Toolshop 241-9942 User manual

5" RANDOM ORBITAL SANDER
241-9942
Owner’s Manual
PRODUCT SPECIFICATIONS
Rating: 120V, 60Hz, AC
Amperes: 2.0 AMP
No load speed: 12,000 OPM
Disc diameter: 5"
Weight: 3 lb 6 oz (1.53 kg)
Need Assistance?
Call us on our toll free customer support line:
1-866-349-8665
•Technical questions
•Replacement parts
•Parts missing from package

2
Product specifications ………….………………………………………………………………... 1
Table of contents …………………………………………………………………….................. 2
General safety warnings ………………………………………………………………………… 3–4
Eye, ear & lung protection ………………………………………………………………………. 3–4
Electrical safety …………………………………………………………………………………... 4
Power tool safety …………………………………………………………………….................. 5–6
General safety rules ……………………………………………………………………………... 5
Work area ………………………………………………………………….……………………... 5
Electrical safety …………………………………………………………………………………... 5
Personal safety …………………………………………………………………………………... 5–6
Power tool use and care.………………………………………………………………………… 6
Service ……………………………………………………………………………………………. 6
Specific safety rules ……………………………………………………………………………... 7
Extension cord safety ………………………………………………………….………………… 8
Symbols …………………………………………………………………………………………… 9
Know your sander ………………………….......................................................................... 10
Assembly and operating ………………………………………………………………………… 11–13
Installing a sanding disc …………………………………………………………….................. 11
ON/OFF switch …………………………………………………………………………………… 11
Connect the dust bag assembly to the sander ……………………………………………….. 11
Cleaning the dust bag ……………………………………………………………….................. 12
Sanding disc selection …………………………………………………………………………... 12
Sanding …………………………………………………………………………………………… 12–13
Maintenance ……………………………………………………………………………………… 14
Exploded view ………………………………………………………………………................... 15
Parts listing ……………………………………………………………………………………….. 16
Warranty ……………………………………………………………………….…………………. 17
TABLE OF CONTENTS

3
EYE, EAR & LUNG PROTECTION
SAVE THESE INSTRUCTIONS FOR REFERENCE
GENERAL SAFETY WARNINGS
This instruction manual includes the following:
•General Safety Rules
•Specific Safety Rules and Symbols
•Functional Description
•Assembly
•Operation
•Maintenance
•Accessories
WARNING: Before using this tool or any of its accessories, read this
manual and follow all Safety Rules and Operating Instructions. The important
precautions, safeguards and instructions appearing in this manual are not
meant to cover all possible situations. It must be understood that common
sense and caution are factors which cannot be built into the product.
!
!
ALWAYS WEAR EYE PROTECTION THAT CONFORMS WITH CSA
REQUIREMENTS or ANSI SAFETY STANDARD Z87.1
FLYING DEBRIS can cause permanent eye damage. Prescription
eyeglasses ARE NOT a replacement for proper eye protection.
WARNING: Non-compliant eyewear can cause serious injury if
broken during the operation of a power tool.
WARNING: Use hearing protection, particularly during extended
periods of operation of the tool, or if the operation is noisy.
!
SAVE THESE INSTRUCTIONS FOR REFERENCE

4
ELECTRICAL SAFETY
GENERAL SAFETY WARNINGS
WEAR A DUST MASK THAT IS DESIGNED TO BE USED WHEN
OPERATING A POWER TOOL IN A DUSTY ENVIRONMENT.
WARNING: Dust that is created by power sanding, sawing, grinding,
drilling, and other construction activities may contain chemicals that are
known to cause cancer, birth defects, or other genetic abnormalities. These
chemicals include:
Lead from lead-based paints
Crystalline silica from bricks, cement, and other masonry products
Arsenic and chromium from chemically treated lumber
The level of risk from exposure to these chemicals varies, according to how
often this type of work is performed. In order to reduce exposure to these
chemicals, work in a well-ventilated area, and use approved safety
equipment, such as a dust mask that is specifically designed to filter out
microscopic particles.
!
WARNING: To avoid electrical hazards, fire hazards or damage to the
tool, use proper circuit protection.
This tool is wired at the factory for 120 V AC operation. It must be
connected to a 120 V AC, 15 A circuit that is protected by a time-delayed
fuse or circuit breaker. To avoid shock or fire, replace power cord
immediately if it is worn, cut or damaged in any way.
SAVE THESE INSTRUCTIONS FOR REFERENCE

5
WARNING: Read all safety warnings
and instructions. Failure to follow the warnings
and instructions may result in electric shock, fire
and/or serious injury.
Save all warnings and instructions for future
reference.
Work area safety
Keep 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 residual current device
(RCD) protected supply. Use of a ground fault
circuit interrupter (GFCI) reduces the risk of
electric shock.
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 inattention 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, clothing and
gloves away from moving parts. Loose
clothes, jewelry or long hair can be caught in
moving 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.
POWER TOOL SAFETY
!

6
PERSONAL SAFETY – cont’d
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 the battery pack 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. 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.
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.
POWER TOOL SAFETY
POWER TOOL SAFETY

7
WARNING : Know your sander. Do not
plug in the sander until you have read and
understand this Instruction Manual. Learn
the tool’s applications and limitations, as
well as the specific potential hazards related
to this tool. Following this rule will reduce the
risk of electric shock, fire, or serious injury.
Always wear eye protection. Any
power tool can throw foreign
objects into your eyes and cause
permanent eye damage.
ALWAYS wear safety goggles (not glasses) that
comply with ANSI safety standard Z87.1.
Everyday glasses have only impact resistant
lenses. They ARE NOT safety glasses.
WARNING: Glasses or goggles not in
compliance with ANSI Z87.1 could cause
serious injury when they break.
WARNING: Always use a dust mask
when sanding.
WARNING: Always use hearing
protection when sanding, particularly during
extended periods of operation.
WARNING: Always unplug the tool from
the power source before changing the
sanding disc or buffing pad and when
cleaning the tool.
Do not wear gloves, neckties or loose clothing.
Secure the workpiece. Use clamps or a vice to
hold the work when practical. It is safer than
using your hand and it frees both hands to
operate the tool.
Do not sand material too small to be securely
held.
Make sure there are no nails or foreign objects
in the part of the workpiece to be sanded.
Always keep hands out of the path of the
sanding pad. Avoid awkward hand positions
where a sudden slip could cause your hand to
move into the path of the sanding pad.
To avoid injury from accidental starting, always
remove the plug from the power source before
installing or removing sandpaper or the dust
duct bag.
SPECIFIC SAFETY RULES
SAVE THESE INSTRUCTIONS FOR REFERENCE
!
!
!
!
!

8
WARNING: Keep the extension cord
clear of the working area. Position the cord so
it will not get caught on the workpiece, tools or
any other obstructions while you are working
with the power tool.
Make sure any extension cord used with this
tool is in good condition. When using an
extension cord, be sure to use one of heavy
enough gauge to carry the current the tool will
draw. An undersized cord will cause a drop in
line voltage resulting in loss of power and
overheating.
The table at right shows the correct size to use
according to cord length and nameplate ampere
rating. If in doubt, use the next heavier gauge.
The smaller the gauge number the heavier the
cord.
Be sure your extension cord is properly wired
and in good condition. Always replace a
damaged extension cord or have it repaired by a
qualified electrician before using it. Protect your
extension cord from sharp objects, excessive
heat and damp or wet areas.
Use a separate electrical circuit for your power
tools. This circuit must not be less than 14
gauge wire and should be protected with either
a 15 AMP time delayed fuse or circuit breaker.
Before connecting the power tool to the power
source, make sure the switch is in the OFF
position and the power source is the same as
indicated on the nameplate. Running at lower
voltage will damage the motor.
WARNING: Repair or replace damaged
or worn extension cords immediately.
Select the appropriate extension cord gauge
and length using the chart below.
When operating a power tool outdoors, use
an outdoor extension cord marked “W-A” or
“W”. These cords are rated for outdoor use and
reduce the risk of electric shock.
WARNING: Keep the extension cord
clear of the working area. Position the cord
so it will not get caught on the workpiece,
tools or any other obstructions while you are
working with the power tool.
MINIMUM GAUGE (AWG)
EXTENSION CORDS (120V use only)
Amperage
rating Total length
More
than
Not
more
than 25' (7.5 m) 50' (15 m) 100' (30 m) 150' (45 m)
0 6 18 16 16 14
6 10 18 16 14 12
10 12 16 16 14 12
12 16 14 12 Not Applicable
EXTENSION CORD SAFETY
!
!
!

9
This symbol designates that this tool is
listed with U.S. requirements by
ETL Testing Laboratories, Inc.
Conforms to UL Std. 60745-1 and
60745-2-4.
3042597
JD2522U
V
Volts
A
Amperes
Hz
Hertz
W
Watts
kW
Kilowatts
Microfarads
L
Liters
kg
Kilograms
H
Hours
N/cm
2
Newtons per square
centimeter
Pa
Pascals
OPM
Oscillations per minute
Min
Minutes
S
Seconds
or a.c.
Alternating current
Three-phase alternating
current
Three-phase alternating
current with neutral
Direct current
No load speed
Alternating or direct
current
Class II construction
Splash-proof
construction
Watertight construction
Protective grounding at
grounding terminal,
Class I tools
Revolutions or
reciprocations per
minute
Diameter
Off position
Arrow
Warning symbol
Wear your safety
glasses
SYMBOLS
WARNING: Some of the following symbols may appear on the sander. Study
these symbols and learn their meaning. Proper interpretation of these symbols will
allow for more efficient and safer operation of this tool.
!

10
KNOW YOUR SANDER
Dust Bag
Assembly
Palm Grip
8 Hole-Hook
and Loop
sanding base
Motor vents
Hook & loop
fastening system
ON/OFF
switch
Motor vents
3 sanding discs:
• 1 x 60 grit
• 1 x 80 grit
• 1 x 120 grit

11
INSTALLING A SANDING DISC
To install a sanding disc, firmly press the
sanding disc (1) onto the hook & loop pad (2)
(Fig. 1).
NOTES:
a) Place the sanding disc so the holes in the
disc line up with the matching holes in the hook
& loop pad.
b) Press the sanding disc firmly onto the hook &
loop pad.
To remove the sanding disc (1), simply peel the
disc away from the hook & loop pad (2) (Fig. 2).
ON/OFF SWITCH
To turn the switch ON, press the left hand side
of the switch (1) (Fig. 3). To turn the switch OFF,
press the right hand side of the switch (2).
CONNECTING THE DUST BAG ASSEMBLY
TO THE SANDER
1. Slide the dust bag connector (1) into the
dust port (2) in the rear of the sander
(Fig. 4).
NOTE: Make sure the dust bag connector key
(3) mates with the dust port key way (4).
2. When the dust bag connector is pressed
fully into the dust port, turn the dust bag
approximately 15°clockwise to lock the
dust bag onto the sander.
ASSEMBLY AND OPERATING
Fig. 3
NOTE:
The drawings in the assembly and
operating section of this manual may
differ slightly from the tool you purchased.
Fig. 1
Fig. 2
Fig. 4

12
CLEANING THE DUST BAG
Remove the dust bag assembly (1) from the
dust port by rotating it COUNTER CLOCKWISE
approximately 15°and pulling it out of the dust
port (Fig. 5). Carefully shake the dust bag
assembly with the end cap opening (2) pointing
downward to remove the sanding dust. Reinstall
the dust bag assembly as noted in Fig 4.
SANDING DISC SELECTION
Make sure you select the correct size and style
of sanding disc for your sander. The correct disc
will:
 Have a diameter of 5"
 Have a row of eight 3/8" holes that match
the hole pattern in the sander base
 Have a backing for use with the hook &
loop disc attachment system.
Selecting the correct grit and type of sandpaper
is extremely important 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.
In general, coarse grit will remove most
material. Fine 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 best job.
NOTE: Where the sanding disc grits are shown
numerically, higher numbers indicate finer grit
and lower numbers indicate coarser grit.
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. Fine grit should be used for
finishing the surface. Always continue sanding
with each grit until the surface is uniform.
SANDING
Clamp or otherwise secure your workpiece to
prevent it from moving under the sander while
being sanded. Secure the workpiece in a vice if
possible.
WARNING: Any unsecured workpiece
could be thrown toward the operator causing
injury.
ASSEMBLY AND OPERATING
WARNING
!
For safety reasons, the operator must
read the sections of this Owner’s Manual
entitled "GENERAL SAFETY
WARNINGS", "POWER TOOL SAFETY",
"SPECIFIC SAFETY RULES",
"EXTENSION CORD SAFETY" and
"SYMBOLS" before using this sander.
Verify the following every time the sander
is used:
1. Sander cord is not damaged.
2. Sanding disc is in good condition
and properly installed on the sander.
3. The workpiece is properly secured
and free from any foreign objects.
4. Safety glasses, safety goggles, or
face shield is being worn.
5. Hearing protection and dust mask
are being worn.
Failure to adhere to these safety rules
can greatly increase the chances of
serious injury.
!
Fig. 5

13
SANDING – cont’d
Place the sander on the workpiece so the
complete sanding disc surface is in contact with
the workpiece. Turn the sander ON by pressing
on the left hand side of the ON/OFF switch.
Move the sander slowly over the workpiece
making successive passes in parallel lines,
circles or crosswise movements. Because the
random orbital motion of the sanding disc
moves in tiny circles, it is not necessary to move
the sander with the grain or in the same
direction for successive passes (Fig. 6).
Upon completion of the sanding operation, turn
sander OFF by pressing on the right hand side
of the ON/OFF switch. Wait until the sanding
disc comes to a complete stop before removing
it from the workpiece.
WARNING: Your sander should only be
turned ON when the entire surface of the
sanding disc is in contact with the workpiece.
Failure to follow this sanding procedure could
result in a loose sanding disc, which could result
in possible injury.
NOTE: Hold the sander with one hand on the
hand grip (1) on top of the sander (Fig. 7). Be
careful NOT to cover the cooling vents (2) with
your hand. Covering the cooling vents could
cause the motor to be damaged by overheating.
CLEAN THE DUST BOX OFTEN
Clean the dust bag often. It will be more efficient
when it is not clogged with sanding dust. To
clean the dust bag, see Fig. 5 on Page 12.
DO NOT FORCE THE SANDER. The weight of
the sander usually provides adequate pressure.
Let the sander and the sanding disc do the
work. Applying added pressure will slow the
motor, increase the wear on the sandpaper and
greatly reduce the sander speed. Excessive
pressure will overload the motor causing
possible damage from the motor overheating. It
will also create an inferior finish on sanded
work. Any finish or resin on wood will soften
from the frictional heat, causing sandpaper to
become clogged quickly. Do not sand in 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 the
sander OFF, wait until the sanding disc comes
to a complete stop and remove it from the
workpiece. Check to make sure your hands
have not been covering the cooling vents. Let
the motor cool before continuing the sanding
operation.
ASSEMBLY AND OPER
ATING
!
Fig. 6
Fig. 7

14
GENERAL
WARNING: When servicing, use only
identical replacement parts. The use of any
other part may create a hazard or cause
product damage.
DO NOT use solvents when cleaning plastic
parts. Plastics are susceptible to damage from
various types of commercial solvents and may
be damaged by their use. Use a clean cloth to
remove dirt, dust, oil, grease etc.
WARNING: Do not allow brake fluids,
gasoline, petroleum-based products,
penetrating oils, etc. to come into contact
with plastic parts. They contain chemicals
that can damage, weaken or destroy plastic.
DO NOT abuse power tools. Abusive practices
can damage the tool and the workpiece.
WARNING: DO NOT attempt to modify
tools or create accessories. Any such
alteration or modification is misuse and
could result in a hazardous condition leading
to possible serious injury. It will also void
the warranty.
It has been found that electric tools are
subjected to accelerated wear and possible
premature failure when they are used on
fiberglass boats and sports cars, wallboard,
spackling compounds or plaster. The chips and
grindings from these materials are highly
abrasive to electric tool parts such as 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 these materials it is
extremely important that the tool is cleaned
frequently by blowing it out with an air jet.
WARNING: Always wear safety goggles
or safety glasses with side shields during all
sanding operations. It is critical that you also
wear safety goggles or safety glasses with
side shields and a dust mask while blowing
dust out of the sander with an air jet. Failure
to take these safety precautions could result
in permanent eye or lung damage.
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 conditions.
Therefore, no further lubrication is required.
MAINTENANCE
!
!
!
!

15
EXPLODED VIEW

16
WARNING: When servicing, use only original equipment replacement parts. The use of any
other parts may create a safety hazard or cause damage to the sander.
Any attempt to repair or replace electrical parts on this sander may create a safety hazard unless
repairs are performed by a qualified technician. For more information, call the Toll-free Helpline, at 1-
866-349-8665.
Always order by PART NUMBER, not by key number.
Key # Part # Part Name Quantity
1 3011060024 Housing assembly 1
2 3150060005 Brush holder support 2
3 2030070001 Brush holder 2
4 1230010120 Carbon brush 2
5 3140080036 Switch cover 1
6 1061250001 Switch 1
7 1020060021 Stator 1
8 3140060001 Rubber buffer 2
9 4030010106 Tapping screw ST3.9*19 5
10 1250010002 Tapping screw 1
11 4030010099 Tapping screw ST3.9*14 2
12 3150020001 Cord clamp 1
13 3140010054 Cord guard 1
14 1190030006 Cord 1
15 4010010053 Bearing 607 2RS 1
16 3140020023 "O" ring 1
17 1010060020 Rotor 1
18 4010010054 Bearing 6000 2RS 1
19 3180040048 Vacuum adaptor 1
20 3150010087 Fan 1
21 2030030196 Counterbalance 1
22 6150030048 Dust Bag 1
23 2010130030 Eccentric seat 1
24 2030170007 Dustproof washer 1
25 2020130001 Bearing block 1
26 4010010084 Bearing 6000RS 1
27 2030020033 Washer 1
28 4020080004 Hexagon screw M5*16 1
29 2030160007 Large washer 1
30 1150020007 Bubber backing pad 1
31 4040030011 Spring washer 5 5
32 4020010081 Special screw M5*14 4
PARTS LIST
!

17
!
Rev 1.3 04/05/2012
TOOL SHOP
®
RAN
DOM ORBIT SANDER
WARRANTY
1-YEAR LIMITED WARRANTY:
This TOOL SHOP
®brand power tool carries a 1-Year Limited Warranty to the
original purchaser. If the tool fails within one (1) year from the date of purchase,
simply bring this tool with your original sales receipt back to your nearest
MENARDS
®retail store. At its discretion,
TOOL SHOP
®agrees to have the
tool replaced with the same or similar TOOL SHOP
®product free of charge,
within the stated warranty period, when returned by the original purchaser with
original sales receipt. Notwithstanding the foregoing, this limited warranty does
not cover any damage that has resulted from abuse or misuse of the
Merchandise. This warranty: (1) excludes expendable parts including but not
limited to blades, belts, bits, light bulbs, and/or batteries; (2) shall be void if this
tool is used for commercial and/or rental purposes; and (3) does not cover any
losses, injuries to persons/property or costs. This warranty does give you
specific legal rights and you may have other rights, which vary from state to state.
Be careful, tools are dangerous if improperly used or maintained. Seller’s
employees are not qualified to advise you on the use of this Merchandise. Any
oral representation(s) made will not be binding on seller or its employees. The
rights under this limited warranty are to the original purchaser of the Merchandise
and may not be transferred to any subsequent owner. This limited warranty is in
lieu of all warranties, expressed or implied including warranties or merchantability
and fitness for a particular purpose. Seller shall not be liable for any special,
incidental, or consequential damages. The sole exclusive remedy against the
seller will be for the replacement of any defects as provided herein, as long as
the seller is willing or able to replace this product or is willing to refund the
purchase price as provided above. For insurance purposes, seller is not allowed
to demonstrate any of these power tools for you.
For questions / comments, technical assistance or repair parts –
Please call toll free at: 1-866-349-8665 (M-F 8am – 6pm)
SAVE YOUR RECEIPTS. THIS WARRANTY IS VOID WITHOUT THEM.
Distributed by: Menard, Inc., Eau Claire, WI 54703