Ryobi Sander RS240 User Guide

OPERATOR'S MANUAL  
Random Orbit Sander  
Model RS240  
DOUBLE INSULATED  
SPECIFICATIONS:  
Sanding disc diameter  
5 in. (127 mm)  
12,500 opm  
No load speed  
Diameter of orbit  
Rating  
3/32 in. (2.5 mm)  
120 volts, 60 Hz, AC  
2.4 Amperes  
Net Weight  
2.75 lbs.  
THANK YOU FOR BUYING A RYOBI RANDOM ORBIT SANDER.  
Your new Random Orbit Sander 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 sander.  
Pay close attention to the Rules for Safe Operation, Warnings, and Cautions. If you use your sander properly and only for what  
it is intended, you will enjoy years of safe, reliable service.  
Thank you again for buying Ryobi tools.  
SAVE THIS MANUAL FOR FUTURE REFERENCE  
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RULES FOR SAFE OPERATION  
READ ALL INSTRUCTIONS  
1. 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.  
13. PROTECT YOUR HEARING. Wear hearing  
protection during extended periods of  
operation.  
14. DON'T ABUSE CORD. Never carry tool by  
cord or yank it to disconnect from receptacle.  
Keep cord from heat, oil and sharp edges.  
2. GUARD AGAINST ELECTRICAL SHOCK by  
preventing body contact with grounded  
surfaces. For example: Pipes, radiators,  
ranges, refrigerator enclosures.  
15. SECURE WORK. Use clamps or a vise to  
hold work. It's safer than using your hand and  
it frees both hands to operate the tool.  
3. KEEP GUARDS IN PLACE and in working  
order.  
16. DON'T OVERREACH. Keep proper footing  
and balance at all times. Do not use while  
standing on a ladder or unstable support.  
4. KEEP WORK AREA CLEAN. Cluttered areas  
and benches invite accidents.  
17. MAINTAIN TOOLS WITH CARE. Keep tools  
sharp at all times, and clean for best and  
safest performance. Follow instructions for  
lubricating and changing accessories.  
5. AVOID DANGEROUS ENVIRONMENT. Don't  
use power tool in damp or wet locations or  
expose to rain. Keep work area well lit.  
6. KEEP CHILDREN AND VISITORS AWAY.  
All visitors should wear safety glasses and be  
kept a safe distance from work area. Do not  
let visitors contact tool or extension cord.  
18. DISCONNECT TOOLS. When not in use,  
before servicing, or when changing or  
adjusting attachments, blades, bits, cutters,  
sandpaper, etc., all tools should be  
disconnected from power supply.  
7. STORE IDLE TOOLS. When not in use tools  
should be stored in a dry and high or locked-  
up place - out of the reach of children.  
19. REMOVE ADJUSTING KEYS AND  
WRENCHES. Form habit of checking to see  
that keys and adjusting wrenches are removed  
from tool before turning it on.  
8. DON'T FORCE TOOL. It will do the job better  
and safer at the rate for which it was designed.  
9. USE RIGHT TOOL. Don't force small tool or  
attachment to do the job of a heavy duty tool.  
Don't use tool for purpose not intended - for  
example - A circular saw should never be  
used for cutting tree limbs or logs.  
20. AVOID ACCIDENTAL STARTING. Don't  
carry plugged-in tools with finger on switch.  
Be sure switch is off when plugging in.  
21. MAKE SURE YOUR EXTENSION CORD IS  
IN GOOD CONDITION. When using an  
extension cord, be sure to use one heavy  
enough to carry the current your product will  
draw. An undersized cord will cause a drop in  
line voltage resulting in loss of power and  
overheating. A wire gage size (A.W.G.) of at  
least 16 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.  
10. WEAR PROPER APPAREL. Do not wear  
loose clothing or jewelry that can get caught  
in the tool's moving parts and cause personal  
injury. Rubber gloves and nonskid footwear  
are recommended when working outdoors.  
Wear protective hair covering to contain long  
hair and keep it from being drawn into nearby  
air vents.  
11. ALWAYS WEAR SAFETY GLASSES.  
Everyday eyeglasses have only impact-  
resistant lenses; they are NOT safety glasses.  
12. PROTECT YOUR LUNGS. Wear a face or  
dust mask if operation is dusty.  
Look for this symbol to point out important safety precautions.  
It means attention!!! Your safety is involved.  
Page 3  
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RULES FOR SAFE OPERATION  
22. OUTDOOR USE EXTENSION CORDS. 32. INSPECT FOR and remove all nails from  
When tool is used outdoors, use only  
extension cords suitable for use outdoors.  
Outdoor approved cords are marked with  
the suffix W-A, for example - SJTW-A or  
SJOW-A.  
lumber before sanding.  
33. DRUGS, ALCOHOL, MEDICATION. Do not  
operate tool while under the influence of drugs,  
alcohol, or any medication.  
34. WHEN SERVICING USE ONLY IDENTICAL  
23. NEVER USE THIS OR ANY POWER  
SANDER FOR WET SANDING OR LIQUID  
POLISHING. Failure to comply can result in  
electrical shock causing serious injury or  
worse.  
RYOBI REPLACEMENT PARTS.  
35. MAKE THE WORKSHOP CHILD-PROOF  
with padlocks, master switches, or by  
removing starter keys.  
36. POLARIZED PLUGS. To reduce the risk of  
electric shock, this tool has 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 the proper outlet. Do not  
change the plug in any way.  
24. KEEP HANDS AWAY FROM SANDING  
AREA.  
25. NEVER USE IN AN EXPLOSIVE ATMO-  
SPHERE. Normal sparking of the motor could  
ignite fumes.  
26. INSPECT TOOL CORDS PERIODICALLY  
and if damaged, have repaired at your nearest  
authorized service center. Stay constantly  
aware of cord location.  
37. SAVE THESE INSTRUCTIONS. Review them  
frequently and use them to instruct others  
who may use this tool. If you loan someone  
this tool, loan them these instructions also.  
27. INSPECT EXTENSION CORDS PERIODI-  
CALLY and replace if damaged.  
28. KEEP HANDLES 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.  
WARNING:  
Some dust created by power sanding, sawing,  
grinding, drilling, and other construction activities  
contains chemicals known to cause cancer, birth  
defectsorotherreproductiveharm. Someexamples  
of these chemicals are:  
29. STAY ALERT. Watch what you are doing  
and use common sense. Do not operate tool  
when you are tired. Do not rush.  
• lead from lead-based paints,  
30. 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 is damaged should  
be properly repaired or replaced by an  
authorized service center unless indicated  
elsewhere in this instruction manual.  
• 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  
speciallydesignedtofilteroutmicroscopicparticles.  
31. DO NOT USE TOOL IF SWITCH DOES NOT  
TURN IT ON AND OFF. Have defective  
switches replaced by an authorized service  
center.  
Page 4  
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FEATURES  
KNOW YOUR SANDER  
RANDOM ORBIT  
See Figure 1.  
The random orbit motion provides overlapping sanding  
movements by combining orbital and turning motion. These  
overlapping sanding movements provide fast cutting action  
with excellent sanding results.  
Before attempting to use your sander, familiarize yourself  
with all operating features and safety requirements.  
WARNING:  
If any parts are missing do not operate your sander until  
the missing parts are replaced. Failure to do so could  
result in possible serious injury.  
ELECTRICAL CONNECTION  
Your sander 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.  
SWITCH  
This tool is equipped with a simple switch control. To turn  
your sander ON, depress the switch button as shown in  
Figure 1. Depress the switch button in the opposite direction  
to turn your sander OFF.  
WARNING:  
Do not allow familiarity with your sander to make you  
careless. Remember that a careless fraction of a second  
is sufficient to inflict severe injury.  
Your sander has a comfortable palm grip that provides easy  
handling and positive control and is suitable for sanding with  
coarse, medium, and fine grit sanding disc.  
CONVERSION PAD  
Converts the standard sanding pad from use with pressure  
sensitivesandingdiscsforusewithvelcrotypesandingdiscs.  
APPLICATIONS  
(Use only for the purposes listed below)  
Sanding on wood surfaces.  
Removing rust from and sanding steel surfaces.  
SWITCH BUTTON  
0
I
ON  
OFF  
BACKING PAD  
SANDING DISC  
DUST BAG ASSEMBLY  
Fig. 1  
WARNING:  
WEAR YOUR  
The operation of any sander can result in foreign objects being thrown into your eyes,  
which can result in severe eye damage. Before beginning power tool operation, always  
wear safety goggles or safety glasses with side shields and a full face shield when  
needed. We recommend Wide Vision Safety Mask for use over eyeglasses or standard  
safety glasses with side shields.  
SAFETY GLASSES  
FORESIGHT IS BETTER  
THAN NO SIGHT  
Page 5  
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UNPACKING  
Carefully remove the sander, and accessories from box.  
PACKING LIST  
Make sure all items listed in the Packing List are included.  
Sanding Disc (quantity 3)  
Conversion Pad (for velcro type sanding discs)  
Dust Bag Assembly  
Donotdiscardthepackingmaterialuntilyouhavecarefully  
inspected and satisfactorily operated sander.  
Examine all parts and accessories to make sure that no  
breakage has occurred during shipping. Any damaged  
part should be replaced before attempting to use the tool.  
Warranty Card  
Operator's Manual  
OPERATION  
The backing pad on your sander provides the capability to  
use sanding discs with pressure sensitive adhesive back-  
ing material. You also receive a conversion pad which al-  
lows use of sanding discs with velcro type backing material.  
ADHESIVE  
SANDING DISC  
WARNING:  
BACKING  
PAD  
Your sander should never be connected to power supply  
when you are assembling parts, making adjustments,  
assemblingorreplacingsandingdisc, cleaning, orwhennot  
in use. Disconnecting your sander will prevent accidental  
starting that could cause serious personal injury.  
TO ATTACH PRESSURE SENSITIVE ADHESIVE  
SANDING DISC  
See Figure 2.  
Unplug your sander.  
Fig. 2  
WARNING:  
Failure to unplug your sander could result in accidental  
SANDING DISC SELECTION  
Selecting the correct size grit and type sanding disc is an  
extremely important step in achieving a high quality sanded  
finish. Aluminum oxide, silicon carbide, and other synthetic  
abrasives are best for power sanding. Natural abrasives,  
such as flint and garnet are too soft for economical use in  
power sanding.  
starting causing possible serious personal injury.  
Carefully peel paper backing from the pressure sensitive  
adhesive type sanding disc.  
Align holes in sanding disc with holes in backing pad,  
then carefully press sticky side of disc against pad as  
tight as possible.  
In general, coarse grit will remove the most material and finer  
grit will produce the best finish in all sanding operations. The  
condition of the surface to be sanded will determine which  
grit will do the job. If the surface is rough, start with a coarse  
grit and sand until the surface is uniform. Medium grit may  
then be used to remove scratches left by the coarser grit and  
finer grit used for finishing of the surface. Always continue  
sanding with each grit until surface is uniform.  
NOTE: Holes in sanding disc must line up with holes in  
the backing pad in order for the dustless feature of your  
sander to function properly.  
NOTE: It is recommended that you clean backing pad  
occasionally by brushing lightly with a small brush. Dust  
build-up on backing pad could cause sanding disc not to  
stick properly.  
Page 6  
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OPERATION  
REMOVINGSANDINGDISCBEFORESTORAGE  
DUSTLESS SANDING  
See Figures 3 and 4.  
Do not store your sander with the sanding disc installed.  
Heat generated from sanding causes the pressure sensitive  
adhesive to flow and form a tight bond between the backing  
pad and sanding disc.  
The dust bag assembly provides a dust collection system for  
your sander. It can be installed by slipping it over the blower  
exhaust with a twisting motion. Sanding dust is drawn up  
through the holes of the sanding disc to collect in the dust bag  
during sanding operation.  
Removing the sanding disc soon after you have finished a  
sanding operation avoids letting the adhesive set up. If the  
sanding disc is left on the backing pad for an extended period  
of time after use, the adhesive will set up and cause the  
sanding disc to become difficult to remove.  
NOTE: For more efficient operation, empty dust bag when no  
more than half full. This will permit the air to flow through the  
bag better.  
It may also tear when removing. When this situation occurs,  
it becomes difficult to clean the backing pad for the next  
sanding disc.  
WARNING:  
To prevent the possibility of sanding dust or foreign  
objects being thrown into your face or eyes, never attempt  
to use your sander without the dust bag properly installed.  
Sanding dust or foreign objects being thrown into your  
face could result in possible serious personal injury.  
NOTE: If you forget to remove the sanding disc after a  
sanding operation, sand for a few minutes to soften the  
adhesive backing before attempting to remove sanding disc.  
TO ATTACH CONVERSION PAD AND VELCRO  
TYPE SANDING DISC  
The conversion pad provided with your sander has a  
pressure sensitive adhesive backing material. It is applied  
by the same method as pressure sensitive adhesive paper.  
SANDER  
Unplug your sander.  
WARNING:  
Failure to unplug your sander could result in accidental  
starting causing possible serious personal injury.  
Carefully peel paper backing from the conversion pad  
and align with holes in backing pad. Firmly press sticky  
side of conversion pad against backing pad. Your sander  
is now ready to use velcro type sanding discs.  
BLOWER EXHAUST  
DUST BAG  
Align holes in velcro type sanding disc with holes in  
conversion pad, then carefully press fuzzy side of sanding  
disc against pad as tight as possible.  
Fig. 3  
NOTE: Velcro type sanding discs can be reused for the  
life of the sanding abrasive. It is recommended that you  
keep the sanding disc backing and the conversion pad  
clean to provide the best attachment. Clean occasionally  
by brushing lightly with a small brush.  
BLOWER EXHAUST  
Fig. 4  
Page 7  
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OPERATION  
ATTACHING SANDER TO VACUUM  
When sanding for an extended period of time, you can easily  
attach the dust collection system of your sander to a vacuum.  
TO ATTACH:  
See Figure 5.  
Unplug your sander.  
WARNING:  
Failure to unplug your sander could result in accidental  
starting causing possible serious personal injury.  
VACUUM HOSE  
Remove dust bag from sander.  
Fig. 5  
Attach vacuum hose to blower exhaust as shown in  
Figure 5.  
NOTE: Vacuum hose fits inside blower exhaust.  
WARNING:  
Donotusethisproductasacomponentofotherproducts.  
Also, do not use attachments or accessories not  
recommended for use with this product. Any such use  
could result in possible serious personal injury.  
Connect sander and vacuum to power supply.  
WARNING:  
When sander is not connected to vacuum, always install  
dust bag back on sander. Failure to do so could cause  
sandingdustorforeignobjectstobethrownintoyourface  
or eyes which could result in possible serious injury.  
CAUTION:  
To ensure proper brake operation after extended use,  
periodically check its operation by removing the sanding  
disc and running your sander without load (off the  
workpiece). The backing pad should not take longer  
than 6 seconds to stop. If it takes longer than 6 seconds  
to stop, return the sander to your nearest RYOBI  
AUTHORIZED SERVICE CENTER for repair.  
EXTENSION CORDS  
Theuseofanyextensioncordwillcausesomelossofpower.  
To keep the loss to a minimum and to prevent tool from  
overheating, use an extension cord that is heavy enough to  
carry the current the tool will draw.  
A wire gage size (A.W.G.) of at least 16 is recommended for  
an extension cord 100 feet or less in length. When working  
outdoors, use an extension cord that is suitable for outdoor  
use. The cord's jacket will be marked WA.  
WARNING:  
Do not wear loose clothing or jewelry when operating  
sander. They could get caught in moving parts causing  
serious injury. Keep head away from sander and sanding  
area. Hair could be drawn into sander causing serious  
injury.  
CAUTION:  
Keep extension cords away from the sanding area and  
position the cord so that it will not get caught on lumber,  
tools, etc., during sanding.  
WARNING:  
Before connecting your sander to power supply source,  
always check to be sure the switch is not in ON position.  
Failure to do so could result in accidental starting of your  
sander resulting in possible serious injury.  
WARNING:  
Check extension cords before each use. If damaged  
replaceimmediately. Neverusetoolwithadamagedcord  
since touching the damaged area could cause electrical  
shock resulting in serious injury.  
Page 8  
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OPERATION  
Flush sanding can be performed with your sander. As  
PREPARING FOR OPERATION  
shown in Figure 7, the front edge of your sander allows  
flush sanding. Upon completion of sanding operation, turn  
sander off and wait until sanding disc comes to a complete  
stop before removing from workpiece.  
CAUTION:  
Be careful not to let your hand cover the air vents.  
SANDING  
See Figures 6 and 7.  
Clamp or otherwise secure the work to prevent it from  
moving under your sander.  
WARNING:  
Unsecured work could be thrown towards the operator  
causing injury.  
Placesanderonworkpiecesothatallofsandingdiscsurface  
is in contact with workpiece. Start your sander and move it  
slowly over workpiece making successive passes in parallell  
lines, circles, or crosswise movements. Upon completion of  
sandingoperation, turnsanderoffandwaituntilsandingdisc  
comes to a complete stop before removing from workpiece.  
Fig. 6  
DO NOT FORCE. The weight of the unit supplies adequate  
pressure, so let the sanding disc and sander do the work.  
Applying additional pressure only slows the motor, rapidly  
wears sanding disc and greatly reduces sander speed.  
Excessive pressure will overload the motor causing possible  
damage from motor overheating and can result in inferior  
work. Any finish or resin on wood may soften from the  
frictional heat. Do not allow sanding on one spot too long  
as the sander's rapid action may remove too much material,  
making the surface uneven.  
Extended periods of sanding may tend to overheat the  
motor. If this occurs, turn sander off and wait until sanding  
disc comes to a complete stop, then remove it from  
workpiece. Remove your hand from vent area, remove  
sanding disc, then with your hand removed from vent area,  
turn sander on and run it free without a load to cool motor.  
Fig. 7  
OPTIONAL ACCESSORIES  
The following recommended accessories are current and were available at the time this manual was printed:  
4600150  
4600220  
4600320  
4600600  
4600503  
150 Grit Sanding Disc  
220 Grit Sanding Disc  
320 Grit Sanding Disc  
600 Grit Sanding Disc  
Conversion Pad  
5 Per Pack  
5 Per Pack  
5 Per Pack  
5 Per Pack  
2 Per Pack  
4601500  
4600040  
4600060  
4600080  
4600100  
15 Grit Sanding Disc  
40 Grit Sanding Disc  
60 Grit Sanding Disc  
80 Grit Sanding Disc  
100 Grit Sanding Disc  
5 Per Pack  
5 Per Pack  
5 Per Pack  
5 Per Pack  
5 Per Pack  
All individual sanding grits are available in handy five sheet packs.  
Page 9  
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MAINTENANCE  
DUST BAG  
WARNING:  
When servicing use only identical Ryobi replacement  
parts. Use of any other parts may create a hazard or  
cause product damage.  
CLEANING DUST BAG ASSEMBLY  
See Figures 8 and 9.  
As previously mentioned, for more efficient operation, empty  
dust bag when no more than half full. This will permit the air  
to flow through the bag better.  
Fig. 8  
TO EMPTY DUST BAG:  
DUST BAG  
FRAME  
Unplug your sander.  
WARNING:  
Failure to unplug your sander could result in accidental  
starting causing possible serious personal injury.  
Remove dust bag from sander and shake out dust. See  
Figure 8.  
Foramorethoroughcleaningofthedustbag,removedust  
Fig. 9  
bag from frame, as shown in figure 9, and shake out dust.  
Replace dust bag over frame then install dust bag on  
sander.  
WARNING:  
Always wear safety goggles or safety glasses with side  
shieldsduringpowertooloperationorwhenblowingdust.  
If operation is dusty, also wear a dust mask.  
GENERAL  
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, carbon dust, etc.  
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.  
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.  
When electric tools are used on fiberglass boats, sports  
cars, wallboard, spackling compounds, or plaster, it has  
been found that they are subject to accelerated wear and  
possible premature failure, as the fiberglass chips and  
grindings are highly abrasive to bearings, brushes,  
commutators, etc. Consequently, it is not recommended  
that this tool be used for extended work on any fiberglass  
material, wallboard, spackling compounds, or plaster. During  
any use on fiberglass it is extremely important that the tool  
is cleaned frequently by blowing with an air jet.  
Page 10  
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NOTES  
Page 11  
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OPERATOR'S MANUAL  
Random Orbit Sander  
Model RS240  
Double Insulated  
EXTENSION CORD CAUTION  
**Ampere rating  
(on tool data plate) 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 re-  
quired 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 workpiece, 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 refer to the Service Center insert or call 1-800-  
525-2579 in the United States or 1-800-265-6778 in Canada for your nearest Ryobi  
Authorized Service Center.  
• MODEL NO. AND SERIAL NO.  
The model number and serial number of this tool will be found on a plate attached to the  
motor housing.  
Please record the serial number in the space provided below.  
• MODEL NUMBER RS240  
• SERIAL NUMBER  
RYOBI CANADA INC.  
RYOBI AMERICA CORP.  
1424 Pearman Dairy Road  
Anderson, SC 29625  
Post Office Box 910  
Cambridge, Ontario N1R 6K2  
Phone 1-800-265-6778  
Post Office Box 1207  
Anderson, SC 29622-1207  
Phone 1-800-525-2579  
972000-388  
7-00  
Printed in U.S.A.  
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