Ryobi S605D8 User manual

OPERATOR'S MANUAL
1/4 SHEET SANDER – S605D8
DOUBLE INSULATED
THANK YOU FOR BUYING A RYOBI SANDER.
Your new 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
SPECIFICATIONS:
Size of Paper 1/4 Sheet
Motion Orbital Action
Rating 120 volts, 60 Hz, AC
Input 2.0 Amperes
No Load Speed 14,000 OPM
Orbit Diameter 1/16 in. (1.6 mm)

Page 2
IMPORTANT
Servicing of a tool with double insulation requires extreme
care and knowledge of the system and should be performed
onlybyaqualifiedservicetechnician. Forservicewesuggest
you return the tool to your nearest RYOBI AUTHORIZED
SERVICE CENTER for repair. When servicing use only
identical Ryobi replacement parts.
DOUBLE INSULATION
Your Ryobi power tool is double insulated. This means you
areseparatedfromthetool'selectricalsystembytwocomplete
sets of electrical insulation. This extra layer of insulation is
intended to protect the user from electrical shock due to a
break in the wiring insulation. All exposed metal parts are
isolated from the internal metal motor components with
protecting insulation.
RULES FOR SAFE OPERATION
READ ALL INSTRUCTIONS
1.KNOWYOURPOWERTOOL-Readoperator's
manual carefully. Learn its applications and
limitations as well as the specific potential haz-
ards related to this tool.
2. GUARD AGAINST ELECTRICAL SHOCK BY
PREVENTING BODY CONTACT WITH
GROUNDEDSURFACES. Forexample: Pipes,
radiators, ranges, refrigerator enclosures.
3. KEEP GUARDS IN PLACE and in working
order.
4. KEEP WORK AREA CLEAN. Cluttered areas
and benches invite accidents.
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
keptasafedistancefromworkarea. Donotlet
visitors contact tool or extension cord.
7. STORE IDLE TOOLS. When not in use, tools
should be stored in a dry, high or locked-up
place - out of the reach of children.
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 - Don't use a circular saw for cutting
tree limbs or logs.
WARNING: THE DOUBLE INSULATED SYSTEM IS INTENDED TO PROTECT THE USER FROM SHOCK
RESULTING FROM A BREAK IN THE TOOL'S INTERNAL WIRING. OBSERVE ALL NORMAL SAFETY
PRECAUTIONS RELATED TO AVOIDING ELECTRICAL SHOCK.
WARNING: DO NOT ATTEMPT TO OPERATE THIS TOOL UNTIL YOU HAVE READ THOROUGHLY AND
UNDERSTANDCOMPLETELYALLINSTRUCTIONS, SAFETY RULES,ETC.CONTAINEDINTHIS MANUAL.
FAILURE TO COMPLY CAN RESULT IN ACCIDENTS INVOLVING FIRE, ELECTRIC SHOCK, OR SERIOUS
PERSONAL INJURY. SAVE OPERATOR'S MANUAL AND REVIEW FREQUENTLY FOR CONTINUING
SAFE OPERATION AND INSTRUCTING OTHERS WHO MAY USE THIS TOOL.
10. WEAR PROPER APPAREL. No loose cloth-
ing or jewelry to get caught in moving parts.
Rubberglovesandnon-skidfootweararerec-
ommendedwhenworkingoutdoors.Also,wear
protective hair covering to contain long hair
and keep it from being drawn into air vents.
11. ALWAYSWEARSAFETYGLASSES.Every-
day eyeglasses have only impact-resistant
lenses; they are NOT safety glasses.
12. PROTECT YOUR LUNGS. Wear a face or
dust mask if the sanding operation is dusty.
13. PROTECT YOUR HEARING. Wear hearing
protection during extended periods of opera-
tion.
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.
15. SECUREWORK.Useclampsoravisetohold
work. It's safer than using your hand and it
frees both hands to operate the tool.
16. DON'T OVERREACH. Keep proper footing
andbalanceatalltimes.Donotuseonaladder
or unstable support.
17. MAINTAIN TOOLS WITH CARE. Keep tools
sharpatalltimes,andcleanforbestandsafest
performance. Follow instructions for lubricat-
ing and changing accessories.
18. DISCONNECT TOOLS. When not in use, be-
fore servicing, or when changing attachments
and accessories such as sandpaper, etc., all
toolsshouldbedisconnectedfrompowersup-
ply.

Page 3
RULES FOR SAFE OPERATION (Continued)
19. REMOVE ADJUSTING KEYS AND
WRENCHES. Form habit of checking to see
thatkeysandadjustingwrenchesareremoved
from tool before turning it on.
20. AVOIDACCIDENTALSTARTING. Don'tcarry
plugged-in tools with finger on switch. Be sure
switch is off when plugging in.
21. MAKESUREYOUREXTENSIONCORDISIN
GOODCONDITION.Whenusinganextension
cord,besureto useoneheavyenoughto carry
the current your product will draw. An under-
sized cord will cause a drop in line voltage
resulting in loss of power and overheating. A
wiregagesize(A.W.G.) ofatleast16is recom-
mended for an extension cord 100 feet or less
in length. A cord exceeding 100 feet is not
recommended.Ifindoubt,usethenextheavier
gage.Thesmallerthegagenumber,theheavier
the cord.
22 OUTDOORUSEEXTENSIONCORDS. When
toolisusedoutdoors, use onlyextensioncords
suitable for use outdoors. Outdoor approved
cords are marked with the suffix W-A, for ex-
ample - SJTW-A or SJOW-A.
23. NEVERUSETHISORANYPOWERSANDER
FOR WET SANDING OR LIQUID POLISH-
ING. Failure to comply can result in electrical
shock causing serious injury or worse.
24. KEEPHANDSAWAYFROMSANDINGAREA.
25. NEVER USE IN AN EXPLOSIVE ATMO-
SPHERE. Normal sparking of the motor could
ignite fumes.
26. INSPECTTOOLCORDSPERIODICALLYand
if damaged, have repaired by an authorized
service center. Stay constantly aware of cord
location.
27. INSPECT EXTENSION CORDS PERIODI-
CALLY and replace if damaged.
28. KEEP HANDLES DRY, CLEAN, AND FREE
FROMOILANDGREASE. Alwaysuseaclean
cloth when cleaning. Never use brake fluids,
gasoline,petroleum-basedproductsorsolvents
to clean your tool.
29. STAY ALERT. Watch what you are doing and
use common sense. Do not operate tool when
you are tired. Do not rush.
30. CHECK DAMAGED PARTS. Before further
use of the tool, a guard or other part that is
damagedshouldbecarefullycheckedtodeter-
minethatitwilloperateproperlyandperformits
intendedfunction.Checkforalignmentofmov-
ing parts, binding of moving parts, breakage of
parts, mounting, and any other conditions that
may affect its operation. A guard or other part
thatisdamagedshould be properly repaired or
replaced by an authorized service center.
31. DO NOT USE TOOL IF SWITCH DOES NOT
TURNITONANDOFF.Havedefectiveswitches
replaced by an authorized service center.
32. Inspect for and remove all nails from lumber
before sanding.
33. DRUGS, ALCOHOL, MEDICATION. Do not
operatetoolwhileunder the influenceofdrugs,
alcohol, or any medication.
34. When servicing use only identical Ryobi
replacement parts.
35. POLARIZED PLUGS. To reduce the risk of
electric shock, this equipment 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
theplug. Ifitstilldoesnotfit,contactaqualified
electrician to install the proper outlet. Do not
change the plug in any way.
36. SAVETHESEINSTRUCTIONS. Refertothem
frequently and use them to instruct others who
mayusethistool. Ifyouloansomeonethistool,
loan them these instructions also.
WARNING:
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 ex-
amples 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.
Your risk from these exposures varies, depend-
ing on how often you do this type of work. To re-
duce 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.

Page 4
Theoperationofanysandercanresultinforeignobjectsbeingthrownintoyoureyes,which
canresultinsevereeyedamage. Beforebeginningpowertooloperation,alwayswearsafety
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. Always wear eye protection which is marked to comply with ANSI Z87.1.
FEATURES
Your sanderissuitableforsandingwithcoarse,medium,andfinegritsandpaper.Itwillproduceafinescratchfreefinishwhen
used to sand with the grain on wood surfaces. It has been designed so that flush corner sanding on three sides of the sander
is possible.
Yoursanderhasacomfortablepalmgriphandlethatprovidesmaximumone-handcontrolandcomfort,plusitreducesoperator
fatique during continuous sanding operations.
Your sander has quick action paper clamps. This makes changing or replacing sandpaper fast and easy.
Your sander also has a built in dust collection that collects dust through punched holes in the sandpaper and cushion. See
Figure 1.
Before attempting to use your sander, familiarize yourself with all operating features and safety requirements.
SWITCH
Thistoolisequippedwithasimpleswitchcontrol.Toturnyoursander"ON",depresstheswitchbuttonasshowninFigure 1.
Depress the switch button in the opposite direction to turn your sander "OFF".
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
(normalhouseholdcurrent). Donotoperatethistoolondirectcurrent(DC).Avoltagedropofmorethan10percentwillcause
a loss of power and overheating. If your tool does not operate when plugged into an outlet, double-check the power supply.
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 PERSONAL
INJURY.
WARNING:
WARNING: DONOTALLOWFAMILIARITYWITHYOURSANDERTOMAKEYOUCARELESS. REMEMBER
THAT A CARELESS FRACTION OF A SECOND IS SUFFICIENT TO INFLICT SEVERE INJURY.
PAPER PUNCH Fig. 1
TAB
LEVER
CUSHION
SWITCH
ON OFF
SWITCH
PAPER CLAMP
PLATEN
DUST BAG

Page 5
OPERATION
WARNING: YOUR SANDER SHOULD NEVER BE CONNECTED TO POWER SUPPLY WHEN YOU ARE
ASSEMBLINGPARTS,MAKINGADJUSTMENTS,ASSEMBLING ORREPLACINGSANDPAPER,CLEANING,
OR WHEN NOT IN USE. DISCONNECTING SANDER WILL PREVENT ACCIDENTAL STARTING THAT
COULD CAUSE SERIOUS PERSONAL INJURY.
INSTALLING NON-ADHESIVE SANDPAPER
See Figure 2.
Inspectsandpaper beforeinstalling. DO NOT use if broken
or defective.
1. Unplug your sander.
WARNING: FAILURETOUNPLUG YOURSANDER
COULD RESULT IN ACCIDENTAL STARTING
CAUSING POSSIBLE SERIOUS PERSONAL
INJURY.
2. Ifreplacingsandpaper,removeoldsandpaper. Toremove
paper, release paper clamp by lifting up on lever and
disengaging it from the tab on the platen.
3. Insert end of new 1/4 sheet sandpaper approximately 1/2
in.(13mm)underthepaperclamp. Note: 1/2in.(13mm)
clampingofsandpaperisnecessaryformulti-sheetstacking
of paper.
4. Lift up on lever and lock into place. Apply downward
pressure to conform sandpaper to platen.
5. Wrap sandpaper around cushion. Lift lever on opposite
end of sander and insert loose end of sandpaper under
paper clamp. Fit sandpaper tight against cushion.
6. Lift up on lever and lock into place.
7. Multiple sheets of sandpaper can be installed at one time
for convenience.
INSTALLING ADHESIVE SANDPAPER
See Figure 2.
Inspectsandpaperbeforeinstalling. DONOTusebrokenor
defective sandpaper.
1. Unplug your sander.
WARNING: FAILURETOUNPLUG YOURSANDER
COULD RESULT IN ACCIDENTAL STARTING
CAUSING POSSIBLE SERIOUS PERSONAL
INJURY.
2. Ifreplacing sandpaper,removeold sandpaperbypeeling
it off cushion. If removing regular sandpaper, release
paper clamp by lifting up on lever and disengaging it from
the tab on the platen.
3. Remove non-adhesive sandpaper, then lift up on paper
clamp lever and lock it into place.
4. Carefully peel adhesive backing from new 1/4 sheet
sandpaper.
5. Positionsandpaper,makingsurefrontedgeofsandpaper
is aligned with front edge of the cushion, then carefully
press sticky side of sandpaper on cushion. Note:
Sandpaper must be aligned with the front edge of the
cushionforproperfunctioningoftheflushsandingfeature.
See Figure 2.
Note: The cushion on your sander is approximately 1/4 in.
(6.4 mm) smaller than precut adhesive backed sanding
sheets. If desired you may want to trim off the overhang of
sandpaper on the back side of cushion. The cushion has
been made smaller so that multiple sheets of non-adhesive
sandpaper can be installed.
PAPER PUNCH
See Figure 3.
Apaperpunchtemplate hasbeensuppliedwithyoursander.
Thispunchshouldbeusedforaligningandpunchingholesin
the sandpaper. Punched holes must align with the holes in
the cushion.
Punching the holes properly is a necessary step in order for
the dustless feature of your sander to function properly.
Fig. 3
Fig. 2
TAB
CUSHION
PLATEN
PAPER CLAMP
ADHESIVE
SANDPAPER
PAPER CLAMP
IN UNLOCKED
POSITION
NON-ADHESIVE
SANDPAPER
ORIENT PAPER
PUNCH AS SHOWN
PAPER PUNCH

Page 6
OPERATION
APPLICATIONS
(Use only for the purposes listed below)
1. Sanding on wood surfaces.
2. Removing rust from and sanding steel surfaces.
3. Sanding plastics.
SANDPAPER SELECTION
Selecting the correct size grit and type sandpaper 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.
Ingeneral,coarsegritwillremovethemostmaterialandfiner
gritwillproducethebestfinishinallsandingoperations. The
conditionofthesurfacetobesandedwilldeterminewhichgrit
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
beused to removescratchesleft by thecoarsergrit and finer
gritusedforfinishingofthesurface. Alwayscontinuesanding
with each grit until surface is uniform.
Note: DONOTusesanderwithoutsandpaper. Doingsowill
damage the cushion.
PREPARING FOR OPERATION
CAUTION: Becarefulnottoletyourhandcompletelycover
air vents.
SANDING
Clamporotherwisesecuretheworktopreventitfrommoving
under your sander.
WARNING: UNSECURED WORK COULD BE
THROWN TOWARDS THE OPERATOR CAUSING
INJURY.
Holdyoursanderin front andawayfromyou,keepingit clear
of the workpiece. Start your sander by pressing the switch
button to "ON" position and letting the motor build to its
maximum speed. Gradually lower your sander on the work
withaslightforwardmovement. SeeFigure4. Moveitslowly
using forward and backward strokes.
DO NOT FORCE. The weight of the unit supplies adequate
pressure, so let the sandpaper and sander do the work.
Applying additional pressure only slows the motor, rapidly
wears sandpaper and greatly reduces sander speed.
Excessivepressure will overloadthemotorcausing 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.
Fig. 4
WARNING: ALWAYS WEAR SAFETY GOGGLES OR SAFETY GLASSES WITH SIDE SHIELDS WHEN
OPERATING YOUR SANDER. FAILURE TO DO SO COULD RESULT IN FOREIGN OBJECTS BEING
THROWN INTO YOUR EYES, RESULTING IN POSSIBLE SERIOUS INJURY. IF THE SANDING OPERATION
IS DUSTY, ALSO WEAR A FACE OR DUST MASK.
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.
Fig. 5
Flush sanding can be performed with your sander. See
Figure5. Thefront edge ofyoursander allows flushsanding
in corners. Always remove sander from workpiece before
turning your sander off.

Page 7
OPERATION
ORBITAL MOTION
Orbitalmotionisidealforfastcuttingactionwhenremoving
old finishes, smoothing rough wood, cutting stock down to
requireddimensions,orforfinishingsurfacestobepainted.
As shown in figure 6, the sandpaper moves in tiny circles
at a very high speed, allowing the sander to move easily.
DUSTLESS SANDING
The dust bag located on the rear of your sander provides a
dust collection system for your sander. Sanding dust is
drawnupthroughtheholesofthecushionandcollectsinthe
dust bag during sanding operation. For more efficient
operation, empty dust bag when half full.
TO EMPTY DUST BAG
■Unplug your sander.
WARNING: FAILURE TO UNPLUG YOUR SANDER
COULD RESULT IN ACCIDENTAL STARTING
CAUSING POSSIBLE SERIOUS PERSONAL
INJURY.
■Unzip Dust Bag.
■Shake dust bag to empty.
■Zip dust bag up after emptying.
TO REMOVE DUST BAG FOR EMPTYING OR
CLEANING
See Figure 7.
■Unplug your sander.
WARNING: FAILURE TO UNPLUG YOUR SANDER
COULD RESULT IN ACCIDENTAL STARTING
CAUSING POSSIBLE SERIOUS PERSONAL
INJURY.
■Slide dust bag retainer from sander as shown by the
arrow in figure 7.
Note: Grooves on dust bag retainer align with grooves
on your sander.
■Empty dust bag.
TO INSTALL DUST BAG
See Figure 8.
■Unplug your sander.
WARNING: FAILURE TO UNPLUG YOUR SANDER
COULD RESULT IN ACCIDENTAL STARTING
CAUSING POSSIBLE SERIOUS PERSONAL
INJURY.
■Realign grooves on dust bag retainer with grooves on
your sander.
■Slide dust bag assembly into place as shown by the
arrow in figure 8.
Fig. 6
Fig. 7
ORBITAL MOTION
DUST BAG
TO REMOVE
DUST BAG
DUST BAG
RETAINER GROOVES
Fig. 8
GROOVES
ON SANDER
DUST BAG

Page 8
WARNING: WHEN SERVICING USE ONLY IDENTICAL RYOBI REPLACEMENT PARTS. USE OF ANY
OTHER PARTS MAY CREATE A HAZARD OR CAUSE PRODUCT DAMAGE.
EXTENSION CORDS
Theuse ofanyextension cord willcause some lossofpower. To keeptheloss to aminimum and topreventtool overheating,
usean extensioncord thatisheavy enoughto carrythecurrent thetool willdraw. Followthe recommendedcord sizesonthe
chart provided to determine the minimum wire size required in an extension cord.
Extension Cord Length Wire Gauge Size (A.W.G.)
0-100 Feet 16
Whenworkingwith your tooloutdoors,useanextension cord suitableforoutdooruseand so marked. Outdooruseextension
cords are marked with the letters "WA" on the cord's jacket.
CAUTION: Keep extension cords away from the sanding area and position the cord so that it will not get caught on lumber,
tools, etc., when sanding.
MAINTENANCE
GENERAL
Avoid using solvents when cleaning plastic parts. Most
plasticsaresusceptibletovarioustypesofcommercialsolvents
and may be damaged by their use. Use clean cloths to
remove dirt, carbon dust, etc.
WARNING: DO NOT AT ANY TIME LET BRAKE
FLUIDS, GASOLINE, PETROLEUM-BASED
PRODUCTS, PENETRATING OILS, ETC. COME IN
CONTACTWITH PLASTICPARTS.THEYCONTAIN
CHEMICALS THAT CAN DAMAGE, WEAKEN, OR
DESTROY PLASTIC.
Whenelectrictoolsareusedonfiberglassboats,sportscars,
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, commutator, etc.
Consequentlyitisnotrecommendedthatthistoolbeusedfor
extendedworkonanyfiberglassmaterial,wallboard,spackling
compounds, or plaster. During any use on these materials, it
is extremely important that the tool is cleaned frequently by
blowing with an air jet.
WARNING: ALWAYS WEAR SAFETY GOGGLES,
OR SAFETY GLASSES WITH SIDE SHIELDS
DURING POWER TOOL OPERATION OR WHEN
BLOWINGDUST. IFOPERATIONISDUSTY ALSO
WEAR A DUST MASK.
WARNING: CHECK EXTENSION CORDS BEFORE EACH USE. IF DAMAGED REPLACE IMMEDIATELY.
NEVER USE TOOL WITH A DAMAGED CORD SINCE TOUCHING THE DAMAGED AREA COULD CAUSE
ELECTRICAL SHOCK RESULTING IN SERIOUS INJURY.
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 normal
operating conditions. Therefore, no further lubrication is required.

Page 9
NOTES

OPERATOR'S MANUAL
1/4 SHEET SANDER – S605D8
DOUBLE INSULATED
972000-870 .
RYOBI TECHNOLOGIES, INC.
1428 Pearman Dairy Road Anderson, SC 29625
Post Office Box 1207 Anderson, SC 29622-1207
Phone [phone]
www.ryobitools.com
• 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
www.ryobitools.com for a complete list of Authorized Service Centers.
•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.
•MODEL NUMBER
•SERIAL NUMBER
S605D8