OPERATOR'S MANUAL
1/4 SHEET SANDER – S650D
DOUBLE INSULATED
Your new Sander has been engineered and manufactured to Ryobi’s high standard for dependability, ease of operation, and
operator safety. When properly cared for, the sheet sander will give you years of rugged, trouble-free performance.
WARNING: To reduce the risk of injury, the user must read and understand the operator’s manual.
Thank you for buying a Ryobi product.
SAVE THIS MANUAL FOR FUTURE REFERENCE
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GENERAL SAFETY RULES
■ Avoid accidental starting. Be sure switch is off before
WARNING:
Read and understand all instructions. Failure to
follow all instructions listed below, may result in elec-
tric shock, fire and/or serious personal injury.
plugging in. Carrying tools with your finger on the switch
or plugging in tools that have the switch on invites acci-
dents.
■ Remove adjusting keys or wrenches before turning
the tool on. A wrench or a key that is left attached to a
rotating part of the tool may result in personal injury.
SAVE THESE INSTRUCTIONS
■ Do not overreach. Keep proper footing and balance
at all times. Proper footing and balance enables better
control of the tool in unexpected situations.
■ Use safety equipment. Always wear eye protection.
Dust mask, nonskid safety shoes, hard hat, or hearing
protection must be used for appropriate conditions.
Work Area
■ Keep your work area clean and well lit. Cluttered
benches and dark areas invite accidents.
■ Do not operate power tools in explosive atmo-
spheres, such as in the presence of flammable liq-
uids, gases, or dust. Power tools create sparks which
may ignite the dust or fumes.
■ Keep bystanders, children, and visitors away while
operating a power tool. Distractions can cause you to
lose control.
Tool Use and Care
■ Use clamps or other practical way to secure and sup-
port the workpiece to a stable platform. Holding the
work by hand or against your body is unstable and may
lead to loss of control.
■ Do not force tool. Use the correct tool for your appli-
cation. The correct tool will do the job better and safer at
the rate for which it is designed.
■ Do not use tool if switch does not turn it on or off.
Any tool that cannot be controlled with the switch is dan-
gerous and must be repaired.
■ Disconnect the plug from the power source before
making any adjustments, changing accessories, or
storing the tool. Such preventive safety measures re-
duce risk of starting the tool accidentally.
Electrical Safety
■ Double insulated tools are equipped with 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 in-
stall a polarized outlet. Do not change the plug in any
way. Double insulation
three wire grounded power cord and grounded power
supply system.
eliminates the need for the
■ Store idle tools out of reach of children and other
untrained persons. Tools are dangerous in the hands of
untrained users.
■ Avoid body contact with grounded surfaces such as
pipes, radiators, ranges and refrigerators. There is an
increased risk of electric shock if your body is grounded.
■ Maintain tools with care. Keep cutting tools sharp and
clean. Properly maintained tools with sharp cutting edges
are less likely to bind and are easier to control.
■ Don't expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of elec-
tric shock.
■ Check for misalignment or binding of moving parts,
breakage of parts, and any other condition that may
affect the tool's operation. If damaged, have the tool
serviced before using. Many accidents are caused by
poorly maintained tools.
■ Do not abuse the cord. Never use the cord to carry
the tools or pull the plug from an outlet. Keep cord
away from heat, oil, sharp edges or moving parts.
Replace damaged cords immediately. Damaged cords
increase the risk of electric shock.
■ Use only accessories that are recommended by the
manufacturer for your model. Accessories that may
be suitable for one tool, may become hazardous when
used on another tool.
■ When operating a power tool outside, use an outdoor
extension cord marked “W-A” or “W”. These cords are
rated for outdoor use and reduce the risk of electric shock.
Personal Safety
Service
■ Stay alert, watch what you are doing and use com-
mon sense when operating a power tool. Do not use
tool while tired or under the influence of drugs, alco-
hol, or medication. A moment of inattention while operat-
ing power tools may result in serious personal injury.
■ Tool service must be performed only by qualified re-
pair personnel. Service or maintenance performed by
unqualified personnel could result in a risk of injury.
■ When servicing a 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 elec-
tric shock or injury.
■ Dress properly. Do not wear loose clothing or jew-
elry. Contain long hair. Keep your hair, clothing, and
gloves away from moving parts. Loose clothes, jewelry,
or long hair can be caught in moving parts.
Page 3
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GENERAL SAFETY RULES
■ Keep the tool and its handle dry, clean, and free from
ing. Never use brake fluids, gasoline, petroleum-based
products, or any strong solvents to clean your tool.
oil and grease. Always use a clean cloth when clean-
SPECIFIC SAFETY RULES
■ 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. 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 exceed-
ing 100 feet is not recommended. If in doubt, use the next
heavier gage. The smaller the gage number, the heavier
the cord. An undersized cord will cause a drop in line
voltage resulting in loss of power and overheating.
Additional Rules for Safe Operation
■ Know your power tool. Read operator's manual care-
fully. Learn its 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 safety glasses with side shields. Every-
day eyeglasses have only impact resistant lenses; they
are NOT safety glasses.
■ Drugs, Alcohol, Medication. Do not operate tool while
under the influence of drugs, alcohol, or any medication.
Following this rule will reduce the risk of electric shock,
fire, or serious injury.
■ Protect your lungs. Wear a face or dust mask if the
operation is dusty.
■ Protect your hearing. Wear hearing protection during
extended periods of operation.
■ Inspect tool cords periodically and if damaged, have
repaired at your nearest authorized service center. Stay
constantly aware of cord location.
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 examples of these
chemicals are:
■ Check damaged parts. Before further use of the tool, it
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,
breakageofparts,mounting,andanyotherconditionsthat
may affect its operation. A part that is damaged should be
properly repaired or replaced by an authorized service
center. Following this rule will reduce the risk of electric
shock, fire, or serious injury.
• lead from lead-based paints,
• crystalline silica from bricks and cement and other
masonry products, and
• arsenic and chromium from chemically-treated
■ Do not abuse cord. Never carry tool by cord or yank
it to disconnect from receptacle. Keep cord from
heat, oilandsharpedges. Followingthisrulewillreduce
the risk of electric shock or fire.
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 specially designed to filter
out microscopic particles.
SAVE THESE INSTRUCTIONS
Page 4
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SYMBOLS
Important: Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper
interpretation of these symbols will allow you to operate the tool better and safer.
SYMBOL
NAME
DESIGNATION/EXPLANATION
Voltage
V
Volts
A
Amperes
Hertz
Current
Hz
min
Frequency (cycles per second)
Time
Minutes
Alternating Current
Direct Current
Type or a characteristic of current
Type or a characteristic of current
---
n
No Load Speed
Rotational speed, at no load
0
Revolutions, strokes,
surface speed, orbits etc. per minute
.../min
Revolutions or Reciprocation Per Minute
Indicatesdanger,warningorcaution.
It means attention!!! Your safety is
involved.
Safety Alert Symbol
Always wear safety goggles or
safetyglasseswithsideshieldswhen
operating this product.
Eye Protection
Do not expose to rain or use in damp
locations.
Wet Conditions Alert
The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and the
explanations with them, deserve your careful attention and understanding. The safety warnings do not by themselves
eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention
measures.
Symbol
Meaning
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices that may cause property damage.
NOTE:
Advises you of information or instructions vital to the operation or maintenance of the equipment.
SAVE THESE INSTRUCTIONS
Page 5
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FEATURES
Your sanderissuitableforsandingwithcoarse, medium, and
ELECTRICAL CONNECTION
fine grit sandpaper. It will produce a fine scratch free finish
when 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.
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.
Yoursanderhasacomfortablepalmgriphandlethatprovides
maximum one-hand comfort, and reduces operator fatigue
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.
Beforeattemptingtouseyoursander,familiarizeyourself
with all operating features and safety requirements.
SWITCH
This tool is equipped with a simple switch control. To turn the
sander "ON", slide the switch to the left (|) as shown in
Figure 1. Slide the switch to the right (O) to turn the sander
"OFF".
TO
TURN OFF
SWITCH
TO
TURN ON
PAPER CLAMP
PAPER PUNCH
DUST BAG
LEVER
TAB
CUSHION
Fig. 1
WARNING: Do not allow familiarity with your sander to make you careless. Remember, a careless fraction
of a second is sufficient to inflict severe injury.
Page 6
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SPECIFICATIONS
Size of Paper .......................................................................................................................................................... 1/4 sheet
Motion ............................................................................................................................................................... Orbital Action
Orbit Diameter............................................................................................................................................. 1/16 in. (1.6 mm)
No Load Speed .................................................................................................................................................. 14,000 OPM
Input ................................................................................................................................................................... 2.0 Amperes
Rating.................................................................................................................................................... 120 Volts, 60 Hz, AC
UNPACKING
INSTRUCTIONS
Your sander has been shipped completely assembled.
PACKING LIST
1/4 Sheet Orbital Sander
Sandpaper (3 sheets)
Dust Bag Assembly
Operator’s Manual
■ Carefully remove the tool and accessories from the box.
Make sure that all items listed in the packing list are
included.
■ Inspect the tool carefully to make sure no breakage or
damage occurred during shipping.
WARNING:
■ Do not discard the packing material until you have care-
fully inspected and satisfactorily operated the tool.
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.
■ If any parts are damaged or missing, please call
1-800-525-2579 for assistance.
APPLICATIONS
APPLICATIONS
(Use only for the purposes listed below)
1. Sanding on wood surfaces.
2. Removing rust from and sanding steel surfaces.
3. Sanding plastics.
Page 7
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OPERATION
WARNING:
Your sander should never be connected to power supply
when you are assembling parts, making adjustments,
assembling or replacing sandpaper, cleaning, or when
not in use. Disconnecting sander will prevent accidental
starting that could cause serious personal injury.
PAPER CLAMP
INSTALLING NON-ADHESIVE SANDPAPER
See Figure 2.
CUSHION
LEVER
Inspect sandpaper before installing. DO NOT use if broken
or defective.
1. Unplug your sander.
PLATEN
TAB
NON-ADHESIVE
SANDPAPER
WARNING:
Failure to unplug your sander could result in accidental
starting causing possible serious injury.
ADHESIVE
SANDPAPER
2. Ifreplacingsandpaper,removeoldsandpaper. Toremove
paper, release paper clamp by lifting up on lever, and
disengagingitfromthetab, andallowingthelevertolower.
3. Insert end of new 1/4 sheet sandpaper approximately 1/2
in. (13 mm) under the paper clamp. Note: 1/2 in. (13 mm)
clampingofsandpaperisnecessaryformulti-sheetstacking
of paper.
Fig. 2
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.
PAPER PUNCH
INSTALLING ADHESIVE SANDPAPER
See Figure 2.
Inspectsandpaperbeforeinstalling. DONOTusebrokenor
defective sandpaper.
1. Unplug your sander.
ORIENT PAPER
PUNCH AS SHOWN
Fig. 3
WARNING:
Failure to unplug your sander could result in accidental
starting causing possible serious personal injury.
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
2. If replacing sandpaper, remove old sandpaper by peeling
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.
sandpaper can be installed.
PAPER PUNCH
See Figure 3.
A paper punch template has been supplied with your sander
for aligning and punching holes in sandpaper. The punched
holes must align with the holes in the sander cushion.
1. Install sandpaper on your sander.
2. Align sander cushion over the paper punch. See Figure 3.
3. Push down on sander.
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.
Page 8
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OPERATION
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
resultinginpossibleseriousinjury.Ifthesandingoperating
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
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
be used to remove scratches left by the coarser grit and finer
gritusedforfinishingofthesurface. Alwayscontinuesanding
with each grit until surface is uniform.
Fig. 4
Note: DO NOT use sander without sandpaper. Doing so will
damage the cushion.
PREPARING FOR OPERATION
CAUTION:
Be careful not to let your hand completely cover air vents.
SANDING
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.
Fig. 5
Flush sanding can be performed with your sander. See
Figure 5. The front edge of your sander allows flush sanding
in corners. Always remove sander from workpiece before
turning your sander off.
Hold your sander in front and away from you, keeping it 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
with a slight forward movement. See Figure 4. Move it slowly
using forward and backward strokes.
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.
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.
Page 9
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OPERATION
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.
WARNING:
Collected sanding dust from sanding surface coatings
such as polyurethanes, linseed oil, etc. can self-ignite in
your sander dust bag or elsewhere and cause fire. To
reducetheriskoffirealwaysemptyyourdustbagfrequently
while sanding and never store or leave a sander without
totally emptying its dust bag. Also follow the
recommendations of the coatings manufacturers.
ORBITAL MOTION
Fig. 6
USING THE DUST BAG ASSEMBLY
Thedustbagassemblyprovidesadustcollectionsystem
for the sander. Sanding dust is drawn up through the
holes of the sanding disc and collected in the dust bag
during sanding.
TO ATTACH THE DUST BAG ASSEMBLY
See Figure 7.
Follow these directions to attach the dust bag assembly.
■ Unplug the sander.
WARNING:
Failuretounplugthetoolcouldresultinaccidentalstarting
causing possible serious injury.
DUST BAG
ASSEMBLY
■ Slide the dust bag assembly onto the blower exhaust on
the sander using a slight twisting motion.
TO EMPTY THE DUST BAG ASSEMBLY
See Figure 7 and 8.
Fig. 7
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. Always empty and clean the dust
bag thoroughly upon completion of a sanding operation
and before placing the sander in storage.
DUST BAG
TO EMPTY DUST BAG
■ Unplug your sander.
WARNING:
Failure to unplug your sander could result in accidental
starting causing possible serious personal injury.
■ Remove the dust bag assembly from the sander.
■ Remove the dust bag from the frame.
■ Shake out the dust.
DUST BAG FRAME
■ Replace the dust bag on the frame.
■ Replace the dust bag assembly on the sander.
Fig. 8
Page 10
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MAINTENANCE
WARNING:
WARNING:
Always wear safety goggles, or safety glasses with side
shields during power tool operation or when blowing dust.
If operation is dusty, also wear a dust mask.
When servicing use only identical Ryobi replacement
parts. Useofanyotherpartsmaycreateahazardorcause
product damage.
EXTENSION CORDS
GENERAL
The use of any extension cord will cause some loss of power.
Tokeepthelosstoaminimumandtopreventtooloverheating,
use an extension cord that is heavy enough to carry the
current the tool will draw. Follow the recommended cord
sizes on the chart provided to determine the minimum wire
size required in an extension cord.
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:
Extension Cord Length
0-100 Feet
Wire Gauge Size (A.W.G.)
16
Do not at any time let brake fluids, gasoline, petroleum-
based products, penetrating oils, etc., come in contact
withplasticparts.Theycontainchemicalsthatcandamage,
weaken, or destroy plastic.
When working with your tool outdoors, use an extension cord
suitable for outdoor use and so marked. Outdoor use
extension cords are marked with the letters "WA" on the
cord's jacket.
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, commutator, etc.
Consequently it is not recommended that this tool be used for
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.
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.
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
normaloperatingconditions. Therefore, nofurtherlubrication
is required.
Page 11
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OPERATOR'S MANUAL
1/4 SHEET SANDER – S650D
DOUBLE INSULATED
• 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
• 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.
S650D
• MODEL NUMBER
• SERIAL NUMBER
RYOBI TECHNOLOGIES, INC.
1428 Pearman Dairy Road
Anderson, SC 29625
Post Office Box 1207
Anderson, SC 29622-1207
Phone 1-800-525-2579
983000-276
.
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