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
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
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
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
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
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
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
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
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
NOTES
Page 11
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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