Festool ROTEX SERIES User Manual (English)

Questions and Answers:

R
Rebecca WilkersonJul 27, 2025
What to do if my Festool ROTEX Sander motor does not start?
- T
  Thomas JohnsonJul 27, 2025
  If your Festool Sander's motor isn't starting, check the following: Ensure the power cord is properly plugged into the outlet and that the Plug-it connector is fully tightened. Verify the outlet has power by checking the circuit breaker or trying another outlet. If using a Festool dust extractor, confirm the selector switch is set to “Auto”. Inspect the power cord for any damage. The motor brushes may need replacement. Note: Do not attempt to open the sealed power switch.
D
Danielle FoleyAug 1, 2025
Why does my Festool Sander run sporadically or lose power?
- L
  Leah GarrisonAug 1, 2025
  If your Festool Sander runs sporadically or loses power, make sure the Plug-it cord is properly tightened. Inspect the plug and tool power inlet for signs of overheating. If you see signs of overheating, stop using the tool and have it serviced. If the Plug-it cord is overheating, don't use it with other tools to prevent damage.
R
rosstimothyAug 6, 2025
How to fix a sanding disk that doesn’t stick or flies off my Festool Sander?
- J
  Joyce WilliamsAug 6, 2025
  To fix a sanding disk that won’t stick or flies off your Festool Sander, ensure the disk is firmly pressed onto the pad. Try a different disk to rule out a defect. Make sure the bottom of the pad is clean and free of debris. The sanding pad might need replacement, as it's a wear item. Avoid generating excessive heat by holding the sander motionless on sharp edges, as heat degrades the Stickfix hooks.
B
Brandy GarnerAug 11, 2025
Why am I getting deep scratches in finish sanding with my Festool ROTEX Sander?
- D
  Dr. Jason Norris Jr.Aug 11, 2025
  Deep scratches during finish sanding with your Festool Sander are likely caused by scratches from a coarse grit paper being too deep for the current grit. To resolve this, ensure you don’t skip a grit in progression. If switching from Rotex to random orbit mode, stay with the same grit. Rework the finish with a grit appropriate to remove the scratches, then progress to the finish grit. Avoid starting with a grit that's too coarse for your project's needs; use only what's needed for smoothing and leveling.
J
Juan SanchezAug 15, 2025
What to do if my Festool ROTEX jumps or is hard to control?
- G
  Gregory DavisAug 15, 2025
  If your Festool Sander jumps or is hard to control, ensure you're holding it level on the work surface. Reduce sanding pressure and ensure the dust collection vacuum is running at reduced power. Inspect the sanding pad for proper installation; a loose or misaligned pad can cause runout.
C
Charles SpearsAug 21, 2025
How to prevent excessive swirl marks with my Festool ROTEX Sander?
- S
  Sarah MooreAug 21, 2025
  To prevent excessive swirl marks with your Festool Sander: Make sure the dust collection vacuum is set for reduced power. Reduce your sanding pressure. With the sander turned off, check the sanding pad's freewheel motion; if it's too stiff, apply a thin lubricant like paste wax between the pad brake and sanding pad.

Festool ROTEX SERIES Specifications

General

Brand	Festool
Model	ROTEX SERIES
Category	Sander
Language	English

Summary

Limited Warranty

30 Day Money Back Guarantee

Offers a refund of purchase price or lowest retail price within 30 days.

Service All-Inclusive Warranty

Covers defects in materials and workmanship for three years from original retail purchase.

Repairs

Procedure for contacting the service department for warranty or non-warranty repairs.

Liability Statement

Assumes user liability for misuse or operation without adequate training; Festool not liable for consequential damages.

Warrantor Information

Provides contact details for Festool USA and Festool Canada.

About This Manual

Save These Instructions

Emphasizes reading and understanding the manual for safety and problem prevention.

Tool Symbols

Explains the meaning of various symbols used in the manual (Warning, Caution, Notice, Note).

General Power Tool Safety Warnings

Work Area Safety

Guidelines for maintaining a clean, well-lit work area and avoiding explosive atmospheres.

Electrical Safety

Precautions regarding plugs, earthed surfaces, rain, wet conditions, and cord usage.

Personal Safety

Advice on staying alert, using PPE, preventing unintentional starting, and proper attire.

Power Tool Use and Care

Instructions on correct tool usage, maintenance, storage, and avoiding misuse.

Specific Safety Rules for Sanders

Respiratory Exposure Safety Warnings

Details risks of dust inhalation and methods to reduce exposure.

Sander Overview

Brief description of the sander's main components and functions.

Intended Use

Specifies the proper applications for the Rotex sanders and warnings against misuse.

Technical Specifications

Lists key technical data for the RO 90, RO 125, and RO 150 FEQ models.

Functional Description

Sander Component Identification

Identifies components of the sanders (RO 90, RO 125, RO 150) with reference page numbers.

RO 90 DX Detail Pad

Illustrates the detail pad for the RO 90 sander.

Sanding Action/Mode

Dual-Action Sanding Explained

Describes the simultaneous eccentric orbit and rotation motion of the sanding pad.

Gear Driven (Rotex) Mode

Explains the direct coupling of dual-action rotation to orbital motion for aggressive removal.

Random Orbit Mode

Details the freewheeling rotation component, creating less visible scratches.

Optimizing Random Orbit Sanding

Provides tips on using light pressure to achieve optimal random orbit scratch patterns.

Anatomy of Sandpaper

Sandpaper Components Explained

Details abrasive grit, backing, base bond, top bond, and dispersion.

Sandpaper Dispersion Types

Explains open coat, closed coat, and semi-open coat dispersions and their effects.

Choosing the Appropriate Grit

Selecting Sanding Grit for Tasks

Guides on choosing grit based on task, progression, and material type.

Best Sandpaper for Task Chart

A chart detailing different sandpaper types, their specs, and recommended uses.

Setup

Changing Sanding Pads

Instructions and cautions for replacing sanding pads.

Choosing the Correct Sanding Pad

Guidance on selecting pads based on hardness for different sanding tasks.

Removing and Installing Sanding Pads

Step-by-step instructions for pad removal and installation.

Changing Delta (RO90) Sanding Pads

Installing Delta Pad Holder on Sander

Procedure for attaching the Delta pad holder to the RO90 sander.

Installing Sanding Pad on Holder

Steps for securing the sanding pad to the Delta pad holder.

Changing Sandpaper

Connecting Plug-It Power Cord

Instructions for connecting and securing the removable power cord.

Connecting a Dust Extractor

How to connect a Festool 27mm vacuum hose to the sander's dust port.

Setting the Variable Speed

Adjusting the sander's speed using the speed control dial.

Installing the Sanding Bumper

Setting the Sanding Mode

Instructions for switching between Rotex, Random Orbit, and Delta modes.

Turning on the Sander

Procedure for safely turning the sander on and off with soft-start circuitry.

Operation

Using Dust Extraction Effectively

Explains the importance and mechanics of dust extraction for optimal performance.

Dust Extraction System Setup

Steps for connecting the sander to a dust extractor and adjusting vacuum power.

Choosing Hand Positions

Working With Sanding Grits

Guidance on selecting and progressing through grits for different tasks and materials.

Grit Progression and Material

How grit choice relates to material type, finish desired, and avoiding burnishing.

Sanding Techniques

Optimal Sanding Pressure

Advice on applying minimal downward force to maintain control and finish quality.

Sanding Pattern and Movement

Techniques for moving the sander for smooth patterns, including circular and grain-line motions.

Sanding Examples

Faceframe Leveling Technique

Method for sanding faceframe joints to avoid depressions and ensure flushness.

Frame to Carcase Leveling

Precautions and techniques for leveling joints between frame and carcase veneer.

Maintenance and Adjustment

Routine Maintenance

General advice on keeping the sander clean and examining parts for wear.

Motor Brush Replacement

Instructions for replacing worn motor brushes for the RO 90 model.

RO 125 Motor Brushes

RO 125 Motor Brush Replacement

Step-by-step guide for replacing motor brushes on the RO 125 model.

RO 150 Motor Brushes

RO 150 Motor Brush Replacement

Detailed instructions for replacing motor brushes on the RO 150 model.

Troubleshooting

Troubleshooting Motor Issues

Addresses common motor problems like not starting or losing power.

Troubleshooting Sanding Disk Issues

Solutions for sanding disks not sticking or flying off.

Troubleshooting Finish Imperfections

Guidance on resolving deep scratches and excessive swirl marks.

Troubleshooting Control Issues

Solutions for sanders jumping or being hard to control.

Related product manuals

Festool Rotex RO 150 E

21 pages

Festool Rotex RO 150 FEQ

16 pages

Festool ROTEX RO 125 FEQ