RotoZip RZ5 Quick guide

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
RZ5
RZ10
RZ20
RZFT
For English Version Version française Versión en español
See page 2 Voir page 20 Ver la página 38
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RZ 2610954840 07-07 8/16/07 3:55 PM Page 1

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
apolarized 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 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” in
the Accessory 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. Amoment 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”. Awrench 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
!
WARNING
Power Tool Safety Rules
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-3-
Rotary Cutter Safety Rules
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.
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. Any alteration or
modification is a misuse and may result in a
dangerous condition.
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 recom-
mended 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. For
example: internal wires may be misplaced or
pinched, safety guard return springs may be
improperly mounted.
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.
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.
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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.
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.
Never use bits that have a cutting
diameter greater than the opening in the
base.
Do not use the tool for drilling purposes.
This tool is not intended to be used with drill
bits.
Always use the tool with the depth guide
securely attached and positioned flat
against material being cut. The guide
securely positioned on the material improves
the stability and control of your tool.
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, and
•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.
-4-
!
WARNING
Zipmate Abrasive Cut-Off Attachment Safety Rules
Always use wheel guard, and the tool’s
auxiliary handle with this abrasive cut off
tool. The guard must always be securely
attached to the tool and positioned for
maximum safety, so the least amount of
wheel is exposed on the operators side of
the tool. Aguard protects operator from
broken wheel fragments. The support ribs
and auxiliary handle provide additional
guarding, stability and control in cut off
applications. The body of your Rotozip tool
or your Zipmate attachment can also be
used as a handle.
Always be certain that the wheel guard,
and tool’s auxiliary handle are
reassembled and securely fastened to the
tool when changing the point of operation
from
fire forward to fire reverse or after
changing the wheels. Atool missing an
essential safety component is dangerous to
operate.
BIT
WORK
DIRECTION OF
FEED
START
HERE
RZ 2610954840 07-07 8/16/07 3:55 PM Page 4

-5-
Hold tool by insulated gripping surfaces
when performing an operation where the
abrasive wheels may contact hidden
wiring or its own cord. Contact with a “live”
wire will make exposed metal parts of the
tool “live” and shock the operator.
Wear proper apparel while using an
abrasive cut off tool. Face shield or at least
safety goggles, dust mask, leather gloves
and shop apron capable of stopping small
wheel or workpiece fragments.
This attachment is not intended to be
used with Wet Diamond Wheels. Using
water or other liquid coolants with this tool
may result in electrocution or shock. Use of
Dry Diamond Wheels is acceptable.
Use only Type 1 abrasive cut off wheels
with the correct size arbor hole. Never
use damaged or incorrect wheel flanges
or round nut. Other types of wheels are not
intended to apply load on periphery and may
shatter. Wheels with arbor holes that do not
match the mounting hardware of the tool will
run eccentrically, vibrate excessively and will
cause loss of control.
Do not grind on the side of Type 1
abrasive cut off wheels. Side forces applied
to these wheels may cause them to shatter.
Do not use this attachment with
“Woodcarving” blade or standard wood
cutting toothed blades. These blades are
not intended for this tool and can create loss
of control during use.
Abrasive Cut Off Wheels must have a
maximum safe operating speed greater
than the “no load RPM” marked on the
attachment. Wheels running over the rated
speed can fly apart and cause injury.
Before each use inspect the cut off wheel
for chips and cracks. Do not use a wheel
that may be damaged. Install a new wheel
if tool was dropped. When installing a
new wheel carefully handle individual cut
off wheels to avoid chipping or cracking.
Run the tool at no load for one minute,
holding the tool in the direction away
from people. Wheels with flaws will
normally break apart during this time.
Fragments from a wheel that bursts during
operation will fly away at great velocity
possibly striking you or bystanders.
Do not use a cut off wheel that is larger
than the maximum recommended size for
your tool, or worn down damaged wheels
from larger abrasive cut off tools. Wheels
intended for larger tools are not suitable for
the higher speed of a smaller tool, these
wheels may easily burst and the fragments
strike you or bystanders.
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 or the attachment. Hold
the tool firmly to prevent loss of control.
NEVER place your hand behind the wheel
since the tool may recoil over your hand.
Do not attempt to remove cut material
when wheel is moving. If both hands are
holding the tool, they cannot be cut by the
wheel
Do not “jam” the abrasive wheel into the
work, apply excessive pressure or
attempt to use large depths of cut while
using this tool. Let the rotating wheel do the
work, Abrasive Cut Off Tools are intended to
“cut” the material in a series of shallow depth
of cuts. See the instructions for depth of cut
later in this manual.
Avoid bouncing and snagging the wheel,
especially when working corners, sharp
edges etc. This can cause loss of control
and tool’s recoil.
Do not run the tool while carrying it at
your side. Accidental contact with the
spinning wheel could result in serious
personal injury.
Never lay the tool down until the motor
has come to a complete standstill. The
spinning wheel can grab the surface and pull
the tool out of your control.
Do not use the Zipmate near flammable
materials. Sparks from the wheel could
ignite these materials.
Never cut or attempt to cut magnesium
with this attachment. The dust generated
when cutting magnesium is highly flammable
and may be explosive under certain
conditions.
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-6-
Regularly clean the tool’s air vents by
compressed air. Excessive accumulation of
powdered metal inside the motor housing
may cause electrical failures.
Causes and Operator
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 the directional
arrow points toward the operator, and it is in
the reverse fire position when the arrow is
pointing away from the operator.
If an abrasive wheel or diamond wheel
becomes twisted or misaligned in the cut, the
side of the wheel that is entering into the
material can dig into the top surface of the
material causing the wheel to climb out or
recoil out of the kerf either toward or away
from the operator, depending on the fire
forward or reverse fire orientation.
Abrasive wheels may also shatter under
these conditions causing pieces or fragments
to strike or impale the operator and
bystanders. Recoil or shattered wheels are
the result of tool misuse and/or incorrect
operating procedures or conditions and can
be avoided by taking proper precautions as
given below:
Maintain a firm grip with both hands on
the tool handles and position your body
and arm to allow you to resist
recoil
forces. Recoil forces can be controlled by
the operator, if proper precautions are taken.
When wheel is binding, or when
interrupting a cut for any reason, slowly
ease the wheel out of the material while
maintaining a firm grip on the tool and
auxiliary handle with both hands.
Investigate and take corrective action to
eliminate the cause of wheel binding.
When restarting a tool in a workpiece,
center the wheel in the kerf and check
that the sides of the wheel are not
engaged into the material. If wheel is
binding, it may walk up or
recoil from the
workpiece as the tool is restarted.
Support large panels to minimize the risk
of wheel pinching and
recoil. Large panels
tend to sag under their own weight. Supports
must be placed under the panel on both
sides, near the line of cut and near the edge
of the panel.
Use extra caution when making a “Pocket
Cut” into existing walls or other blind
areas. The protruding wheel may cut objects
that can cause
recoil.
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, and
•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.
!
WARNING
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-7-
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.
n0No 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
Ni-Cad RBRC seal Designates Ni-Cad battery recycling
program
Symbols
0
This symbol designates
that this tool is listed by
Underwriters Laboratories.
This symbol designates
that this tool is listed by
the Canadian Standards
Association.
This symbol designates
that this tool is listed to
Canadian Standards by
Underwriters Laboratories. This symbol
designates
that
this tool
complies
to NOM
Mexican
Standards.
This symbol designates that
this tool is listed by
Underwriters Laboratories,
and listed to Canadian
Standards by Underwriters
Laboratories.
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-8-
Functional Description and Specifications
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.
!
WARNING
NOTE: For tool specifications refer to nameplate on your tool.
DEPTH
GUIDE
SHAFT LOCK
DEPTH GUIDE
BRACKET
LOCK LEVER
INTAKE
AIR VENTS
BUMP-OFF SLIDE
"ON/OFF" SWITCH
SPEED
CONTROL DIAL
(Models RZ10 & RZ20 only)
REMOVABLE
HARD
AUXILIARY
CONTROL
HANDLE
KEYLESS CHUCK
(Model RZ20 only)
EXHAUST
AIR VENTS
DEPTH GUIDE
LOCKING
SCREW
COLLAR
FIG. 1
WORKLIGHT
(Model RZ20 only)
Spiral Saw™
BIT / COLLET
STORAGE
LOCK PIN
WRENCH
STORAGE
COLLET
COLLET
NUT
RZ 2610954840 07-07 8/16/07 3:55 PM Page 8

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 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).
-9-
Assembly
INSTALLING BITS (Keyless models)
The bits are held by a keyless collet system
designed specifically for spiral saw bits with
1/8" (.125"), 1/4" (.250") or 5/32" (.156") shanks.
The bit flutes are sharp and
should be handled with
caution.
Depress and hold the shaft-lock in and rotate
the keyless chuck and shaft until the shaft-
lock engages and holds the shaft.
To prevent damage to tool.
Never use the shaft lock as a
braking devise to stop the tool from rotating.
Rotate the keyless chuck (counter-clockwise)
(Fig. 2). Remove the old bit (if there is one)
insert the new bit as far as possible, but not so
far that the bit flutes engage the jaws of the
chuck (leave approximately 1/8" of shank
exposed) Re-engage the shaft-lock and
securely tighten the keyless chuck (clockwise)
by hand.
Note: When using 1/4" and 5/32" bits it may
be necessary to use a wrench on the front of
the keyless chuck to securely tighten the bit.
INSTALLING BITS (Standard models)
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.
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 standard equipment wrench to
loosen nut (counter-clockwise) (Fig. 3).
Remove the old bit (if there is one) insert the
new bit as far in as possible, but not so far
that the bit flutes engage the collet (leave
approximately 1/8" of shank exposed)
Re-engage the shaft-lock and tighten the nut
(clockwise) by hand and then with the
wrench until bit is held securely.
!
WARNING
!
CAUTION
!
WARNING
KEYLESS
CHUCK
SHAFT
LOCK
1/8"
FIG. 2
COLLET
NUT
FIG. 3
SHAFT
LOCK
1/8"
RZ 2610954840 07-07 8/16/07 3:55 PM Page 9

Operating Instructions
BUMP-OFF SLIDE "ON/OFF" SWITCH
This tool is switched "ON" by the slide switch
located on the front of the motor housing
(Fig. 6).
TO TURN THE TOOL "ON" slide the switch
button up.
TO TURN THE TOOL "OFF" slide the switch
button down or "0" position.
Hold the tool with both
hands while starting, since
torque from the motor can cause the tool to
twist .
0
1
BUMP-OFF SLIDE
"ON/OFF" SWITCH
FIG. 6
!
WARNING
-10-
REMOVING AND INSTALLING THE HARD
AUXILIARY CONTROL HANDLE
Turn the tool OFF and unplug it. Firmly grasp
the tool. Depress and hold lock pin from either
side of the handle. While depressing the lock
pin, depress release button so lock pin is
engaged, then remove handle (Fig. 5).
With the lock pin engaged, gently engage the
two (2) front latches on handle into the tool and
push handle until it snaps securely into place.
Your handle is equipped with a bit and collet
storage area. To open door, pull tab on door
downward away from tool. To close door, lift
door upward toward the tool. Be sure door is
closed to prevent bits from falling out.
FIG. 5
BIT / COLLET
STORAGE DOOR
LOCK
PIN
RELEASE
BUTTON
TAB
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"
diameter bits. To change collets, first
remove the bit. Continue to loosen and
unscrew the collet nut until you can remove it
from the tool. Remove the collet and replace
it with the other (Fig. 4). (Each collet is
double-ended, and either end is acceptable
to use.) By hand, re-tighten the collet nut
around the collet in a clockwise direction.
You are now ready to insert a new bit as
instructed in Installing Bits (Fig. 2 or 3).
COLLET
COLLET
NUT
OUTPUT SHAFT
FIG. 4
RZ 2610954840 07-07 8/16/07 3:55 PM Page 10

ELECTRONIC
VARIABLE SPEED CONTROL
(Models RZ10 & RZ20 only)
The electronic speed control feature allows
motor speed to be matched to cutter size and
material hardness for improved finish,
extended bit life, and higher performance.
Speed changes are achieved by rotating
Control Dial RIGHT to increase speed, LEFT
to decrease as indicated on housing (Fig. 7).
Speed may be changed while tool is on. The
reference numbers on the dial facilitate
re-setting control to desired speed.
For best results, when using RZ bits, we
recommend only using dial setting 25 or 30.
You will not obtain a quality cut if you lower
the dial setting to 15 or 20.
-11-
DEPTH GUIDE ADJUSTMENT
Use the depth guide to adjust the depth of
cut. Using the end of the standard wrench,
loosen (counter clockwise) the screw enough
to enable the depth guide to slide up or down
to the desired depth of cut (about 1/8"
greater than material thickness) and
retighten the locking screw (clockwise)
(Fig. 8).
VARIABLE SPEED CONTROL DIAL
(Models RZ10 & RZ20 only)
1/8"
DEPTH GUIDE
LOCKING
SCREW
WORKLIGHT (Model RZ20 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).
FIG. 8
FIG. 7
DIAL
SETTING APPLICATION
15 Not Recommended
20 Not Recommended
25 All Materials
30 All Materials
MAKE A FEW PRACTICE CUTS
After installing the Zip Bit into the tool and
adjusting your depth guide, you should make
afew practice cuts with the tool before
attempting an actual job.
Afew 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.
RZ 2610954840 07-07 8/16/07 3:55 PM Page 11

-12-
FIG. 9 FIG. 10
MAKING DRYWALL CUT OUTS
After assembling the bit into the tool as
described earlier, it will be necessary to
review the instructions provided below and
make some practice cut-outs with this tool
before attempting an actual job. The best
method is to take some scrap pieces and nail
or screw them in place over wall studs which
have an electrical box or other feature in
place. A few such exercises will give you the
necessary practice to make clean,
professional cutouts around whatever is
behind the drywall you are installing.
Do not attempt to use this
tool to make cut-outs
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.
Step 1: Be certain that the box or fixture
which requires a cut-out is firmly mounted and
all wires or other obstructions around the
opening are pushed back out of the way. The
drywall cut-out bit uses the outer edge of the
box or fixture as a guide, so it is important that
there is nothing in the way which can prevent
it from guiding completely around the opening.
For the purposes of this instruction manual,
the procedure discussed will be to make a cut-
out around a standard 2 1/8" x 3 3/4" electrical
box.
Step 2
Slide switch to turn the tool on. While holding
the Spiral Saw power tool firmly with both
!
WARNING
IMPORTANT USER TIP
Step 3
While holding the tool firmly, insert the Zip Bit
into the material at a 45° angle (Fig. 9).
Step 4
Slowly bring it to a 90° angle to begin the cut
(Fig. 10). The base guide should be flush to
the material surface. For all materials
(EXCEPT cutting around outlet boxes in
drywall), steer the tool in a clockwise direction
with slow, steady pressure to make the cut.
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 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.
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-13-
hands plunge the Zip Bit through the mark you
made. Then guide the Zip Bit to the right until
you feel and hear the Zip Bit touch the inside
edge of the box.
Step 3
Pull the Zip Bit out far enough to slip it over
the edge of the box so it is now against the
outside of the box.
Step 4
While keeping the Zip Bit in contact with the
outside of the box move the tool counter
clockwise while applying light inward and
upward pressure until you feel and hear it
come to the corner. As you round the corner
apply light pressure left and downward.
Step 5
While moving slowly and continuously along
the top contour you will feel the Zip Bit come
to the next corner. Round the corner and
apply light down and inward pressure until the
bottom corner is reached.
Step 6
Move the Zip Bit right and upward maintaining
light continuous pressure toward the box.
Step 7
Round the right bottom corner and begin
moving the bit upward while applying light
pressure left toward the box until you meet
initial upward cut. Push Spiral Saw power tool
switch to off.
Step 8
The completed box, executed quickly, neatly
and in a fraction of the time taken by other
methods.
These step-by-step instructions are
generalized to acquaint you with the Spiral
Saw power tool operation. After some
practice, you may develop a motion
technique with which you are more
comfortable. However, you must always
begin the cut somewhat centrally, and MOVE
THE SPIRAL SAW POWER TOOL ONLY
COUNTERCLOCKWISE to take advantage
of the “hugging” action of the rotating Zip Bit
along the contours of the template.
Remember to use a smooth continuous
motion.
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-14-
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.
!
WARNING
Always use auxiliary
handle for maximum
control over torque reaction or kick-back.
Operation of the tool without the auxiliary
handle could cause loss of control of the tool,
resulting in possible serious personal injury.
REMOVING AND INSTALLING
ABRASIVE CUT OFF ATTACHMENT
(Keyless models)
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 keyless
chuck is securely tightened before turning the
tool on.
1.Depress and hold the shaft-lock in and
rotate the keyless chuck and shaft until the
shaft-lock engages and holds the shaft
(Fig. 2).
2.Rotate the keyless chuck (counter-
clockwise) until chuck it is completely open.
3.Insert drive bit into the keyless chuck up to
the flange, and securely tighten chuck.
4.Open locking lever and position
attachment onto the collar. Note: It may be
necessary to rotate attachment slightly and
hold both the tool and attachment shaft
!
WARNING
!
WARNING
Zipmate attachment must be used only with an hard auxiliary control
side handle. Two handed control of solid gripping handles will provide
sufficient control of the cutting wheel in case of recoil.
!
WARNING
Zipmate®Abrasive Cut Off Attachment
Recommended for use with: Rebel, Revolution,
and all RZ model Rotary Tools.
Hard auxiliary control handle must be obtained for models RZ1 and RZ25.
Call 1-877-ROTOZIP.
Note : The speed of your tool will be reduced 2 : 1 when using your Abrasive Cut-Off attachment.
SHAFT LOCK
WHEEL GUARD
ABRASIVE
WHEEL
LOCK
LEVER
GUARD
LOCK LEVER
ADJUSTMENT
SCREW
WHEEL GUARD
LOCK LEVER
LOCK LEVER
ADJUSTMENT
SCREW
!
WARNING
Assembly
Functional Description and Specifications
FIG. 1
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-15-
locks to engage square end of drive bit into
attachment.
5.Position attachment as shown and lock the
lock lever.
Use the allen wrench to adjust the lock lever
adjustment screw.
Overtightening the lock lever
adjustment screw can
permanently damage the locking mechanism.
Test the tightness of the lever after each full
turn of the adjustment screw.
!
CAUTION
LOCK LEVER
COLLAR
DRIVE BIT
KEYLESS CHUCK
WHEEL GUARD
LOCK LEVER GUARD
LOCK LEVER
ADJUSTMENT
SCREW
SHAFT LOCK
LOCK LEVER
ADJUSTMENT SCREW
FIG. 2
LOCK LEVER
COLLAR DRIVE BIT
COLLET NUT
COLLET
OUTPUT
SHAFT
REMOVING AND INSTALLING
ABRASIVE CUT OFF ATTACHMENT
(Standard models)
1. Depress and hold the shaft-lock in and
rotate the collet nut and shaft until the shaft-
lock engages and holds the shaft.
2.Insert the 1/4” collet into the collet nut.
Loosely thread the collet nut onto the output
shaft (Fig. 3).
3.Insert drive bit into the collet until it stops,
and securely tighten the collet nut with the
wrench.
4. Open locking lever and position attachment
onto the collar. Note: It may be necessary to
rotate attachment slightly and hold both the
tool and attachment shaft locks to engage
square end of drive bit into attachment.
5. Position attachment as shown and lock the
lock lever.
Use the allen wrench to adjust the lock lever
adjustment screw.
Overtightening the lock lever
adjustment screw can
permanently damage the locking mechanism.
Test the tightness of the lever after each full
turn of the adjustment screw.
WHEEL GUARD
LOCK LEVER
GUARD LOCK LEVER
ADJUSTMENT
SCREW
SHAFT
LOCK
LOCK LEVER
ADJUSTMENT
SCREW
FIG. 3
!
CAUTION
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-16-
INSTALLING ABRASIVE WHEELS
Always use the arbor nut that has same
thread size as the output shaft.
1.Install abrasive wheel onto output shaft.
2.Thread arbor nut provided onto
output shaft finger tight, depress shaft lock
and tighten wheel with the wrench provided
(Fig. 4). Do not overtighten. Cracks
in the wheel can occur if
overtightened. Use wrench provided with
tool. Other wrenches may promote
overtightening. Do not depress shaft lock
while the tool is running.
Depressing the shaft lock may cause wheel
to spin off or damage to attachment.
!
WARNING
!
WARNING
GUARD
ABRASIVE
WHEEL
ARBOR
NUT
OUTPUT
SHAFT
SHAFT
LOCK
Operating Instructions
MAKING A CUT
1. Make sure material being cut is secured in
avise or fixture before attempting to cut.
2. Keep your body positioned to either side of
the wheel, but not in line with wheel. It is
important to support the tool properly and to
position your body such as to minimize body
exposure from possible wheel binding and
recoil.
3. Grip the tool with both hands when cutting
and always be ready and able to manage the
cut.
4. Avoid jamming, twisting or pinching the
wheel with the workpiece or otherwise
applying excessive side pressure to the wheel.
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 11/16”.
Overtightening the guard
adjustment screw can
permanently damage the locking mechanism.
Test the tightness of the lever after each full
turn of the adjustment screw.
To prevent recoil and
damage to the tool, always
ensure that the inner or outer flanges never
contacts the workpiece surface.
8. Generally, the harder the material being
worked on, the faster the wheel will wear.
9. When cutting thicker material, never make
the cut in one pass. Make successive passes
until you reach desired depth.
10. When using the Diamond Wheel, do not
make long, continuous cuts. Allow the blade to
cool for approximately 10 seconds for each
minute cutting.APPLICATIONS
This tool is intended for cutting the following
materials.
1/8˝ maximum thick sheet steel.
Floor and wall tile.
Concrete cinder blocks and bricks.
Reinforcing rod-generally under 5/8˝ diameter.
1/8˝ concrete wire mesh.
Electrical conduit 1/8˝ wall thickness.
1/8” maximum thick structural forms such as:
channels, angles, plate and etc.
ATTENTION: If you run the tool continuously
for more than 5 minutes, it is normal for the
housing to feel warm.
It is important to read and understand the
section in this manual called “Causes and
Operator Prevention of Recoil”.
FIG. 4
!
CAUTION
!
WARNING
RZ 2610954840 07-07 8/16/07 3:55 PM Page 16

-17-
FIG. 5
FOOT
WHEEL
DIRECTION
DIRECTION OF CUT
HARD AUXILIARY
CONTROL HANDLE
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).
Service
Preventive maintenance
performed by unauthorized
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 Bosch Factory Service Center or Autho-
rized Bosch Service Station.
TOOL LUBRICATION
Your Bosch tool has been properly lubricated
and is ready to use. It is recommended that
tools with gears be regreased with a special
gear lubricant at every brush change.
CHUCK LUBRICATION
The wrenchless chuck has been properly
lubricated and is ready to use. If the chuck's
jaws begin to stick during use, the chuck
requires lubrication. To lubricate the chuck,
first remove debris from the inside of the
chuck with compressed air. Apply a pea-
sized amount of general-purpose grease to
the sides of the jaws, and adjust the chuck
through its full range of motion to distribute
the grease. CARBON BRUSHES
The brushes and commutator in your tool
have been engineered for many hours of
dependable service. To maintain peak
efficiency of the motor, we recommend every
two to six months the brushes be examined.
Only genuine Bosch replacement brushes
specially designed for your tool should be
used. BEARINGS
After about 300-400 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.
!
WARNING
Maintenance
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Zipmate abrasive Cut Off Attachment
Dust Extractor
Circle Cutting Guides
Straight Edge Guide
Plunge Router
Jigsaw Handle
Flex Shaft
Grout Removal
Accessories & Attachments
Use only Robert Bosch 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
Attachments that are compatible with Rotozip Spiral Saws are the following:
(Items may be sold separately)
Zip®Bits
Robert Bosch 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.
SC5, TC1, DC1, GP10, GP10, WD1 & FBR1.
X-BITS™
X-BITS are designed for serious
professionals. They offer the strength and
speed of 5/32" bits with the precision of 1/8"
bits, to cut through even toughest materials in
seconds-flat. XB-DWZ, XB-LF1, XB-MC1, XB-
MPG-P2, XB-TC1, XB-UL1, XB-MP2.
-18-
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.
NOTE: The smaller the gauge number, the
heavier the cord.
RECOMMENDED SIZES OF EXTENSION CORDS
120 VOLT ALTERNATING CURRENT TOOLS
!
WARNING
Tool’s
Ampere
Rating
Cord Size in A.W.G. Wire Sizes in mm2
3-6
6-8
8-10
10-12
12-16
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 — — — — — —
25 50 100 150 15 30 60 120
Cord Length in Feet Cord Length in Meters
Extension Cords
Cleaning
To avoid accidents always
disconnect the tool from
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
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
!
CAUTION
RZ 2610954840 07-07 8/16/07 3:55 PM Page 18

-19-
RZmas2
Masonry Cut-off Wheel
For brick, cement, cinder
block, concrete, stone,
limestone, composition
board, fiberglass,
laminates.
RZmet2
Metal Cut-off Wheel
For ferrous metals, angle
iron, gutters, iron, pipe,
sheet metal, stainless
steel.
RZdia1
Dry Diamond Wheel
For floor tile, concrete,
stone, ceramic tile, and
other very-hard non-
metal material.
Sanding Discs
Rotozip’s sanding discs handle the most
difficult prep work with ease, and are versatile
enough for many fine finishing and polishing
applications. RZ-DISC36, RZ-DISC50, RZ-
DISC120 & RZ-SANDKIT.
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-20-
Vous devez lire et comprendre toutes les instructions. Le non-respect, même
partiel, des instructions ci-après entraîne un risque de choc életrique, d'incendie et/ou
de blessures graves. CONSERVEZ CES INSTRUCTIONS
Aire de travail
Veillez à ce que l'aire de travail soit propre et bien
éclairée. Le désordre et le manque de lumière
favorisent les accidents.
N'utilisez pas d'outils électriques dans une
atmosphère explosive, par exemple enprésence de
liquides, de gaz ou de poussières inflammables. Les
outils électriques créent des étincelles qui pourraient
enflammer les poussières ou les vapeurs.
Tenez à distance les curieux, les enfants et les
visiteurs pendant que vous travaillez avec un outil
électrique. Ils pourraient vous distraire et vous faire
faire une fausse manoeuvre.
Sécurité électrique
Les outils à double isolation sont équipés d'une fiche
polarisée (une des lames est pluslarge que l'autre),
qui ne peut se brancher que d'une seule façon dans
une prise polarisée. Si la fiche n'entre pas
parfaitement dans la prise, inversez sa position ; si
elle n'entre toujours pasbien, demandez à un
électricien qualifié d'installer une prise de courant
polarisée. Ne modifiez pas la fiche de l'outil. La
double isolation élimine le besoin d'un cordon
d'alimentationà trois fils avec mise à la terre ainsi que
d'une prise de courant mise à la terre.Avant de brancher
l'outil, assurez-vous que la tension de la prise
correspond, à plus ou moins 10 %, à celle indiquée sur
la plaque signalétique. N'utilisez pas d'outils prévus
pour courant alternatif seulement avec une source de
courant continu.
Évitez tout contact corporel avec des surfaces mises à
la terre (tuyauterie, radiateurs, cuisinières,
réfrigérateurs, etc.). Le risque de choc électrique est
plus grand si votre corps est encontact avec la terre.Si
l'utilisation de l'outil électrique dans un endroit humide
est inévitable, un disjoncteur de fuite à la terre doit être
utilisé pour alimenter votre outil. Des chaussures et des
gants en caoutchouc d'électricien contribueront à
accroître davantage votre sécurité personnelle.
N'exposez pas les outils électriques à la pluie ou à
l'eau. La présence d'eau dans un outil électrique
augmente le risque de choc électrique.
Ne maltraitez pas le cordon. Ne transportez pas l'outil
par son cordon et ne débranchez pas la fiche en tirant
sur le cordon. N'exposez pas le cordon à la chaleur, à
des huiles, à des arêtes vives ou à des pièces en
mouvement. Remplacez immédiatement un cordon
endommagé. Un cordon endommagé augmente le
risque de choc électrique.
Lorsque vous utilisez un outil électrique à l'extérieur,
employez un prolongateur pour l'extérieur marqué
«W-A » ou « W ». Ces cordons sont faits pour être
utilisés à l'extérieur et réduisent le risque de choc
électrique. Reportez-vous aux « Dimensions
recommandées des cordons de rallonge » dans la
section Accessoires de ce manuel.
Sécurité des personnes
Restez alerte, concentrez-vous sur votre travail et
faites preuve de jugement. N'utilisez pas un outil
électrique si vous êtes fatigué ou sous l'influence de
drogues, d'alcool ou de médicaments. Un instant
d'inattention suffit pour entraîner des blessures graves.
Habillez-vous convenablement. Ne portez ni
vêtements flottants ni bijoux. Confinez les cheveux
longs. N'approchez jamais les cheveux, les
vêtements ou les gants des pièces en mouvement.
Des vêtements flottants, des bijoux ou des cheveux
longs risquent d'être happés par des pièces en
mouvement. Gardez les poignées sèches, propres et
exemptes d'huile et de graisse.
Méfiez-vous d'un démarrage accidentel. Avant de
brancher l'outil, assurez-vous que son interrupteur est
sur ARRÈT. Le fait de transporter un outil avec le doigt
sur la détente ou de brancher un outil dont l'interrupteur
est en position MARCHE peut mener tout droit à un
accident.
Enlevez les clés de réglage ou de serrage avant de
démarrer l'outil. Une clé laissée dans une pièce
tournante de l'outil peut provoquer des blessures.
Ne vous penchez pas trop en avant. Maintenez un bon
appui et restez en équilibre entout temps. Un bonne
stabilité vous permet de mieux réagir à une situation
inattendue.
Utilisez des accessoires de sécurité. Portez toujours
des lunettes ou une visière. Selon les conditions,
portez aussi un masque antipoussière, des bottes de
sécurité antidérapantes, un casque protecteur et/ou un
appareil antibruit.
Utilisation et entretien des outils
Immobilisez le matériau sur une surface stable au
moyen de brides ou de toute autre façon adéquate. Le
fait de tenir la pièce avec la main ou contre votre corps
offre une stabilité insuffisante et peut amener un
dérapage de l'outil.
Ne forcez pas l'outil. Utilisez l'outil approprié à la
tâche. L'outil correct fonctionne mieux et de façon plus
sécuritaire. Respectez aussi la vitesse de travail qui lui
est propre.
Règles de Sécurité Générales
AVERTISSEMENT
!
RZ 2610954840 07-07 8/16/07 3:55 PM Page 20