RYOBI PCL540 Fixed 18 Volt Cut Out Tool Instruction Manual

RYOBI PCL540 Fixed 18 Volt Cut Out Tool

Specifications

• Product Name: 18 Volt Cut-Out Tool
• Model: PCL540
• Includes: Cut-Out Tool, Collet (1/4 in.), Operator’s Manual

General Power Tool Safety Warnings
Read all safety warnings, instructions, illustrations, and] specifications provided with this power tool. Failure to follow all instructions may result in electric shock, fire, and/or serious injury. Save all warnings and instructions for future reference.

Work Area Safety

• Keep the work area clean and well lit to prevent accidents.
• Avoid operating power tools in explosive atmospheres or around flammable materials.
• Keep children and bystanders away from the work area to prevent distractions.

Electrical Safety

• Ensure power tool plugs match the outlet and do not modify them.
• Avoid body contact with earthed or grounded surfaces to reduce the risk of electric shock.
• Do not expose power tools to rain or wet conditions to prevent electric shock.
• Avoid abusing the cord and use it properly to prevent electric shock hazards.
• When operating outdoors, use an extension cord suitable for outdoor use to reduce the risk of electric shock.
• If operating in a damp location, use a ground fault circuit interrupter (GFCI) protected supply.

FAQ (Frequently Asked Questions)
Q: What should I do if the power tool malfunctions?
A: If the power tool malfunctions, stop using it immediately and refer to the maintenance section of the operator’s manual for troubleshooting steps. Do not attempt to repair the tool yourselfif you are not qualified to do so.

OPERATOR’S MANUAL

WARNING: To reduce the risk of injury, the user must read and understand the operator’s manual before using this product.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING
Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery- operated (cordless) power tool.

WORK AREA SAFETY

• Keep the work area clean and well-lit. Cluttered or dark areas invite accidents.
• Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

ELECTRICAL SAFETY

• Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
• Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
• When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
• If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.
• Use this product only with batteries and chargers listed in tool/appliance/battery pack/charger correlation supplement 987000-432.

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inatten-tion while operating power tools may result in serious personal injury.
• Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.
• Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
• Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry or long hair can be caught in mov-ing parts.
• If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.
• Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.
• Do not wear loose clothing or jewelry. Contain long hair. Loose clothes, jewelry, or long hair can be drawn into air vents.
• Do not use on a ladder or unstable support. Stable footing on a solid surface enables better control of the power tool in unexpected situations.

POWER TOOL USE AND CARE

• Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
• Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source and/or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
• Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
• Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
• Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.
• Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.
• Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.
• When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.
• Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.
• Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, explosion or risk of injury.
• Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 265°F may cause explosion.
• Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

SERVICE

• Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.
• Never service damaged battery packs. Service of bat-tery packs should only be performed by the manufacturer or authorized service providers.
• Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by your hand or against the body leaves it unstable and may lead to loss of control.
• Hold power tool by insulated gripping surfaces, when performing an operation where the cutting accessory may contact hidden wiring. Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.

CUT-OUT TOOL SAFETY WARNINGS

• Know your power tool. Read operator’s manual carefully. Learn its applications and limitations, as well as the specific potential hazards related to this power tool. Following this rule will reduce the risk of electric shock, fire, or serious injury.
• Always wear eye protection with side shields marked to comply with ANSI Z87.1 when assembling parts, operating the tool, or performing maintenance. Following this rule will reduce the risk of serious personal injury.
• Protect your lungs. Wear a face or dust mask if the operation is dusty. 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 injury.
• Battery tools do not have to be plugged into an electrical outlet; therefore, they are always in operating condition. Be aware of possible hazards when not using your battery tool or when changing accessories. Following this rule will reduce the risk of electric shock, fire, or serious personal injury.
• Do not place battery tools or their batteries near fire or heat. This will reduce the risk of explosion and possibly injury.
• Do not crush, drop or damage battery pack. Do not use a battery pack or charger that has been dropped or received a sharp blow. A damaged battery is subject to explosion. Properly dispose of a dropped or damaged battery immediately.
• Batteries can explode in the presence of a source of ignition, such as a pilot light. To reduce the risk of serious personal injury, never use any cordless product in the presence of open flame. An exploded battery can propel debris and chemicals. If exposed, flush with water immediately.
• Under extreme usage or temperature conditions, bat-tery leakage may occur. If liquid comes in contact with your skin, wash immediately with soap and water. If liquid gets into your eyes, flush them with clean water for at least 10 minutes, then seek immediate medical attention. 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 instructions also.

SYMBOLS

The following signal words and meanings are intended to explain the levels of risk associated with this product.

SYMBOL| SIGNAL| MEANING
| DANGER:| Indicates a hazardous situation, which, if not avoided, will result in death or serious injury.
| WARNING:| Indicates a hazardous situation, which, if not avoided, could result in death or serious injury.
| CAUTION:| Indicates a hazardous situation, that, if not avoided, may result in minor or moderate injury.
| NOTICE:| (Without Safety Alert Symbol) Indicates information considered important, but not related to a potential injury (e.g. messages relating to property damage).

FEATURES

PRODUCT SPECIFICATIONS

No Load Speed (RPM) ………………………………………………………………………………………………………………………..28,000/min.
Collet …………………………………………………………………………………………………………………………………………..1/4 in. or 1/8 in.

ASSEMBLY

WARNING
Do not use this product if it is not completely assembled or if any parts appear to be missing or damaged. Use of a product that is not properly and completely assembled or with damaged or missing parts could result in serious personal injury.

WARNING
Do not attempt to modify this product or create accessories or attachments not recommended for use with this product. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious personal injury.

If any parts are damaged or missing, please call 1-800-525-2579 for assistance.

OPERATION

WARNING
Do not allow familiarity with products to make you careless. Remember that a careless fraction of a second is sufficient to inflict severe injury.

WARNING
Always remove battery pack from the tool when you are assembling parts, making adjustments, cleaning, or when not in use. Removing battery pack will prevent accidental starting that could cause serious personal injury.

WARNING
Always wear eye protection with side shields marked to comply with ANSI Z87.1. Failure to do so could result in objects being thrown into your eyes, resulting in possible serious injury.

WARNING
Do not use any attachments or accessories not recommended by the manufacturer of this product. The use of attachments or accessories not recommended can result in serious personal injury.

APPLICATIONS
You may use this product for the purposes listed below:

• Cutting through drywall.

STARTING/STOPPING THE CUT-OUT TOOL
See Figure 1, page 9

WARNING
Always check that the spindle lock button is fully released before switching on the tool.

• Install the battery pack as described later in this section.
• Hold the cut-out tool in front and away from you, keeping the bit clear of the material.
• To start the cut-out tool, push the switch forward to the ON position.
• To stop the cut-out tool, push the switch to the OFF position.

LED WORK LIGHT
See Figure 1, page 9.
The LED work light illuminates when the cut-out tool is on.

• A – To turn ON
• B- To turn OFF
• C – Switch
• D – LED work light

WARNING
Battery tools are always in operating condition. Make sure the switch is in the OFF position when not in use or carrying at your side, when installing or removing the battery pack, and when installing or removing bits.

INSTALLING/REMOVING BATTERY PACK

See Figure 2, page 9.

• Place the switch in the OFF position.
• Insert the battery pack into the product as shown.
• Make sure the latches on each side of the battery pack snap into place and the battery pack is secured in the product before beginning operation.
• Depress the latches to remove the battery pack.
  For complete charging instructions, see the operator’s manuals for your battery pack and charger.

INSTALLING/REMOVING BITS

See Figures 3 – 5, pages 9 and 10.

• A Depth lock lever

• B Wrench/depth guide

• C- To release

• A – Spindle lock

• B- Collet nut

• C- Wrench/depth guide

• D- To loosen

• E – To tighten

• F -Bit
  

• A – Collet nut

• B – Collet

• C – Output

• D – Collet

WARNING
This tool is designed for use with specialized cut-out tool bits only. Do not use brad point bits, spade bits, or other bits with sharp points. Using incorrect bits could result in a hazardous condition leading to possible serious personal injury.

• Remove the battery pack.
• Release the depth lock lever and pull the wrench/depth guide out of the tool.
• Place the wrench/depth guide onto the collet nut as shown.
• Depress spindle lock.

NOTICE
To prevent damage to the spindle or spindle lock, always allow motor to come to a complete stop before engaging spindle lock.

• Loosen collet nut by turning counterclockwise with the wrench/depth guide.

NOTE : The tool ships with a preinstalled collet that is machined to precision tolerances to fit bits with 1/8 in. diameter shanks. To use bits with 1/4 in. shank, remove the collet nut and 1/8 in. collet then insert the 1/4 in. collet into the output shaft. Replace the collet nut before inserting the bit.

WARNING
Always use the correct collet. Use the 1/8 in. collet for bits with 1/8 in. diameter shanks and the 1/4 in. collet for bits with 1/4 in. diameter shanks.

WARNING
If you are changing a bit immediately after use, be careful not to touch the bit or collet with your hands or fingers. You could get burned because of the heat buildup from cutting. Always use the wrench/depth guide to remove or install bits.

• To insert bit: Insert shank end of bit into collet.
• To remove bit: Loosen collet nut and remove bit.
• Tighten collet nut securely by turning clockwise with the wrench/depth guide.

WARNING
If the collet nut is not securely tightened, the bit can detach during use causing serious personal injury.

Release spindle lock.

WARNING

• Do not use bits with undersized shanks. Undersized shanks will not tighten properly and could be thrown from the tool causing serious personal injury.
• Remove the wrench/depth guide and slide it back into the tool.
• Engage the depth lock lever to secure the wrench/depth guide in place.

NOTICE
We suggest that you practice with your cut-out tool before installing a bit and making cuts.

OPERATING THE CUT-OUT TOOL

See Figures 6 – 7, page 10.

• Place the switch in the OFF position and install the battery pack.
• Hold cut-out tool firmly.
• Slide the switch to the ON position and allow bit to come up to full speed.
• Tilt cut-out tool at a 45o angle.
• Plunge bit into material using the wrench/depth guide as a pivot.
• Raise cut-out tool slowly to a 90o angle.
• Begin cutting.

DANGER
Do not cut electrical outlet openings with live electrical wires. Do not cut walls that could have live electrical wiring behind them. Shut off breakers or remove fuses to disconnect the circuit. Always hold the tool by its motor housing.

ADJUSTING DEPTH OF CUT
See Figure 8, page 10.

• A- Depth lock lever
• B- Adjust up or down
• C- Wrench/depth guide
• Remove battery pack.
• Release the depth lock lever.
• Move wrench/depth guide to desired position.
• Engage the depth lock lever to secure the wrench/depth guide in place.

MAINTENANCE

WARNING
When servicing use only identical replacement parts. Use of any other parts can create a hazard or cause product damage.

CAUTION
The bit flutes are sharp and should be handled with caution.

GENERAL MAINTENANCE

Avoid using solvents when cleaning plastic parts. Most plastics are susceptible to damage from various types of commercial solvents and may be damaged by their use. Use clean cloths to remove dirt, dust, oil, grease, etc.

BITS
Get faster and more accurate cutting results by keeping bits clean. Remove all accumulated build-up from bits after each use. Replace bits when they become dull.

COLLET
Over time it may become necessary to clean the collet and collet nut. To do so, simply remove collet nut and collet from the shaft and clean the dust and chips that have collected. Then return collet nut to its original position. Tighten collet nut on collet without a bit installed.

NOTE : ILLUSTRATIONS START ON PAGE 9 AFTER FRENCH AND SPANISH LANGUAGE SECTIONS.

OPERATOR’S MANUAL/18 VOLT CUT-OUT TOOL

• To request service, purchase replacement parts,  locate an Authorized Service Center or obtain Customer or Technical Support:

• Visit www.ryobitools.com or call 1-800-525-2579

• If any parts or accessories are damaged or missing, do not return this product to the store. Call 1-800-525-2579 for immediate service.

• Please obtain your model and serial number from the product data plate.
  This product is covered under a 3-year limited Warranty. Proof of purchase is required.

• MODEL NUMBER* ___

• SERIAL NUMBER ____

Model number on product may have additional letters at the end. These letters designate manufacturing information and should be provided when calling for service.
RYOBI is a trademark of Ryobi Limited and is used pursuant to a license granted by Ryobi Limited.

References

• REIMAGINE WITH RYOBI - RYOBI Tools

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