OPERATOR'S MANUAL 4 in. (100 mm) Angle Grinder Model AG401 / Double Insulated rin 4'' G der SPECIFICATIONS: Grinding Wheel Capacity Rating No Load Speed Amperes Net Weight 4 in. (100 mm) 120 V c.a., 60Hz 11,000 RPM 4.4 A 4.0 lbs. (1.8 kg.) THANK YOU FOR BUYING A RYOBI ANGLE GRINDER. Your new angle grinder 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 angle grinder. Pay close attention to the Rules for Safe Operation, Warnings, and Cautions. If you use your grinder properly and only for what it is intended, you will enjoy years of safe, reliable service. Please fill out and return the Warranty Registration Card so that we can be of future service to you. Thank you again for buying Ryobi tools. SAVE THIS MANUAL FOR FUTURE REFERENCE TABLE OF CONTENTS Product Specifications .................................................................................................................................. 1 Introduction ................................................................................................................................................... 2 Rules for Safe Operaton ............................................................................................................................ 3-5 Symbols ........................................................................................................................................................ 6 Electrical and Unpacking .............................................................................................................................. 7 Features ........................................................................................................................................................ 8 Assembly....................................................................................................................................................... 9 Adjustments ................................................................................................................................................ 10 Operation ............................................................................................................................................... 10-11 Maintenance .......................................................................................................................................... 12-13 Parts Ordering / Service .............................................................................................................................. 14 INTRODUCTION DOUBLE INSULATION Your Ryobi power tool is double insulated. This means you are separated from the tool's electrical system by two complete 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. Double insulated tools do not need to be grounded. IMPORTANT Servicing of a tool with double insulation requires extreme care and knowledge of the system and should be performed only by a qualified service technician. For service we suggest you return the tool to your nearest RYOBI AUTHORIZED SERVICE CENTER for repair. When servicing use only identical Ryobi replacement parts. WARNING: Do not attempt to operate this tool until you have read thoroughly and understand completely all instructions, safety rules, etc. contained in this 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. 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: Always use the guard that accompanied the grinder. Comply with mounting and use instructions and warnings found in the manual for the grinder and ANSI B7.1. Failure to heed these warnings can result in wheel breakage and serious personal injury. For more information on ANSI Standards, contact the American National Standards Institute, Inc., 11 West 42nd Street, 13th Floor, New York, NY 10036. WARNING: WEAR YOUR SAFETY GLASSES FORESIGHT IS BETTER THAN NO SIGHT The operation of any angle grinder can result in foreign objects being thrown into your eyes, which can result in severe eye damage. Before beginning power tool operation, always wear safety 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. Page 2 RULES FOR SAFE OPERATION WARNING: Read and understand all instructions. Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal injury. of inattention while operating power tools may result in serious personal injury. Dress properly. Do not wear loose clothing or jewelry. 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. Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch on invites accidents. 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. 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, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions. SAVE THESE INSTRUCTIONS Work Area Keep your work area clean and well lit. Cluttered benches and 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 bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control. 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 install a polarized outlet. Do not change the plug in any way. Double insulation eliminates the need for the three wire grounded power cord and grounded power supply system. 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. Don't 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 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. 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. Tool Use and Care Use clamps or other practical way to secure and support 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 application. 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 dangerous 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 reduce risk of starting the tool accidentally. Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users. 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. 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. Personal Safety Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medication. A moment Page 3 RULES FOR SAFE OPERATION 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. Dust and waste materials should not be allowed to build up in the workshop. Hot metal sparks could start a fire. Do not enlarge or alter the center hole of the grinding wheel as this could result in breaking it. Use only the normal grinder surface. Never use the side or upper surfaces for cutting. Keep the tool and its handle dry, clean, and free from oil and grease. Always use a clean cloth when cleaning. Never use brake fluids, gasoline, petroleumbased products, or any strong solvents to clean your tool. Service Tool service must be performed only by qualified repair 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 electric shock or injury. Additional Rules for Safe Operation Know your power tool. Read operator's manual carefully. 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. Everyday eyeglasses have only impact resistant lenses; they are NOT safety glasses. 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. Check damaged parts. Before further use of the tool, a guard or other part that is damaged 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, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other 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. Do not abuse cord. Never carry tool by cord or yank it to disconnect from receptacle. Keep cord from heat, oil and sharp edges. Following this rule will reduce the risk of electric shock or fire. 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 exceeding 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. Specific Safety Rules for Grinders Always use proper guard with grinding wheel. A guard protects operator from broken wheel fragments. Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other accessories running over rated speed can fly apart and cause injury. Hold tool by insulated gripping surfaces when performing an operation where the tool may contact hidden wiring or its own cord. Contact with a "live" wire will make exposed metal parts of the tool "live" and shock the operator. Grinding wheel and guard must be securely attached as described in this operating manual before connecting the grinder to a power source. Grinding wheels must be stored in a dry place. B ...