , a cord wi th
adequate size conductors that is capable
of carrying the current necessary for your
tool mu st be us ed . Thi s wil l preve nt
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
heav i er the cord.
Accessories & Attachments
WARNING
!
packaging or the attachment itself.
Your Rotozip Spiral Saw® is compatible with any Rotozip attachment bearing
the Rotozip Connect™ icon. This icon can be located on the attachment
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
2
WARNING
!
Do not use metal cutting bits, router bits, or non-approved accessories
with this product unless a control handle, such as the Jigsaw Handle
Attachment, is attached.
ROTOZIP CONNECT™ Attachments include the following: (Items may be sold separately)
ZM5 ZIPMATE® Abrasive Cut Off Attachment
XSHIELD2™ Flush Cut Guard Attachment
JSH5 Jigsaw Handle Attachment
DM5 Dust Management Kit
CRCT4 Circle Cutting Attachment
-22-
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