Ryobi P440 - SHEET SANDER Manual

GENERAL POWER TOOL SAFETY WARNINGS

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

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

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 ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.
• Use this product only with batteries and chargers listed in tool/appliance/battery pack/charger correlation supplement 987000-432.

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of 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, nonskid 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 energising 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 jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery 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.
• Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.
• Do not wear loose clothing or jewelry. Contain long hair. Loose clothes, jewelry, or long hair can be drawn into air vents.
• Do not use on a ladder or unstable support. Stable footing on a solid surface enables better control of the power tool in unexpected situations.

POWER TOOL USE AND CARE

• Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
• Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source and/ or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
• Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
• Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool's operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
• Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

BATTERY TOOL USE AND CARE

• Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.
• Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.
• When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.
• Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.
• Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, explosion or risk of injury.
• Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 265°F may cause explosion.
• Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

SERVICE

• Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.
• Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.
• When servicing a power tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual. Use of unauthorized parts or failure to follow Maintenance instructions may create a risk of shock or injury.

PRODUCT SAFETY WARNINGS

• Hold power tool by insulated gripping surfaces, when performing an operation where the cutting accessory may contact hidden wiring. Cutting accessory contacting a "live" wire may make exposed metal parts of the power tool "live" and could give the operator an electric shock.
• Know your power tool. Read operator's manual carefully. Learn its applications and limitations, as well as the specific potential hazards related to this power tool. Following this rule will reduce the risk of electric shock, fire, or serious injury.
• Always wear eye protection with side shields marked to comply with ANSI Z87.1 when assembling parts, operating the tool, or performing maintenance. Following this rule will reduce the risk of serious personal injury.
• Protect your lungs. Wear a face or dust mask if the operation is dusty. Following this rule will reduce the risk of serious personal injury.
• Protect your hearing. Wear hearing protection during extended periods of operation. Following this rule will reduce the risk of serious personal injury.
• Battery tools do not have to be plugged into an electrical outlet; therefore, they are always in operating condition. Be aware of possible hazards when not using your battery tool or when changing accessories. Following this rule will reduce the risk of electric shock, fire, or serious personal injury.
• Do not place battery tools or their batteries near fire or heat. This will reduce the risk of explosion and possibly injury.
• Do not crush, drop or damage battery pack. Do not use a battery pack or charger that has been dropped or received a sharp blow. A damaged battery is subject to explosion. Properly dispose of a dropped or damaged battery immediately.
• Batteries can explode in the presence of a source of ignition, such as a pilot light. To reduce the risk of serious personal injury, never use any cordless product in the presence of open flame. An exploded battery can propel debris and chemicals. If exposed, flush with water immediately.
• Do not charge battery tool in a damp or wet location. Do not use, store, or charge battery packs or products in locations where the temperature is less than 50°F or more than 100°F. Do not store outside or in vehicles.
• Under extreme usage or temperature conditions, battery leakage may occur. If liquid comes in contact with your skin, wash immediately with soap and water. If liquid gets into your eyes, flush them with clean water for at least 10 minutes, then seek immediate medical attention. Following this rule will reduce the risk of serious personal injury.
• Save these instructions. Refer to them frequently and use them to instruct others who may use this tool. If you loan someone this tool, loan them these instructions also.

SYMBOLS

PRODUCT SPECIFICATIONS

OVERVIEW

1. Dust bag
2. Lever
3. Paper punch
4. Tab
5. Cushion
6. Paper clamp
7. On/off switch
8. To turn off
9. To turn on
10. Dust exhaust port
11. Dust vacuum adapter (not included)

ASSEMBLY

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

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

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

OPERATION

WARNING:
Do not allow familiarity with this product to make you careless. Remember that a careless fraction of a second is sufficient to inflict serious injury.

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

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

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

APPLICATIONS

You may use this product for the purposes listed below:

• Sanding on wood surfaces
• Removing rust from and sanding steel surfaces
• Sanding plastics

WARNING:
Battery products are always in operating condition. Therefore, the switch should always be in the OFF position when not in use or carrying at your side.

INSTALLING/REMOVING BATTERY PACK

1. Battery pack
2. Latches
3. Depress latch to release battery pack

To install:

• Insert the battery pack.
• Make sure the latches on each side of the battery pack snap into place and the battery pack is secured in the product before beginning operation.

To remove:

• Depress the latches on each side of the battery pack.

For complete charging instructions, see the operator's manuals for your battery pack and charger.

INSTALLING SANDPAPER

The cushion on the sander gives you the option of using either non-adhesive sandpaper that clamps to the platen or adhesive backed sandpaper with pressure sensitive adhesive backing that sticks to the cushion.

INSTALLING NON-ADHESIVE SANDPAPER

1. Cushion
2. Lever
3. Non-adhesive sandpaper
4. Adhesive sandpaper
5. Tab
6. Platen
7. Paper clamp

• Remove the battery pack.
• Inspect sandpaper before installing; do not use if broken or defective.
• If replacing sandpaper, remove old sandpaper. To remove paper, release paper clamp by lifting up on lever, and disengaging it from the tab on the platen.
• Insert end of new 1/4 sheet sandpaper approximately 1/2 in. under the paper clamp.
  NOTE: 1/2 in. clamping of sandpaper is necessary for multi-sheet stacking of paper.
• Lift up on paper clamp lever and lock into place. Apply downward pressure to conform sandpaper to platen.
• Wrap sandpaper around cushion. Lift lever on opposite end of sander and insert loose end of sandpaper under paper clamp. Fit sandpaper against cushion tightly.
• Lift up on lever and lock into place.

INSTALLING ADHESIVE SANDPAPER

See Figure 2.

• Remove the battery pack.
• If replacing adhesive sandpaper, remove old sandpaper by peeling it off cushion.
  NOTE: Sand for a few minutes to soften the adhesive backing before attempting to remove old sandpaper.
• If replacing regular sandpaper, release paper clamp by lifting up on lever and disengaging it from the tab on the platen. Remove non-adhesive sandpaper, then lift up on paper clamp lever and lock it into place.
• Carefully peel adhesive backing from new 1/4 sheet sandpaper.
• Position sandpaper, making sure front edge of sandpaper 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 cushion for proper functioning of the flush sanding feature.

NOTE: The cushion on the sander is approximately 1/4 in. 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

1. Paper punch

A paper punch template has been supplied with the sander for aligning and punching holes in sandpaper. The punched holes must align with the holes in the sander cushion. Punching the holes properly is a necessary step for dustless sanding.

• Install sandpaper on the sander.
• Align sander cushion to paper punch as shown.
• Push down on sander.

WARNING:
Always wear eye protection with side shields marked to comply with ANSI Z87.1. Failure to do so could result in objects being thrown into your eyes resulting in possible serious injury. If the sanding operating is dusty, also wear a face or dust mask.

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.

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: DO NOT use sander without sandpaper. Doing so will damage the cushion.

SANDING

Clamp or otherwise secure the work to prevent it from moving under the sander.

WARNING:
Unsecured work could be thrown towards the operator causing injury.

WARNING:
Keep your head away from the sander and the sanding area. Your hair could be drawn into the sander, causing serious injury.

NOTICE:
To avoid damaging the motor from overheating, be careful not to let your hand cover the air vents.

Hold the sander in front and away from you, keeping it clear of the workpiece. Start the sander by pressing the switch button to ON position and letting the motor build to its maximum speed. Gradually lower the sander on the work with a slight forward movement. Move it slowly 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.

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.

Flush sanding can be performed with the sander. The front edge of the sander allows flush sanding in corners. Always remove the sander from the workpiece before turning the sander off.

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.

ORBITAL MOTION

Orbital motion is ideal for fast cutting action when removing old finishes, smoothing rough wood, cutting stock down to required dimensions, or for finishing surfaces to be painted.
As shown in figure 6, the sandpaper moves in tiny circles at a very high speed, allowing the sander to move easily.

REMOVING PRESSURE SENSITIVE ADHESIVE (PSA) SANDPAPER BEFORE STORAGE

Do not store the sander with the sandpaper installed. Heat generated from sanding causes the pressure sensitive adhesive to flow and form a tight bond between the backing pad and sandpaper.

Removing the sandpaper soon after you have finished a sanding operation avoids letting the adhesive set up. If the sandpaper is left on the backing pad for an extended period of time after use, the adhesive will set up and cause the sandpaper to become difficult to remove.

It may also tear when removing. When this situation occurs, it becomes difficult to clean the backing pad for the next sheet of sandpaper.

NOTE: If you forget to remove the sandpaper after a sanding operation, sand for a few minutes to soften the adhesive backing before attempting to remove sandpaper.

USING THE DUST BAG

The dust bag provides a dust collection system for the sander. Dust is drawn up through holes in the sandpaper and cushion and collected in the dust bag during sanding.

ATTACHING THE DUST BAG ASSEMBLY

1. Dust bag assembly

• Remove the battery pack.
• Slide the dust bag into the dust exhaust port on the sander.

CLEANING THE DUST BAG

1. Dust bag
2. Zipper

For more efficient operation, empty the dust bag when it is no more than half full. This will permit the air to flow through the bag better.

To empty the dust bag:

• Remove the battery pack.
• Remove the dust bag.
• Unzip the dust bag.
• Thoroughly clean the dust bag by shaking out all debris.
• Zip up the dustbag.
• Replace the dust bag.

WARNING:
Collected sanding dust from sand ing surface coatings such as polyurethanes, linseed oil, etc., can self-ignite in the sander dust bag or elsewhere and cause fire. To reduce the risk of fire, always empty the dust bag frequently (10-15 minutes) while sanding and never store or leave a sander without totally emptying its dust bag. Also follow the recommendations of the coatings manufacturers.

ATTACHING THE UNIT TO A VACUUM

(ADAPTOR NOT INCLUDED)

1. Dust vacuum adapter (not included)
2. Vacuum hose

The dust bag can be removed and a 1-1/4 in. vacuum can be attached to the dust port.

• Remove the battery pack.
• Remove the dust bag.
• Attach the dust vacuum adaptor (not included) to the dust exhaust port.
• Attach a vacuum hose to the dust vacuum adaptor.
• Connect the vacuum to a power supply.

MAINTENANCE

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

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

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

WARNING:
Do not at any time let brake fluids, gasoline, petroleumbased products, penetrating oils, etc., come in contact with plastic parts. Chemicals can damage, weaken, or destroy plastic which may result in serious personal injury.

ACCESSORIES

Look for these accessories at the service center:

WARNING:
Current attachments and accessories available for use with this tool are listed above. Do not use any attachments or accessories not recommended by the manufacturer of this tool. The use of attachments or accessories not recommended can result in serious personal injury.

REGISTER YOUR TOOLS
http://register.ryobitools.com
1-800-525-2579

Documents / Resources

References

• Registration - RYOBI Tools

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