Ryobi Cordless Saw RJ161V User Guide

OPERATOR'S MANUAL  
RECIPROCATING SAW  
RJ161V  
VARIABLE SPEED - DOUBLE INSULATED  
6
Your new reciprocating 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.  
WARNING: To reduce the risk of injury, the user must read and understand the operator’s manual.  
Thank you for buying a Ryobi reciprocating saw.  
SAVE THIS MANUAL FOR FUTURE REFERENCE  
 
GENERAL SAFETY RULES  
Dress properly. Do not wear loose clothing or  
WARNING:  
Read and understand all instructions. Failure to  
follow all instructions listed below, may result in elec-  
tric shock, fire and/or serious personal injury.  
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 mov-  
ing parts or drawn into air vents.  
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.  
SAVE THESE INSTRUCTIONS  
WORK AREA  
Remove adjusting keys or wrenches before turn-  
ing the tool on. A wrench or a key that is left at-  
tached to a rotating part of the tool may result in  
personal injury.  
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 may create  
sparks which may ignite the dust or fumes.  
Do not overreach. Keep proper footing and bal-  
ance at all times. Proper footing and balance en-  
ables better control of the tool in unexpected situa-  
tions. Do not use on a ladder or unstable support.  
Keep bystanders, children, and visitors away  
while operating a power tool. Distractions can  
cause you to lose control.  
Use safety equipment. Always wear eye protec-  
tion. Dust mask, nonskid safety shoes, hard hat, or  
hearing protection must be used for appropriate con-  
ditions.  
ELECTRICAL SAFETY  
Double insulated tools are equipped with a po-  
larized 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-  
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 un-  
stable and may lead to loss of control.  
lation  
eliminates the need for the three-wire  
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.  
grounded power cord and grounded power supply  
system.  
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.  
Avoid body contact with grounded surfaces,  
such as pipes, radiators, ranges, and refrigera-  
tors. There is an increased risk of electric shock if  
your body is grounded.  
Disconnect the plug from power source before  
making any adjustments, changing accessories,  
or storing the tool. Such preventive safety mea-  
sures reduce the risk of starting the tool acciden-  
tally.  
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.  
Store idle tools out of the 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.  
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.  
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 inat-  
tention while operating power tools may result in  
serious personal injury.  
Use only accessories that are recommended by  
the manufacturer for your model. Accessories that  
may be suitable for one tool, may become hazard-  
ous when used on another tool.  
3
 
GENERAL SAFETY RULES  
When servicing a tool, use only identical replace-  
SERVICE  
ment parts. Follow instructions in the Mainte-  
nance section of this manual. Use of unauthorized  
parts or failure to follow Maintenance Instructions  
may create a risk of electric shock or injury.  
Tool service must be performed only by quali-  
fied repair personnel. Service or maintenance per-  
formed by unqualified personnel could result in a risk  
of injury.  
SPECIFIC SAFETY RULES  
Hold tool by insulated gripping surfaces when performing an operation where the tool may contact  
hidden wiring or its cord. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the  
operator.  
Make sure your extension cord is in good condi-  
tion. When using an extension cord, be sure to  
use one heavy enough to carry the current your  
product will draw. A wire gage size (A.W.G.) of at  
least 16 is recommended for an extension cord  
25 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.  
ADDITIONAL SAFETY RULES  
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. Everyday eye-  
glasses have only impact-resistant lenses; they  
are NOT safety glasses. Following this rule will re-  
duce the risk of serious personal injury.  
Protect your lungs. Wear a face or dust mask if  
the operation is dusty. Following this rule will re-  
duce the risk of serious personal injury.  
Inspect for and remove all nails from lumber be-  
fore using this tool. Following this rule will reduce  
the risk of serious personal injury.  
Protect your hearing. Wear hearing protection  
during extended periods of operation. Following  
this rule will reduce the risk of serious personal in-  
jury.  
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 personal injury.  
Inspect tool cords periodically and, if damaged,  
have repaired at your nearest Factory Service  
Center or otherAuthorized Service Organization.  
Constantly stay aware of cord location. Follow-  
ing this rule will reduce the risk of electric shock or  
fire.  
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 instructions also.  
WARNING:  
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 func-  
tion. Check for alignment of moving parts, bind-  
ing of moving parts, breakage of parts, mount-  
ing, and any other conditions that may affect its  
operation. A guard or other part that is damaged  
should be properly repaired or replaced by an  
authorized service center. Following this rule will  
reduce the risk of shock, fire, or serious injury.  
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.  
Do not abuse cord. Never carry the tool by the  
cord or yank it to disconnect it from the recep-  
tacle. Keep cord away from heat, oil, and sharp  
edges. Following this rule will reduce the risk of elec-  
tric shock or fire.  
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
 
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
Hz  
W
Amperes  
Hertz  
Current  
Frequency (cycles per second)  
Watt  
Power  
min  
Minutes  
Time  
Alternating Current  
Type or a characteristic of current  
n
No Load Speed  
Rotational speed, at no load  
0
Class II Construction  
Designates double-insulated  
construction tools  
.../min  
Revolutions or Reciprocation Per Minute  
Safety Alert  
Revolutions, strokes, surface speed,  
orbits etc. per minute  
Indicates danger, warning or caution.  
It means attention!!! Your safety is  
involved.  
Wet Conditions Alert  
Do not expose to rain or use in damp  
locations.  
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  
DANGER:Failuretoobeyasafetywarningwillresultinseriousinjurytoyourselfortoothers. Always  
follow the safety precautions to reduce the risk of fire, electric shock and personal injury.  
WARNING: Failure to obey a safety warning can 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.  
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.  
SAVE THESE INSTRUCTIONS  
5
 
SPECIFICATIONS  
Length of Stroke  
Strokes per Minute (variable)  
Input  
1-3/16 in. (3 cm)  
2,500 max  
120 volts, 60 Hz, AC only, 6.5 amps  
7 lbs. (3.2 kg)  
Net Weight  
UNPACKING  
INSTRUCTIONS  
PACKING LIST  
Your reciprocating saw has been shipped completely  
assembled.  
Reciprocating Saw  
Blades (2)  
Carefully remove the tool and accessories from the  
box. Make sure that all items listed in the packing  
list are included.  
Operator’s Manual  
WARNING:  
Inspect the tool carefully to make sure no breakage  
If any parts are missing do not operate your tool until  
the missing parts are replaced. Failure to do so  
could result in possible serious personal injury.  
or damage occurred during shipping.  
Do not discard the packing material until you have  
carefully inspected and satisfactorily operated the  
tool.  
If any parts are damaged or missing, please call  
1-800-525-2579 for assistance.  
6
 
FEATURES  
DOUBLE INSULATION  
ELECTRIC MOTOR  
Double insulation is a concept in safety in electric power  
tools, which eliminates the need for the usual three-wire  
grounded power cord. All exposed metal parts are  
isolated from the internal metal motor components with  
protecting insulation. Double insulated tools do not need  
to be grounded.  
Your tool has a precision built electric motor. It should  
be connected to a power supply that is 120 volts, 60  
Hz, 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  
overheat. If your tool does not operate when plugged  
into an outlet, double-check the power supply.  
WARNING:  
SWITCH  
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 pre-  
cautions to avoid electrical shock.  
Therecriprocatingsawhasaconvenientlylocatedtrigger  
switch.  
VARIABLE SPEED  
Therecriprocatingsawhasavariablespeeddialdesigned  
to allow operator control of speed and power limits.  
Important: Servicing of a tool with double insulation  
requires extreme care and knowledge of the system and  
should be performed only by a qualified service  
technician. For service, we suggest you return the tool to  
yournearestauthorizedservicecenterforrepair.Always  
use original factory replacement parts when servicing.  
TOOLLESS BLADE CHANGE SYSTEM  
The toolless blade change system eliminates the need  
for tools when changing the blade.  
ERGONOMIC DESIGN  
The design of this tool provides for easy handling. It is  
designed for comfort and ease of grasp when operating  
in different positions and at different angles.  
BLADE  
VARIABLE  
SPEED DIAL  
BASE  
ASSEMBLY  
6
TRIGGER  
SWITCH  
WARNING:  
Do not attempt to modify this tool or create accessories not recommended for use with this tool. Any such  
alteration or modification is misuse and could result in a hazardous condition leading to possible serious  
personal injury.  
7
 
OPERATION  
WARNING:  
Always wear safety goggles or safety glasses with  
side shields when operating this tool. Failure to do  
so could result in dust, shavings, or loose particles  
being thrown into your eyes, resulting in possible  
serious injury.  
TURNING THE SAW ON/OFF  
See Figure 2.  
Follow these directions to turn the saw on and off.  
To turn the saw on: Depress the switch trigger.  
To turn the saw off: Release the switch trigger.  
ADJUSTING THE SPEED  
Fig. 2  
See Figure 3.  
The variable speed feature allows the saw to operate at  
speeds that can be increased by rotating the dial from  
1 to 6. The dial is conveniently located on the handle,  
allowing operator control of blade speed.  
TO DECREASE  
SPEED  
Follow these directions to adjust the speed.  
To increase the speed: Turn the dial to a higher  
setting.  
To decrease the speed: Turn the dial to a lower  
setting.  
1
SELECTING BLADES  
Selecting the correct type of blade is important in order  
toobtainthebestperformancefromyoursaw. Selectthe  
blade based on the application and on the material you  
wish to cut. Selecting the right blade will give you a  
smoother, faster cut and prolong the life of the blade.  
TO INCREASE  
SPEED  
Blades with fewer teeth, 10 teeth per inch (TPI) are  
typically used for cutting wood, while blades with more  
teetharebetterforcuttingmetalorplastic.Werecommend  
14 TPI for plastics and soft metals and 18 TPI for hard  
metals.  
Fig. 3  
INSTALLING BLADES  
The toolless blade change system eliminates the need  
for tools when changing the blade.  
See Figure 4.  
Follow these directions to install blades.  
Unplug the saw.  
WARNING:  
Failure to unplug the tool could result in accidental  
starting causing possible serious injury.  
LIFT TO  
INSTALL  
BLADE  
Lift the blade release lever.  
Insert the blade fully, tooth side down.  
Lower the blade release lever.  
Fig. 4  
8
 
OPERATION  
OPERATING THE SAW  
See Figure 5.  
Follow these directions to operate the saw.  
Secure the workpiece to a work bench or table with  
a vise or with clamps.  
Make sure the saw blade is clear of any foreign  
material and that the power cord and extension cord  
are out of the blade path.  
Hold the saw firmly in front of and clearly away from  
you.  
Mark the line of cut clearly.  
Depress the trigger switch to start the cutting action.  
Set the base assembly against the workpiece.  
Move the blade into the workpiece.  
NOTE: Do not force. Use only enough pressure to  
keep the saw cutting. Let the blade and saw do the  
work. Keep pressure on the base, against the  
workpiece.  
Fig. 5  
PLUNGE CUTTING  
See Figure 6.  
6
Follow these directions to plunge cut.  
Secure the workpiece to a work bench or table with  
a vise or with clamps.  
Make sure the saw blade is clear of any foreign  
material and that the power cord and extension cord  
are out of the blade path.  
Hold the saw firmly in front of and clearly away from  
you.  
Mark the line of cut clearly.  
Choose a convenient starting point inside the cut-  
ting area and place the tip of the blade over that  
point.  
Rest the front edge of the base assembly on the  
workpiece and hold it firmly in position during the  
cut.  
Fig. 6  
Depress the trigger switch and allow the saw blade  
to reach full cutting speed.  
WARNING:  
Blades longer than 6 in. (15.2 cm) can whip and  
should not be used for plunge cutting. Failure to  
heed this warning can resut in serious personal in-  
jury.  
WARNING:  
Make sure the blade does not touch the workpiece  
until the motor reaches full speed. Failure to heed  
this warning can cause you to lose of control of the  
saw and result in serious injury.  
WARNING:  
Tilt the saw downward until the tip of the blade starts  
Cutting into electrical wiring can cause the blade, the  
blade clamp, and the saw bar assembly to become  
electrically live. Do not touch metal parts when cut-  
ting into a wall; grasp only the insulated surfaces on  
the tool. Make sure hidden electrical wiring, water  
pipes, and mechanical hazards are not in the blade  
path when cutting into a wall.  
cutting the workpiece.  
Allow the saw to penetrate the workpiece.  
Tilt the saw until the blade is perpendicular to the  
workpiece.  
9
 
OPERATION  
METAL CUTTING  
See Figure 7.  
Youmaycutmetalssuchassheetsteel, pipe, steelrods,  
aluminum, brass, and copper with your saw.  
Observe the following tips when metal cutting.  
Be careful not to twist or bend the saw blade.  
Do not force the tool.  
Use cutting oil when cutting soft metals and steel.  
Cutting oil also keeps the blades cool, increases  
cutting action, and prolongs blade life.  
Never use gasoline since normal sparking of motor  
could ignite fumes.  
Clamp the workpiece firmly and cut close to the  
clamping point to eliminate any vibration of the work.  
When cutting conduit pipe or angle iron, clamp the  
workpiece in a vise if possible and cut close to the  
vise. To cut thin sheet material, “sandwich” the ma-  
terial between hardboard or plywood and clamp the  
layers to eliminate vibration and material tearing.  
Fig. 7  
Always keep firm pressure on the base to hold it  
securely against the workpiece.  
MAINTENANCE  
WARNING:  
When servicing use only identical Ryobi replacement parts. Use of any other parts may create a hazard or cause  
product damage.  
GENERAL  
WARNING:  
Avoid using solvents when cleaning plastic parts. Most  
Always wear safety goggles or safety glasses with  
plastics are susceptible to damage from various types of  
side shields during power tool operation or when  
commercial solvents and may be damaged by their use.  
blowing dust. If operation is dusty, also wear a dust  
Use clean cloths to remove dirt, carbon dust, etc.  
mask.  
WARNING:  
LUBRICATION  
Do not at any time let brake fluids, gasoline, petro-  
All of the bearings in this tool are lubricated with a  
leum-based products, penetrating oils, etc. come in  
sufficient amount of high grade lubricant for the life of the  
contact with plastic parts. They contain chemicals  
unit under normal operating conditions. Therefore, no  
that can damage, weaken, or destroy plastic.  
further lubrication is required.  
Electric tools used on fiberglass material, wallboard,  
spackling compounds, or plaster are subject to  
accelerated wear and possible premature failure, as the  
fiberglass chips and grindings are highly abrasive to  
bearings, brushes, commutators, etc. Consequently, we  
do not recommended that this tool be used for extended  
work on these types of materials. If, however, you do  
workwithanyofthesematerials,itisextremelyimportant  
that you clean the tool frequently by blowing it with an air  
jet.  
10  
 
NOTES  
11  
 
OPERATOR'S MANUAL  
RECIPROCATING SAW  
RJ161V  
VARIABLE SPEED - DOUBLE INSULATED  
**Ampere rating  
EXTENSION CORD CAUTION  
(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 under-  
sized cord will cause a drop in line voltage, resulting in over-  
heating and loss of power. Use the chart to determine the mini-  
mum wire size required in an extension cord. Only round jack-  
eted 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 ex-  
posed 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:  
RJ161V  
• 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  
983000-131  
9-02  
 

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