Ryobi Cordless Saw RJ160V User Guide

OPERATOR'S MANUAL  
VARIABLE SPEED  
RECIPROCATING SAW  
RJ160V - DOUBLE INSULATED  
6
SPECIFICATIONS:  
Length of stroke  
Variable Strokes per Minute  
1 3/16 in. (30 mm)  
2400 max  
Rating  
120 volts, 60Hz, AC  
6.0 amps  
Input  
Net weight  
7.3 lbs. (3.32 kg.)  
THANK YOU FOR BUYING A RYOBI RECIPROCATING SAW.  
Your new saw has been engineered and manufactured to Ryobi's high standard for dependability, ease of operation, and  
operator safety. Properly cared for, it will give you years of rugged, trouble-free performance.  
CAUTION: Carefully read through this entire operator's manual before using your new saw.  
Pay close attention to the Rules for Safe Operation, Warnings, and Cautions. If you use your saw properly and only for what  
it is intended, you will enjoy years of safe, reliable service.  
Please fill out and return the Warranty Registration Card so we can be of future service to you.  
Thank you again for buying Ryobi tools.  
SAVE THIS MANUAL FOR FUTURE REFERENCE  
 
RULES FOR SAFE OPERATION  
The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and the  
explanations with them, deserve your careful attention and understanding. The safety warnings do not by  
themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper  
accident prevention measures.  
SYMBOL  
MEANING  
SAFETY ALERT SYMBOL:  
Indicates danger, warning, or caution. May be used in conjunction with other symbols or pictographs.  
DANGER: Failure to obey a safety warning will result in serious injury to yourself or to others. Always  
follow the safety precautions to reduce the risk of fire, electric shock and personal injury.  
WARNING:Failuretoobeyasafetywarningcanresultinseriousinjurytoyourselfortoothers.Always  
follow the safety precautions to reduce the risk of fire, electric shock and personal injury.  
CAUTION: Failure to obey a safety warning may result in property damage or personal injury to  
yourself or to others. Always follow the safety precautions to reduce the risk of fire, electric shock and  
personal injury.  
NOTE:  
Advises you of information or instructions vital to the operation or maintenance of the equipment.  
DOUBLE INSULATION  
IMPORTANT  
Your Ryobi power tool is double insulated. This means you  
areseparatedfromthetool'selectricalsystembytwocomplete  
sets of electrical insulation. This extra layer of insulation is  
intended to protect the user from electrical shock due to a  
break in the wiring insulation. All exposed metal parts are  
isolated from the internal metal motor components with  
protecting insulation. Double insulated tools do not need to  
be grounded.  
Servicing of a tool with double insulation requires extreme  
care and knowledge of the system and should be performed  
onlybyaqualifiedservicetechnician.Forservicewesuggest  
you return the tool to your nearest RYOBI AUTHORIZED  
SERVICE CENTER for repair. When servicing use only  
identical Ryobi replacement parts.  
WARNING:  
Do not attempt to operate this tool until you have read  
thoroughly and understand completely all instructions,  
safety rules, etc. contained in this manual. Failure to  
comply can result in accidents involving fire, electric  
shock, or serious personal injury. Save operator's manual  
and review frequently for continuing safe operation, and  
instructing others who may use this tool.  
WARNING:  
The double insulated system is intended to protect the  
user from shock resulting from a break in the tool's  
internal wiring. Observe all normal safety precautions  
related to avoiding electrical shock. Failure to do so  
could result in possible serious injury.  
Page 3  
 
GENERAL SAFETY RULES  
inattention while operating power tools may result in  
WARNING:  
serious personal injury.  
Dress properly. Do not wear loose clothing or  
jewelry. Contain long hair. Keep your hair, cloth-  
ing, and gloves away from moving parts. Loose  
clothes, jewelry, or long hair can be caught in moving  
parts.  
Read and understand all instructions. Failure to  
follow all instructions listed below, may result in elec-  
tric shock, fire and/or serious personal injury.  
SAVE THESE INSTRUCTIONS  
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.  
Work Area  
Keep your work area clean and well lit. Cluttered  
benches and dark areas invite accidents.  
Do not operate power tools in explosive atmo-  
spheres, such as in the presence of flammable  
liquids, gases, or dust. Power tools create sparks  
which may ignite the dust or fumes.  
Remove adjusting keys or wrenches before turn-  
ing the tool on. A wrench or a key that is left  
attached to a rotating part of the tool may result in  
personal injury.  
Keep bystanders, children, and visitors away  
while operating a power tool. Distractions can  
cause you to lose control.  
Do not overreach. Keep proper footing and  
balance at all times. Proper footing and balance  
enables better control of the tool in unexpected situ-  
ations.  
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 insu-  
Use safety equipment. Always wear eye protec-  
tion. Dust mask, non-skid safety shoes, hard hat, or  
hearing protection must be used for appropriate con-  
ditions.  
Tool Use and Care  
Use clamps or other practical way to secure and  
support the workpiece to a stable platform. Hold-  
ing 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 acces-  
sories, or storing the tool. Such preventive safety  
measures reduce risk of starting the tool acciden-  
tally.  
Store idle tools out of reach of children and other  
untrained persons. Tools are dangerous in the  
hands of untrained users.  
lation  
eliminates the need for the three wire  
grounded power cord and grounded power supply  
system.  
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.  
Don't expose power tools to rain or wet condi-  
tions. 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 immedi-  
ately. Damaged cords increase the risk of electric  
shock.  
When operating a power tool outside, use an out-  
door extension cord marked “W-A” or “W”. These  
cords are rated for outdoor use and reduce the risk of  
electric shock.  
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 condi-  
tion that may affect the tool's operation. If dam-  
aged, have the tool serviced before using. Many  
accidents are caused by poorly maintained tools.  
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  
Page 4  
 
GENERAL SAFETY RULES  
Do not abuse cord. Never carry tool by cord or yank  
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.  
it to disconnect from receptacle. Keep cord from  
heat, oil and sharp edges. Following this rule will  
reduce the risk of electric shock or fire.  
Inspect for and remove all foreign objects from  
workpiece before cutting. Following this rule will  
reduce the risk of serious personal injury.  
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 replace-  
ment 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.  
Make sure your extension cord is in good condi-  
tion. Whenusinganextensioncord, besuretouseone  
heavy enough to carry the current your product will  
draw. A wire gage size (A.W.G.) of at least 12 is  
recommended for an extension cord 100 feet or less in  
length. A cord exceeding 100 feet is not recommended.  
If in doubt, use the next heavier gage. The smaller the  
gage number, the heavier the cord. An undersized cord  
will cause a drop in line voltage resulting in loss of power  
and overheating.  
Specific Safety Rules for Reciprocating Saws  
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.  
Drugs, Alcohol, Medication. Do not operate tool  
while under the influence of drugs, alcohol, or any  
medication. Following this rule will reduce the risk of  
electric shock, fire, or serious injury.  
Additional Rules for Safe Operation  
Know your power tool. Read operator's manual  
carefully. Learn its applications and limitations as well  
as the specific potential hazards related to this tool.  
Following this rule will reduce the risk of electric shock,  
fire, or serious injury.  
Always wear safety glasses with side shields.  
Everydayeyeglasseshaveonlyimpactresistantlenses;  
they are NOT safety glasses.  
Keep hands away from cutting area. Following this  
rule will reduce the risk of serious personal injury.  
Save these instructions. Refer to them frequently  
and use them to instruct others who may use this tool.  
If you loan someone this tool, loan them these instruc-  
tions also.  
Protect your lungs. Wear a face or dust mask if the  
WARNING:  
operation is dusty.  
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:  
Protectyourhearing.Wearhearingprotectionduring  
extended periods of operation.  
Inspect tool cords periodically and if damaged, have  
repaired at your nearest authorized service center. Stay  
constantly aware of cord location.  
• lead from lead-based paints,  
• crystalline silica from bricks and cement and other  
masonry products, and  
• arsenic and chromium from chemically-treated  
lumber.  
Check damaged parts. Before further use of the tool,  
a guard or other part that is damaged should be  
carefully checked to determine that it will operate  
properly and perform its intended function. Check for  
alignment of moving parts, binding of moving parts,  
breakage of parts, mounting, and any other conditions  
that may affect its operation. A guard or other part that  
isdamagedshouldbeproperlyrepairedorreplacedby  
an authorized service center. Following this rule will  
reduce the risk of electric shock, fire, or serious injury.  
Keep the tool and its handle dry, clean, and free  
from oil and grease. Always use a clean cloth when  
cleaning. Never use brake fluids, gasoline, petroleum-  
based products, or any strong solvents to clean your  
tool.  
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.  
SAVE THESE INSTRUCTIONS  
Page 5  
 
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  
A
Amperes  
Hertz  
Current  
Hz  
W
Frequency (cycles per second)  
Watt  
Power  
min  
Minutes  
Alternating Current  
Time  
Type or a characteristic of current  
n
No Load Speed  
Strokes, at no load  
0
Designates Double Insulated  
Construction tools  
Class II Construction  
Revolutions, strokes, surface speed,  
orbits etc. per minute  
.../min  
Revolutions or Reciprocation Per Minute  
Safety Alert Symbol  
Indicates danger, warning or caution.  
It means attention!!! Your safety is  
involved.  
ELECTRICAL  
EXTENSION CORDS  
ELECTRICAL CONNECTION  
When using a power tool at a considerable distance from the  
power source, use an extension cord heavy enough to carry  
the current that the tool will draw. An undersized extension  
cord will cause a drop in line voltage, resulting in a loss of  
power and causing the motor to overheat. Use the chart  
provided below to determine the minimum wire size required  
in an extension cord. Only round jacketed cords listed by  
Underwriter's Laboratories (UL) should be used.  
Your saw has a precision built electric motor. It should be  
connected to a power supply that is 120 volts, 60Hz, AC  
only (normal household current). Do not operate this tool  
on direct current (DC). A substantial voltage drop will cause  
a loss of power and the motor will over heat. If your tool does  
not operate when plugged into an outlet, double-check the  
power supply.  
Length of Extension Cord  
Wire Size (A.W.G.)  
CAUTION:  
Keep the cord away from the work area and position the  
cord so that it may not get caught on materials or other  
objects during cutting.  
Up to 25  
26 to 50  
51 to 100  
16  
14  
12  
When working with the tool outdoors, use an extension cord  
that is designed for outside use. This is indicated by the  
letters WA on the cord's jacket.  
Before using an extension cord, inspect it for loose or  
exposed wires and cut or worn insulation.  
Page 6  
 
UNPACKING  
If any parts are damaged or missing, call 1-800-525-2579 to  
UNPACKING  
obtain replacement parts before attempting to operate saw.  
An operator's manual and warranty registration are also  
included.  
Your saw has been shipped completely assembled, except  
fortheblade, andisreadyforuse. Inspectitcarefullytomake  
sure no breakage or damage has occurred during shipping.  
FEATURES  
Variable Speed Dial  
KNOW YOUR RECIPROCATING SAW  
Your reciprocating saw has a variable speed dial designed  
to allow operator control of speed and power limits. See  
Figure 1.  
Before attempting to use your saw, familiarize yourself with  
alloperatingfeaturesandsafetyrequirements.SeeFigure1.  
Hex Key Holder  
A convenient feature on your saw is a hex key holder. It is  
located on the bottom portion of your saw's handle. It is  
convenient for storing the hex key when not in use. See  
Figure 1.  
Fig. 1  
6
Page 7  
OPERATION  
TO  
WARNING:  
DECREASE  
Always wear safety goggles or safety glasses with side  
shields when operating your reciprocating saw. Failure to  
dosocouldresultinforeignobjectsbeingthrownintoyour  
eyes resulting in possible serious injury.  
1
TO  
INCREASE  
SWITCH  
See Figure 2.  
6
To turn your reciprocating saw ON, depress trigger. Release  
trigger to turn your saw OFF.  
WINDOW  
VARIABLE SPEED DIAL  
See Figure 2.  
Your reciprocating saw has a variable speed dial designed to  
allow operator control of speed and power limits. The speed  
and power of your saw can be increased or decreased  
depending on the position of the variable speed dial.  
VARIABLE  
SPEED DIAL  
Avoid running your saw at low speeds for extended periods  
of time. Running at low speeds under constant usage may  
cause the motor of your saw to become overheated. If this  
occurs, cool your saw by running it without a load and at full  
speed.  
Fig. 2  
WARNING:  
Your saw should never be connected to power supply  
when you are assembling parts, making adjustments,  
installing or removing blades, when cleaning, or when not  
in use. Disconnecting your saw will prevent accidental  
starting that could cause serious injury.  
HEX KEY  
BLADE SELECTION  
To obtain the best performance from your saw it is important  
to select a specific blade for the particular application and  
type of material you wish to cut. By doing this you will get a  
smoother, faster cut and prolong blade life. Replacement  
blades for this saw are available from your nearest Ryobi  
dealer.  
BLADE  
CLAMP SCREW  
PIN  
TO INSTALL BLADES  
See Figure 3.  
UNPLUG YOUR SAW.  
WARNING:  
Failure to unplug your saw could result in accidental  
starting causing serious injury.  
SAW BAR  
Removethe3mmhexkeyprovidedwiththissawfromhex  
key holder.  
Note: Hex key holder is located in the side of the saw  
handle. See Figure 1.  
BLADE  
CLAMP  
Loosen the blade clamp screw enough to permit the saw  
blade to be inserted between blade clamp and pin.  
Note: It is never necessary to remove the blade clamp  
from the tool or the blade clamp screw from the blade  
clamp to change the blade.  
Fig. 3  
Page 8  
 
OPERATION  
Align the hole in the shank of the blade and blade clamp  
with the pin in the saw bar, then seat both on the pin in the  
saw bar.  
BLADE  
CLAMP SCREW  
MALLET  
Tighten blade clamp screw securely. Do not overtighten  
screw or use an aid with hex key.  
HEX KEY  
Remove hex key and store it in the hex key holder.  
Note: There may be times when the blade clamp sticks to the  
saw bar and will not loosen enough to allow blades to be  
installed or removed. If this happens, loosen the blade clamp  
screw with the hex key, then tap lightly on the end of the hex  
key with a mallet. See Figure 4.  
SAW BAR  
BASE ASSEMBLY  
See Figure 5.  
The base assembly of your reciprocating saw pivots up and  
down in both directions. The base is adjustable, allowing the  
use of the blade teeth at different positions on the blade.  
BLADE  
CLAMP  
TO CHANGE POSITIONS OF THE BASE ASSEMBLY:  
See Figure 6.  
Fig. 4  
UNPLUG YOUR SAW.  
PIVOT  
WARNING:  
Failure to unplug your saw could result in accidental  
starting causing serious injury.  
Loosen the button head screws in the gear frame with the  
3 mm hex key mentioned above.  
Reposition base assembly.  
Retightenbuttonheadscrewssecurely.Donotovertighten  
screws or use an aid with hex key.  
BASE  
ASSEMBLY  
Remove hex key and store it in hex key holder.  
Fig. 5  
WARNING:  
HEX KEY  
Cutting into electrical wiring in walls can cause blade, blade  
clamp, and saw bar assembly to become electrically live.  
Do not touch metal parts when cutting into a wall; grasp  
only the insulated gripping surface provided on the tool.  
Make sure hidden electrical wiring, water pipes, and  
mechanical hazards are not in the blade path when cut-  
ting into a wall.  
BASE  
ASSEMBLY  
BUTTON  
HEAD SCREWS  
Fig. 6  
Page 9  
 
.
Fig. 8  
ARNING:  
W
Fig. 9  
an operation where the cutting tool may cont act hiden  
o p e r a t o r  
6
Hold tool by insulated gripping surfaces h n performing  
wiring or its own cord. Contact with a “live” wire will make  
exposed metal parts of the tool “live” and shock the  
6
Fig. 7  
OPERATION  
GENERAL CUTTING  
See Figure 7.  
Hold your saw firmly in front of and clearly away from you.  
Make sure saw blade is clear of any foreign material and that  
power cord and extension cord are out of the blade path. Be  
surematerialtobecutisheldfirmly.Smallworkpiecesshould  
be securely clamped in a vise or with clamps to the work  
benchortable.Markthelineofcutclearly.Depressthetrigger  
switch starting the cutting action, set the base assembly  
against the work, then move the blade into the work. DO NOT  
FORCE. Use only enough pressure to keep the saw cutting.  
Let the blade and saw do the work.  
PLUNGE CUTTING  
See Figure 8.  
Mark the line of cut clearly. Choose a convenient starting  
pointinsidetheareatobecutoutandplacethetipoftheblade  
overthatpoint.Restfrontedgeofbaseassemblyonworkand  
hold firmly in position.  
WARNING:  
Make sure blade does not touch work until motor reaches  
full speed, since this can cause loss of control resulting in  
serious injury.  
With saw blade at full cutting speed, slowly tilt saw downward  
until tip of blade starts cutting work. After blade penetrates  
work, tilt saw until blade is perpendicular to the work.  
METAL CUTTING  
See Figure 9.  
Metalssuchassheetsteel,pipe,steelrods,aluminum,brass,  
and copper may be cut with your saw. Be careful not to twist  
or bend the saw blade. DO NOT FORCE. We recommend  
cutting oil when cutting most soft metals and steel. Cutting oil  
will also keep blades cool, increase cutting action, and  
prolong blade life.  
Never use gasoline since normal sparking of motor could  
ignite fumes. Clamp the work firmly and cut close to the  
clamping point to eliminate any vibration of the work being  
cut. When cutting conduit pipe or angle iron, clamp work in a  
vise if possible and cut close to the vise. To cut thin sheet  
material, "sandwich" the material between hardboard or  
plywood and clamp the layers to eliminate vibration and  
material tearing.  
Page 10  
Ithasbeenfoundthatelectrictoolsaresubjecttoaccelerated  
wear and possible premature failure when they are used on  
fiberglassboats,sportscars,wallboard,spacklingcompounds,  
or plaster. The chips and grindings from these materials are  
highlyabrasivetoelectrictoolpartssuchasbearings,brushes,  
commutators, etc. Consequently, it is not recommended that  
thistoolbeusedforextendedworkonanyfiberglassmaterial,  
wallboard, spackling compounds, or plaster. During any use  
on these materials, it is extremely important that the tool is  
cleaned frequently by blowing with an air jet.  
GENERAL  
Avoidusingsolventswhencleaningplasticparts.Mostplastics  
are susceptible to various types of commercial solvents and  
may be damaged by their use. Use clean cloths to remove  
dirt, carbon dust, etc.  
WARNING:  
Do not at any time let brake fluids, gasoline, petroleum-  
based products, penetrating oils, etc. come in contact  
with plastic parts. They contain chemicals that can  
damage, weaken, or destroy plastic.  
LUBRICATION  
All of the bearings in this tool are lubricated with a sufficient  
amount of high grade lubricant for the life of the unit under  
normaloperatingconditions. Therefore, nofurtherlubrication  
is required.  
Standard universal 1/2 inch shank reciprocating saw blades  
available at your local supplier may be used with your Ryobi  
reciprocating saw.  
Page 11  
OPERATOR'S MANUAL  
RECIPROCATING SAW  
RJ160V  
DOUBLE INSULATED  
EXTENSION CORD CAUTION  
**Ampere rating  
(on tool faceplate) 0-2.0  
2.1-3.4 3.5-5.0 5.1-7.0 7.1-12.0 12.1-16.0  
When using a power tool at a considerable distance from a power  
source, be sure to use an extension cord that has the capacity to  
handle the current the tool will draw. An undersized cord will cause  
a drop in line voltage, resulting in overheating and loss of power.  
Use the chart to determine the minimum wire size required in an  
extension cord. Only round jacketed cords should be used.  
Cord Length  
Wire Size (A.W.G.)  
25'  
50'  
16  
16  
16  
16  
16  
16  
16  
16  
14  
16  
14  
12  
14  
14  
10  
14  
12  
100'  
When working with a tool outdoors, use an extension cord that is  
designed for outside use. This is indicated by the letters "WA" on  
the cord's jacket.  
CAUTION: Keep the extension cord clear of the working  
area. Position the cord so that it will not get caught on lumber,  
tools or other obstructions while you are working with a power  
tool.  
Before using any extension cord, inspect it for loose or exposed  
wires and cut or worn insulation.  
**Used on 12 gauge - 20 amp circuit.  
• SERVICE  
Now that you have purchased your tool, should a need ever exist for repair parts or  
service, simply contact your nearest Ryobi Authorized Service Center. Be sure to  
provide all pertinent facts when you call or visit. Please call 1-800-525-2579 for your  
nearest Ryobi Authorized Service Center. You can also check our web site at  
• MODEL NO. AND SERIAL NO.  
The model number of this tool will be found on a plate attached to the motor housing.  
Please record the model number and serial number in the space provided below.  
• HOW TO ORDER REPAIR PARTS  
WHEN ORDERING REPAIR PARTS,  
ALWAYS GIVE THE FOLLOWING INFORMATION:  
RJ160V  
• MODEL NUMBER  
• SERIAL NUMBER  
RYOBI TECHNOLOGIES INC.  
1428 Pearman Dairy Road  
Anderson, SC 29625  
Post Office Box 1207  
Anderson, SC 29622  
Phone 1-800-525-2579  
972000-945  
Printed in U.S.A.  
 

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